lunedì, maggio 27, 2019

Air becomes electric

Specialized since the foundation, in 1955, in the production of laminations for motors and transformers, Trancerie Emiliane, owned by Felisa family, are unavoidably interested in the e-mobility theme.

At the beginning, it was the sound, and precisely the unmistakable one by Beatles. On tour in Italy in the early Sixties, the four from Liverpool clearly needed all possible stage equipment, starting with amplifiers. They were supplied by Davoli’s made in Italy, whose resonance boxes were echoed by the transformers by a small Parma company. We are speaking of Trancerie Emiliane that few years before had stemmed from the entrepreneurship of Pietro Felisa, founder driven by ingeniousness and the will of leaving war miseries behind. Since then, Felisa workshop has developed up to gaining the sizes and the renown as big international manufacturer of laminations for transformers and electric motors, entering the world of induced activities of leader global brands in automotive and not only. Today it relies on a subsidiary in Slovak territory and 350-400 workers in all, with a turnover of 150 millions. The time seems propitious for further great strides, due to the clamour aroused by the race to e-mobility.

Felisa family. From left: Paolo, Nadia, Pietro (founder) and Franco

The managing director Franco Felisa strongly believes that the electrification of light transports, or at least their strong hybridization, represents the (sustainable) future of mobility and perhaps of even human kind, even if he is aware that the road to be travelled is still long and will reserve new surprises.
«E-cars and hybrid», he told Electric Motor Engineering, «are the vehicles of the future but I do not think that their definitive success, that is to say the complete replacement of thermal engines with electric motors, can be implemented in the short term.
Let us just consider the infrastructural deficiencies from which we suffer, for instance, in terms of energy production and distribution capacity.

Trancerie Emiliane has developed up to gaining the sizes and the renown as big international manufacturer of laminations for transformers and electric motors, entering the world of induced activities of leader global brands in automotive and not only

The game and the candle

In spite of that, the investments by big brands and by some representatives of their induced activities do not seem to leave any doubt: they are constantly growing.
The numbers at stake are attractive even if, currently, the planned output is in most cases equal to less than one tenth of means of transport produced in the world in one year.
While vendors generally compete on the distance covered and the mileage of their cars, their supply chain, to which also Parma brand refers, copes with fully different matters, like the development of the production of new components that imply the implementation of equipment to be used in brand-new forefront manufacturing lines.
«Another fundamental step for the success of the electric mobility», commented Franco Felisa, «is represented by the development of batteries, and the issue is not exclusively of commercial or technological character.
The automotive industry is working hard to establish long-term agreements with the owners of lithium mines to be sure it will be supplied with the precious mineral.

A shock of realism

In the opinion of Franco Felisa, batteries must be recharged in the lapse of few minutes and the recharge must be sufficient for hundreds of kilometres to allow zero-impact four-wheels to keep their promises and to meet market requirements.

Nowadays, unfortunately this technology is not available, yet, and, in fact, it needs too much time for a complete recharge, with which it is not possible to travel long distances, yet, and anyway at low average speed.
To succeed in the aim of giving more autonomy and higher average speed to vehicles, manufacturers must strive to produce less energy-eating electric motors.
One of the feasible ways is certainly the reduction of sheet metal thicknesses.
Instead of the common 0.5 mm thickness used for standard electric motors, already today automotive uses thicknesses from 0.35mm to 0.27mm, but some automotive companies report and produce prototypes with sheet metal thickness of 0.19 mm.
This requirement urges the entire chain to an epochal change in the implementation, for instance, of the necessary steels, as well as of apt equipment and machines for blanking the laminations for the production of electric motors.

Today Trancerie Emiliane relies on a subsidiary in Slovak territory and 350-400 workers in all, with a turnover of 150 millions

In my opinion, this is the approximate situation we are likely to face for the whole current year.
From 2020 to 2021, the numbers of electric vehicles introduced by companies into their ranges will be much broader.
Certainly, we cannot get off the running train of the e-mobility and Trancerie Emiliane are ready for racing and for satisfying its customers’ demands and needs.

Zero tolerance

In comparison with past years, before the 2008-crisis, certainly the whole market scenario has radically changed, for instance with delivery terms dropped from some months in the past to the present few weeks, as well as quality, irredeemably shifted to zero PPM. Despite criticalities, Felisa irremissibly considers automotive as the core of his company’s next initiatives and he is certain the future coincides with the diffusion of the e-car.

Trancerie Emiliane, Parma Headquarters

4.0 blanking

«We have clear ideas about what we would like to do», he anticipated, «but in a scenario of such a difficult interpretation caution is mandatory.

We imagine a robotic “next” factory, with electric trains that will handle goods in absolute autonomy, and fully automated warehouses, too, without anyway ever forgetting the human factor that is, and must remain, the focus of each of our thoughts or actions. On the other hand, employees’ competences and their way of working are expected to live an epochal change. Besides machines, workers are and will be called to increasingly use forefront consoles of collection and transfer of data concerning single job orders and all that can be used to fulfil them.

AIDA MSP
AIDA presses in Trancerie Emiliane plant

The AIDA MSP allows producing high precision and high-efficiency motors such as EV motors, HEV motors and energy-efficient home appliances motors. AIDA MSP presses are characterized by a remarkable dynamic precision due to both the compact design and the multiple suspension points architecture in line, to the native AIM function (Adjust In Motion) and to the balance reached between the high rigidity and the large surface of bed area. AIDA MSP presses guarantee unsurpassed accuracy and the longest die life thanks to the lowest deflection characteristics. Moreover, all areas that transmit the press the forming loads, such as the connecting rod bearings and the crankshaft bearings, are made from special metals selected to avoid heat deformations. Ideal for production of parts featuring thicknesses under 0.2 mm Multiple suspension points Oil temperature control unit Caliper type clutch and brake Highly rigid frame Highly rigid guidepost Adjust In Motion function (AIM)

Trancerie Emiliane has recently bought new AIDA presses that will be interconnected with the company, actively participating in the industry 4.0 project

We imagine the next job as absolutely less heavy from the physical point of view but much more committing in intellectual terms.
To compete globally, we must create further flexibility and this is accomplished through studies and investments in people and machines.
Trancerie Emiliane’s programme includes the implementation of a central unit or control tower that tracks in integrated way the information about activities in course and productions, the state of the art of each machining, which can be monitored step by step from remote.
Concerning this, Trancerie Emiliane has recently bought new AIDA presses that will be interconnected with the company, actively participating in the industry 4.0 project.

Stame, complex and precise mechanical parts

Established in 1977 thanks to the farsightedness of the current founders and owners, Canali brothers, during the years Stame has specialized in producing mechanical parts, of complex geometry and fair or good dimensional precision, through compaction and sintering of metal powders.

Nowadays the company produces parts for various mechanical production sectors, from locks to household appliances, from motorcycle to automotive induced activities. A relevant part of the generated turnover is carried out with foreign companies. Due to a basic choice, Stame is deeply interested in scientific and technological innovation. The study and the setting up of innovative sintered materials and advanced mechanical solutions, together with customers’ collaboration in designing, are part of the company philosophy and are more and more often encompassed in the ambit of the activities planned and developed systematically.

To improve the professional level and the technical-scientific competences of its human resources, Stame encourages its engineers’ participation in training activities, seminars and international sector meetings.

Cagnoni goes on its growth, not only electric commutators

With over 70 history behind, Cagnoni prosecutes its growth and expansion course, today even more structural and organizational than ever. In fact, since the first months of the current year the company has carried out its activity in the new headquarters taking up about 4,000 sq. m., still in Osimo (AN), at the service of the numerous supplied sectors. Among them, stand out automotive and appliances, for which Cagnoni plays the role of problem-solver, supporting its customers’ engineers in the design development.

A fundamental synergistic contribution, highly appreciated especially by Research & Development departments, with which they establish and share the targets to be reached. Approach that today can benefit not only from the wider operational spaces of the new Headquarters, but also from an even better structured organization and from an increasingly digital and high-quality process management. A high productivity assured by a machine fleet composed by 12 mechanical presses from 30 to 350 tons, automated by electronic feeders and specific bending machines for the processing of technical materials, completed by EDM plants, very high-precision NC milling and grinding machines. The division, further developed in the new headquarters, can process 15,000 kg a day of raw materials, manufacture about 250,000 items a day, from few tenths of gram up to 400 grams, and machine thicknesses ranging from 0.10 mm up to 4 mm.

The production of electric commutators for electric motors in DC and AC, they too used in several sectors, exploits a unique technology that allows less waste of raw materials, without affecting the product quality and assuring high performances, reliability and extreme flexibility. Robotic isles, in-process controls through sophisticated high-resolution cameras and the use of software for defect diagnosis, decrease in-house machining costs at Cagnoni, offering notable economic advantages, and then more competitiveness, to customers.

Euro Group, magnetic steel laminations worldwide

Stampa

Euro Group is the industrial holding company of an italian metalworking group with 51 years of history. It has grown to become a world top player in the production of magnetic steel laminations for stators and rotors of electric motors and generators.

Euro Groups market presence is worldwide, with 7 production units in Italy and another 5 in Mexico, United States, Tunisia, Russia and China.

The market for electric motors is increasingly demanding in terms of product complexity, shorter project development to market time, price competitiveness and high service level.

Euro Group meets these demands as a global partner who can offer solutions from dedicated production facilities to provide the best fit for all our customer requirements. To achieve these targets it has become master craftsman of its historical technologies (tool design and manufacture, blanking, die-casting, core assembly and slinky).

The company also cooperates as partners in the development of new families of magnetic steels.

Euro Group identifies and develops cutting-edge new technologies (for example laser welding, self-bonding steels, in-die gluing) and approaches new business opportunities with a structured Project Management, who have access to fast prototyping and numerical tools to simulate processes and designs to mitigate risks in serial production.

Zoppas: heating systems for domestic and industrial applications

Heat pump products are increasingly present in each consumer’s experience. Their success is based on the energy saving and the environment protection: pursuing this target, the European Ecodesign regulation is introducing new important transformations at products’ core. However, the new generation of heat pump products will be asked to solve important technical challenges, as in the case of problems connected with the replacement of refrigerating gases.

Zoppas Industries Heating Element Technologies – global supplier and top player in design, production and sale of heating systems for domestic and industrial applications – offers a broad range of suitable solutions for facing the technical challenges in the development of new heating products equipped with heat pump technology. In the case of domestic washers-dryers, for instance, Zoppas Industries has developed innovative solutions of thermal boosters for applications exposed to the flammability risk of refrigerating gases. They have overcome, in particular, the limits of the previous generation, characterized by the use of bare-wire technology. The experience gained, operating for 50 years in over 200 different markets, is the driving engine of a portfolio of systems and technologies suiting tradition and at the same time keeping pace with innovation: new, reliable and advanced heating solutions, for products addressing aware customers.

Risatti Instruments, testing electric motors

In recent years, companie’s investments  in the production of the electric motor for automotive have exponentially grown. This very particular product typology, in its turn, needs very definite and complete testing processes, to make the motor highly performing.

The experience of Risatti Instruments , combined with the new technologies developed by the company, allow customers to reach the prefixed targets. The testing phase starts from the control of losses in the iron of the assembled stator stack (N1), to optimize all manufacturing phases and then to obtain the highest efficiency. This analysis is carried out also on the rotor (O166) where, in addition, it is also possible to assess the die-casting quality, detecting also eventual interruptions and blows of bars, as well as the aluminium quality, which notably decrease efficiency. Concerning instead the stator testing (H5), four standard tests are carried out: ohmic resistance, stiffness, SURGE and rotation sense, with the further addition of: measurement of the insulation resistance, measurement of the ohmic resistance in alternate, at different frequencies, for the control of copper losses and the detection of the presence of partial discharges.

The issue of finished motor testing follows: of both the only motor, loadless or loaded, with the detection of the characteristic curve, and equipped with reduction and differential gear to evaluate the overall efficiency. The scheme proposed here represents the ideal testing process with the machines by Risatti Instruments, produced according to its customers’ single requirements, with the addition of suitable lab instruments (H3) for executing all tests for the design assessment and life tests, as well as complete tests on batteries.

Demak, vacuum casting system

Among the several applications that require the resin-bonding or the vacuum casting, there are also electric motors, whose insulation is absolutely necessary to grant them very long duration. Air bubbles or resin gaps can diminish the motor insulation, damaging performances and service life. Moreover, a partial discharge between the ground and primary insulation can occur.

Another reason for avoiding bubbles is the decrease of the heat dissipation, provided by resin and essential for the long service life of the motor and the preservation of high performances. Therefore, the resin must be “forced” into all inner spaces of the motor (especially in undercuts and in windings). The only possible procedure is vacuum casting.

Demak, thanks to its vacuum casting system, can assure the total absence of air in resin (by means of efficacious degassing systems) and in finished products, too. Then, all dispensing systems used in these process types are equipped with vacuum cabins, but not only: Demak technology for vacuum degassing starts from the resin loading on the machine until the last dispensing time. An efficient vacuum dispensing process, together with epoxy resin featuring high thermal resistance, allows qualifying motors for all durability tests required by OEM.

TE Connectivity offers magnet wire connection solutions

Many manufacturers of motors, solenoids, coils and other assemblies continue to use traditional, manual soldering techniques for magnet wire connections in their products. This can be costly, both in terms of the time required to make these manual connections, and in terms of quality, given that such processes are difficult to control and may result in poor connections.

TE Connectivity (TE) offers alternative solutions for terminating magnet wire, whether it is copper, aluminum or a combination of both. The terminals and splices are supported with application tooling ranging from hand insertion tools up to customer specific machines. High speed, fully automated, integrated systems provide uniform terminations reliably at a very low applied cost. No pre-stripping, soldering or welding of magnet wire is required.

MAG-MATE terminals and SIAMEZE terminals utilize insulation displacement connection technology, while AMPLIVAR terminals and splices utilize compression crimp technology.

GROB, 90 years of manufacturing machines and lines

For over 90 years, GROB has been one of the primary global players operating in the development and production of manufacturing machines and lines. GROB’s customers include the most prestigious automotive companies in the world, their suppliers and several other renowned companies in various sectors.

With production plants in Mindelheim (Germany), Bluffton, Ohio (USA), San Paolo (Brazil), Dalian (China) and Turin (Italy) and service/sale subsidiaries worldwide, GROB is present all over the world. GROB Group generates a global turnover that exceeds 1.5 billion Euros, with a labour force of about 6,900 employees. GROB range goes from universal machining centres to highly complex production systems with automation function, up to encompassing manual assembling stations and fully automated assembling lines.

The broad product range includes also production plants for electric motors and assembling, battery lines and fuel cell technology. GROB engineers are accomplishing technological solutions for the spraying of motor components, for cutting high-strength turbine housings and for machining structural components and chassis. Through the development of GROB-NET4Industry, industrial proprietary software for digitalization and in-net connection of production systems, the company is making great strides in the digital future.

BTSR, electronic sensors for the quality control

BTSR International operates in the design and manufacturing of electronic sensors for the quality control in the manufacturing chains of clothing-textile, mechano-textile and technical textile, besides operating for years also with solutions for the testing of metal wires (copper and precious metals).

CWF 2000 by BTSR  represents an innovative solution that goes beyond the state-of-the-art in the wire feeding technology and will unavoidably exert an impact on the wire winding sector. It is a highly technological multi-patented system, thanks to a completely new and different control modality of wire tension compared to the already known and more traditional ones, it allows reaching unprecedented process efficiencies and quality.

Due to its design and implementation, it allows feeding the wire in constant and uniform manner, irrespective of the speed of the wire itself, connected with the machine speed and the coil size, and of the coil section/shape. Based on the new concept of “dual drive system”, able to grant the perfect combination between the feeding control and the accumulation control, the new CWF 2000 represents the first “positive and driven” feeder released on the market. Compact and ergonomic, this device can be integrated on existing lines and can process wires from 0.014 to 0.6 mm of diameter.

Thanks to its intrinsic peculiarities, it allows programming up to three different values of wire feeding tension, without any interface/connection to the coil winding machine. Alternatively, up to 4 different values of wire feeding tension during the winding cycle, using two outputs of the digital coil winder. Keeping pace with Industry 4.0, the new CWF 2000 is based on control software that can be integrated also into the PLC of the coil winding machine where it is installed, with all consequent operational benefits. Available in two versions, (CWF2000 to work on machines with double winding and coil, and CWF2000 HCL for needle machines and needle winding machines), it finds applications in several sectors including manufacturers of ignition coils for automotive, of solenoids, of transformers, of relays, of stator and rotor windings for household appliance motors.