Electric Mobility
Electric Motor Assembly &
End of Line Testing Solutions
Electric
Motor
Test
Systems
ThyssenKrupp System Engineering
ThyssenKrupp System Engineering
Solutions for industrial series production
Assembly solutions for electric mobility
Our product spectrum
ThyssenKrupp System Engineering is an internationally
acting affiliate of the ThyssenKrupp Industrial Solutions
AG, a system partner for all important components of
the process chains for car body and powertrain in the
automotive industry. The product range also includes
automation solutions for electrical storage and drive
systems, solutions for innovative lightweight designs as
well as lines and test systems for aviation industry.
We deliver turnkey assembly systems for serial and parallel hybrids, range extender and pure electric drive
trains and their components.
ThyssenKrupp System Engineering is a strong and reliable partner to its customers, optimizing their
value chain and strengthening their efficiency.
Electric mobility - Knowledge and expertise
designed to shape the market of the future
Low emission electric propulsion systems will
characterize and shape the mobility of the future.
Currently, electric powertrains and renewable energies
are expanding their market shares. System Engineering
is applying its extensive experience from production
lines of the automotive industry.
Our scope of electric motor: - Assembly lines for electric motors
- End of Line test equipment for electric motors
and hybrid powertrains
- Service and support worldwide
Our comprehensive range of services include the consulting of our customers in the development
of design-to-assembly components, plant and factory planning. Our main scope of supply is the
design, manufacturing and commissioning of turnkey assembly lines out of one hand.
Stator
assembly
Rotor
assembly
Final
assembly
End of Line
Test
2
• Assembly of coils
• Impregnation
• Assembly of contact ring
• Assembly of magnets
• Assembly of laminations with shaft
• Balancing and magnetizing
• Pre-assembly of bearings
• Adjustment of components
• Final assembly and finish
• Isolation test
• Leak test
• Functional test
Customer advantages:
From coil preassembly up to
the final test – turnkey
Highest product quality by
optimally designed systems
Flexible production ramp-up
– investment in several steps
Experience of over 300
engine and transmissions
test benches
3
Assembly solutions for electric mobility
Assembly line for high speed traction motor
We plan our assembly systems by utilizing proven standard elements and augmenting with
custom solutions when necessary. Meeting special customer requests is our priority.
Balancing and magnetizing of rotor
Final assembly of electric motor
• Balancing of rotor shaft
• Magnetizing and pressing of bearing
• 100% automatic operation due to ergonomics
• Combined station with manual and automatic operations
• Precise insertion of magnetized rotor into stator
• Automatic pressing of bearing, manual fastening
Rotor assembly
Stator assembly
• Shrink fit of lamination with shaft
• Heating oven and cryo-bath for parts
• 100% automatic operation due to safety
• Inductive heating of stator housing
• Automatic picking and insertion of coil into housing
• Subsequent cooling tunnel for acclimation of parts
Part insertion
Assembly of transmission
• Cost optimized robot pick solution
• Manual operation of turntable
• Cycle time independent by part buffering
• Semi-automatic work station
• Assembly aids for assisted operation
• Acquiring and saving of all fastening torques
4
5
Testing solutions for electric mobility
Test benches for electric powertrain
Customer advantages
Why choose ThyssenKrupp
System Engineering?
We deliver End of Line test benches for pilot and serial productions not only for individual e-motors
but also for gearbox integrated traction motors in hybrid applications with combustion engines.
EPC Contractor
Customized
Engineering
Cost optimized serial test benches
Flexible pilot test benches
Testing software applicable for e.g.:
• Load test, clutch test
• NVH examination of transmission
• Electric tests for electric motor
• CAN bus/ rest bus simulation
Mechanical elements
• Development of electrical connections
(References: up to 300A / 500V)
• Plugs for manual or automatic
operations
Expertise
• More then 300 test benches already
delivered for engines and transmissions
• Volume s from R&D to serial production
• Sizes from motorcycle to trucks
6
Testing solutions for
electric motors:
Battery assembly
E-Motor assembly
End of Line test benches
Software engineering
• Simultaneous Engineering
• Concept creation and consulting
• Visualization / Simulation / Digital factory
(E)ngineering
(P)rocurement
(C)onstruction
• Single machines
• Workstations / lines
• Factories (Turnkey)
Service and
Maintenance
• Training, coaching, production assistance
• Service and maintenance, spare parts
• Hotline worldwide
• Individual electric motors
• Gearbox integrated
e-motors with
transmission
Project Management Excellence
PMI trained Project Management staff with multi-discipline experience to launch projects on time and at rate
• Complete hybrid drive
trains with battery and
combustion engines
High Technology Standard
Ongoing research and development enables us to
deliver the latest technology to our customers
Global Team Available
Worldwide presence for service and support
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ThyssenKrupp System Engineering
02/2015
Email: systemengineering@thyssenkrupp.com
www.thyssenkrupp-system-engineering.com