AIDA is a top player supplier of high-speed presses, automation equipment and complete metal forming systems for EV motors, electric motors and generators laminations with the highest production quality standard of the market.
Since its foundation in 1917, the company has continuously evolved and today AIDA has production plants in Asia, Europe and Northern America with a global presence in over 60 countries worldwide; currently, AIDA has more than 80.000 presses installed worldwide, with capacities ranging from 35 to 4.000 metric tons. AIDA presses are used to manufacture a broad range of items including automobile components, appliance parts, electric and electronic components, connectors and terminals, and motor laminations.
AIDA manufactures a complete lineof metalforming presses, including gap, straightside, progressive die, transfer, high speed, cold forging and servo-driven mechanical presses. AIDA Service provides spare parts, technical support and presses related services as well, for instance, presses maintenance, presses relocation, presses revamping and second hand presses trade.
From the best Italian engineering and industrial tradition stems a flexible innovative reality, by mentality and sizes: Bluergo.
Appreciated on a world scale for the tachometer coils for washing machines and dishwashers, the company proposes solutions also in other sectors, where the diffusion of smart devices is steeply rising: from cooking to conditioning and automotive.
Organized in one factory in Veneto and one in Slovakia, to be close to its customers in Italy, in Europe and in the world, Bluergo proposes a range of solutions that go from stator coils to laminated and electronic transformers, from solenoid valves to tachometer coils, from injector for motors to electromagnets for servomechanisms, from antennas to ferrite wound components and power supplies.
Specialized in the design and production of electronic and electromagnetic components, the company represents a complete response to the requirements of the most different sectors, with customized products featuring a winning quality-price ratio. A high level of competitiveness assured by a team of 100 young and very motivated people, guided by a dynamic management and willing to accept new challenges unceasingly. All that with a significant productive capacity, with automated processes that benefit from an efficient quality management, with control systems that grant the highest standards, thanks to the use of SPC protocols and test equipment during the entire product development cycle.
BTSRInternational 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 BTSRÂ 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.
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.
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.
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.
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.
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.
Lomagna plants covers 23,000 square metres and can host over 500 people
Managing the entire product lifecycle. These are the skills of Elemaster, which ranges from the design to the industrialization and certification of electronic instruments, from rapid prototyping to mass production, from the manufacturing of custom components, like the printed circuit board, to the supply of “turnkey” products, up to logistics and after sales service.
It operates in the sector of Original Design Manufacturing and of Electronic Manufacturing Services and nowadays its activity includes the design and manufacturing on a world scale of electronic equipment with high technological content. It is Elemaster Group, which in this issue of Electric Motor Engineering we have involved for a focus on industrial sector realities.
Today Elemaster is organized as an Electronic Technology Partner, as it can manage the entire product lifecycle: from the design to the industrialization and certification of electronic instruments, from the rapid prototyping to the mass production, from the manufactoring of custom components like printed circuit boards and custom cables to the electromechanical integration and the supply of “turnkey” products, up to logistics and after sales service.
Elemaster in particular works with a rising number of “fabless” companies, which outsource the manufacturing activity, focusing their strategic efforts on the marketing and sale of products. This market evolution has determined a new value proposal, meant as the offer of integrated services with high added-value generated by the research and development activity that concerns both products and manufacturing processes, increasingly oriented to the lean manufacturing.
Elemaster: from 1978 to 2018 a long entrepreneurial and family course
From left: Giovanni Cogliati (Sales & Marketing Manager); Gabriele Cogliati (CEO and President); Rosella Crippa (Vice President); Valentina Cogliati (Managing Director)
The history of Elemaster started in October 1978, when in a basement in Merate (Lecco province) Gabriele and Rosella Cogliati, two people in their early twenties and recently married, lay the bases of a long entrepreneurial and family course. “The origin of our whole history, from 1978 until now, when we celebrate the fortieth anniversary since the foundation, stemmed from the courageous initial decision of giving up a stable and well paid job to undertake our own autonomous activity, aware of sacrifices and renunciations, putting at disposal our scarce economic resources”, starts explaining Gabriele Cogliati, today CEO and President of a Group worth 220 million Euros of turnover, over one thousand of workers employed in Italy, Europe and worldwide, with a strong bent for internationalization and a constant boost to technological innovation. Cogliati intended to offer a technical service of engineering and industrialization of the electronic product component to its customers and the latter immediately show a growing confidence: orders increase and, in addition to design, the demand for the prototype implementation starts. In Italy, it is the time of the development of electronic and information technologies, there is a growing demand for innovation and Elemaster finds its way with its own business model, becoming partner and reference reality for its customers. From the design and prototyping to the production of pre-series and then of turnkey finished products the distance is short. The space and the small group of collaborators of the origins are no longer sufficient, it becomes necessary to build a factory at Montevecchia, 2,000 square metres hosting about 50 employees: we are in 1988. Initially dedicated to the industrial automation sector, since 1990 onwards Elemaster has approached the energy and afterwards the medical sector, then gaining specialized competences in the transport sector, especially railway and avionics. At Montevecchia the development goes on with the vertical offer integration, through the establishment of a factory intended for the production of printed circuit boards (Eleprint) and, afterwards, through the widening of the manufacturing capacity with a new further local unit, taking up 3,000 square metres and hosting around 150 workers. In 1999, they establish a production site in Basilicata and start taking part in research projects, also due to noteworthy collaborations with the university world. In 2000, all the activities of research, development and hardware and software design are unified in a dedicated company: Eletech. In 2007, a new outstanding enlargement: Elemaster accomplishes the building of the plant at Lomagna that, on 23,000 square metres, can host over 500 collaborators, quadrupling the manufacturing capacity. In the last ten years, the Group has pursued a globalization process that has resulted in the presence, with dedicated design and production units, in Germany, United States, China, India and Africa. In 2016, they launched the “Vision 2020”programme, the industrial plan providing for the strategic development lines of the successive years that the company is currently implementing with great determination and has led to the setup of a commercial branch in France and to the recent takeover of a competitor with premises in Belgium and Romania.
The fortieth anniversary occurs in a time of economic and social uncertainties but Elemaster Group can look at the future with renewed effectiveness, aware it can rely on highly fidelized customers, suppliers and collaborators. The competition is global, the only solution is “Knowing and being able to do” and knowledge, competence, discipline and daily commitment are required in the current context. Elemaster is committed to pursue the outlined course, oriented to the full customer satisfaction, in a context of improvement and constant innovation of processes, services and products.’’ Gabriele Cogliati, Ceo and President of the Group
Elemaster’s supervision of the complete productive cycle, besides allowing a direct control of all process phases, permits customers to rely on a single partner for the entire value creation chain: each of the 6,000 different products (electronic board, electromechanical subassembly or finished product) that the Group manufactures every year is the result of a tailor-made technological solution.Â
In the course of its history, Elemaster Group has widened the number of segments and market niches where to operate, today attaining a diversified business portfolio of over two hundred customers subdivided in ten industrial segments. Currently the range of action, on a world scale in high-tech sectors, goes from railway to avionics, medical, automotive, industrial automation and energy, with an all-round activity that allows a positive contamination.
Giovanni Cogliati, Sales&Marketing Manager, second generation who manages Elemaster Group
The all-round activity of Elemaster allows a positive contamination, thanks to which the best practices of each sector are extended to other sectors’ productions. Wherever there is an innovative high-tech niche, Elemaster can propose its services in compliance with the highest qualitative standards.
Electric mobility
Among high-tech solutions and services in mobility and automotive sector, in particular, the supply encompasses electronic and electromechanical components, besides completely assembled and tested equipment. Among the main applications, it is worth mentioning control systems for hybrid & electric vehicles, earth-moving machines and heavy vehicles; motor & automatic transmission controls; telemetry and localization systems. We asked some questions to Claudio Accorsi, Corporate Business Development Manager of Elemaster Group, about the design and production activity for the electric mobility.
What are the growth prospects in the electric mobility sector and at what products does
Elemaster work? “Elemaster has designed and produced the majority of the electric and electronic systems for the electric mobility for over twenty years. We rank among the primary players in Europe and we are steeply rising in the other continents (USA and China), too, we are working at the biggest machine today existing in the world for the electric mobility: the train. Besides, we supply all ground equipment for the traffic and fleet management. The mantra that accompanies us in the mobility world is Drive by Data”.
Claudio Accorsi, Corporate Business Development Manager Elemaster Group
We are extending the offer for the electric mobility to the automotive industry: we are working with big customers both in Italy and in Germany, from electronic controls for the optimal energy management on board of vehicles to the functional control of sensors as support to the assisted drive. The successive step will concern the cars with autonomous drive.
On what know-how does Elemaster ground its offer? “The expertise is consolidated and developed by constantly evolving projects, from the implementation of the functional safety in components to the management and reduction of consumptions. One of the most challenging projects for us is the wireless train: for the power supply, we will exploit new energy-accumulation systems applied to ultra-light trains that will travel in cities covering also “the last mile”.
Thanks to this know-how we are extending the offer for the electric mobility to the automotive industry: we are working with big customers both in Italy and in Germany, from electronic controls for the optimal energy management on board of vehicles to the functional control of sensors as support to the assisted drive. The successive step will concern the cars with autonomous drive: in the next 10-15 years, they will become Wheel Robots in the mobility integrated with trains and planes”.
What companies of the Group are involved and what is their contribution in the project? Eletech is protagonist in researching and exploring the most advanced technologies available on the market and in supporting customers through co-design services.
Elemaster, due to its ISO TS-certified factories, is the ideal partner to turn innovative ideas into mass productions.
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.
