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Manz, Germany: Automation for highly precise and efficient production of lithium-ion battery modules
In order to serve the rapidly growing electromobility market, particularly efficient manufacturing processes are required when it comes to the production of lithium-ion battery systems. This is made possible by Manz’s BLS 500 laser welding system, which allows individual battery cells to be contacted highly precisely and thus connected to form battery modules.
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TU Berlin, Germany: Battery cell production with XTS and PC-based control
Low-cost lithium-ion battery cells (LIB) are the key to mass electromobility, although the manufacturing process has always been a cost driver – until now. Researchers at TU Berlin are using continuous Z-folding to replace the traditional pick-and-place movements that have been used so far, thus accelerating battery cell production. The XTS linear transport system from Beckhoff has played a crucial role here.
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Thyssenkrupp Presta, Liechtenstein: Precision measurement terminals in the final inspection of steering systems
Nobody wants to hear cracking, scratching, knocking, or whirring while driving. But how can subjective noise perception be quantified and measured objectively? thyssenkrupp Presta tests this by measuring structure-borne noise during end-of-line testing. Joachim Sutterlüty, Karsten Mauersberger, Michael Sauerwein, and Julius Ellmann have replaced the previous external electronics with high-end ELM measurement terminals in conjunction with TwinCAT Scope.
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Beckhoff, Germany: XPlanar greatly increases testing capacity and throughput in I/O terminal production
In the fall of 2021, Beckhoff began to completely rethink the way it carried out final inspections of I/O components. Its aim was to significantly increase testing capacity and throughput, even though many different types of terminals are produced. The system, which was created entirely by the company’s own equipment manufacturing department, can program, adjust, and test around 10,000 terminals per shift fully automatically. The high speed and flexibility are the result of not only the sophisticated system concept, but also the intelligent XPlanar transport system, PC-based control, and the wide range of EtherCAT Terminals.
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IALB, Germany: Automation of a 10 MVA test rig for wind turbines
Major points of interest to the German energy industry right now include the service life of power electronics in wind turbines along with determining the environmental and load conditions that play a role in this regard. Keen to find answers, scientists at the Institute for Electrical Drives, Power Electronics, and Devices (IALB) at the University of Bremen are working closely with the Fraunhofer Institute for Wind Energy Systems (IWES) to learn more.
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Borghi S.p.A., Italy: New machine concept for the industrial production of brooms and brushes
Industrial production of brooms and brushes is not much different from the classic manual approach: the machines just work faster – but still not fast enough for Italian machine builder Borghi S.p.A. This is where the Moon project came in, allowing the company to make a significant leap in terms of productivity. The project saw the development and implementation of a completely new production sequence using PC-based control and the AMP8000 distributed servo drive system based on EtherCAT P.
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MELD Manufacturing, USA: Flexible PC-based control for additive manufacturing with solid-state metals
Meld Manufacturing has pioneered a solid-state metal additive process that is based on applying friction and force. The advantages compared to melt-based processes include very large-format 3D printers and higher part strength. For optimal control of its systems, the company relies on flexible EtherCAT and PC-based control technology from Beckhoff.
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Griffyn Robotech, India: EtherCAT-based servo technology in inspection machine for smart display devices
The grading of cell phones and tablets according to cosmetic defects determines the necessary measures for refurbishment. In its inspection machine – for both new and used smart devices –, AI expert Griffyn Robotech uses PC-based control from Beckhoff for precise motion control in product handling. This enables the detection of micron-level surface defects in split seconds.
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Mitec Enginy, Spain: Sophisticated, highly efficient production line through PC- and EtherCAT-based servo drive technology
Mitec Enginy, a young and dynamic automation integrator based in northern Spain, says it has developed a sophisticated and powerful production technology masterpiece. The core element is a revolutionary motion control system with a total of 67 servo axes synchronized by a camming function. The result is a production line that feeds, cuts and bends wire, produces springs, and mass-produces the final product – a rat trap – in just 1.5 s.