Production equipment

The market in electric vehicles, above all in electric cars, is currently growing rapidly, and this trend is likely to continue in the long term. This means that enormous expansion is called for in the production capacities for the core components of these vehicles, namely the lithium-ion battery cells and systems, drive unit frequency converters and electric motors. This will also apply on a similar scale to fuel cell stacks and fuel cell systems, although this development is due to come slightly later. Even though these components have been manufactured industrially for some time, this has not yet been done in the large quantities and not in the ways needed for the automotive industry in particular.

We can support you in this regard in the following areas:

Product highlights

High-performance and energy-efficient hydraulic systems

Whether it’s in the mixer to mix active materials for battery electrodes, in the calender to compress these electrodes, in test benches for electric motors and transmissions or in presses to deep-draw battery trays – the use of hydraulics continues to be widespread in the production technology for electric vehicles. In this regard, we can supply hydraulic systems that are both well-established and cutting-edge and that excel when it comes to networking, predictive maintenance and energy efficiency. For additional information, see here: CM-Expert, KineSys

Conditioning systems for new fluids

Many technologies and processes that have existed for some time are increasing in importance in the production of electric vehicles. Particularly when fluids are used in these processes, we are on hand to help you with all our fluid care expertise. Typical examples of such processes include the hardening of rotor blades and wire drawing. With the comprehensive HYDAC package of cooling, filtration and sensor systems, your fluids will always be available in the desired quality.

Technical cleanliness

Although the topic of technical cleanliness came into being with the introduction of high-pressure diesel technology, it is also a vital issue in electromobility. High-speed electric motors with increasingly small air gaps, equally high-speed transmissions, fine cooling channels integrated into the housing, bipolar plates for fuel cells or battery housing for batteries with electric voltages of up to 1,000 V – these are all components that cannot tolerate any contamination with (metallic) particles when installed, no matter how small. To allow you to work with high process reliability in spite of this, we are on hand to help you with our many years of expertise in technical cleanliness. Our portfolio ranges from services like consultation, process chain analysis and laboratory services (including mobile lab services) to components and systems that make it possible for you to set up and run a highly effective cleanliness laboratory yourself. (Link: FE/A / TS) If required, we can also offer the design and delivery of a component-specific flushing rig, which you can use to realise the technical cleanliness of your hydrogen container, for example.

Energy-efficient and compact cooling systems

From welding the battery cells to the contact system and joining two-part rotor shafts, to end-of-line test benches for combinations of electric motors and transmissions – at various points in the production of electric vehicles, there is a great need for cooling capacities at different levels of temperature. For these applications, the HYDAC Cooling Group is on hand to help with the usual broad range of fluid/air cooling systems (FLKS), fluid/fluid cooling systems (FWKS) and active cooling units (RFCS).

Components and systems for test benches

For test benches in development and production, HYDAC has supplied components and systems from the areas of cooling and hydraulics for many decades. These same approaches are needed in relation to electric vehicle production. The combined high-speed electric motor and directly flange-mounted reduction gear needs to be hydraulically clamped in the end-of-line test, for example. Both the part being tested and the test bench itself need to be cooled. Ultimately, particular attention also needs to be paid to the transmission oil filling, as the oils have a large amount of additives because of the high speeds and they also need to contain as little air and other gases as possible, in order to prevent foaming in the transmission. HYDAC oil treatment units can be used here to precondition the transmission oil.

More information available on request