Battery Charger
from the One-Stop-Shop
Industrialization and fully automated series production of a correlating 5-part battery management system.
Coordination and full service as the key to product success. How we bring a 5-part battery charger system into series production in an efficient and reproducible process with state-of-the-art insertion and assembly services.
# Initial situation
New product development and one-stop-shop production with high process efficiency and time-to-market requirements
These complex injection-molded assemblies are installed in various models and installation situations in electrified vehicles from the premium segment. The electronics built into the device take over the power management of the e-vehicles as well as the control between driving and charging mode. Our customer was looking for an experienced partner who could offer all services in line with specifications and from a single source – from component optimization and series production to fully automated assembly. Everything is coordinated and with a competent contact person for the entire value chain in the GAUDLITZ HUB.
The aim was to develop the best possible assembly solution in a one-stop-shop strategy for the battery management system in question. The major challenge of the project lies in the compactness of the modules, which previously operated as individual devices in isolation and are now combined into one large device.
Five correlating plastic parts, into which various metal bushings are inserted, overmolded or ultrasonically assembled, must be installed together and then further assembled into a single unit. In addition to the plastic-compatible design, we were also looking for a way to make these disciplines suitable for mass production.
”Together with our customers, we are developing the e-mobility of the future. This shows that we can achieve significant time and resource benefits by bundling and coordinating all services.
Marco WirthChief Sales Officer
# Solution
The GAUDLITZ HUB as a full solution provider
We take over the complete analysis, simulation and plastic-compatible component development as well as the subsequent large-scale production in an extremely short time to market. Our experience and processing expertise in plastics proves its worth particularly when it comes to the holistic coordination of highly complex functions.
As the mold parting burr always occurs due to the mold parting process, we rely on high-precision and clean deburring using CO² snow and micro pressure waves. This extremely efficient CO² deburring process is based on the principle of “dry deburring” and represents an optimum alternative to classic jet deburring.
# Market advantage
Synergies and efficiency benefits from the one-stop store
Extremely fast to market maturity
Everything interlocks and remains in-house. Thanks to the 1-site development with all manufacturing and assembly services, we are accelerating industrialization.
Perfectly coordinated
All correlating components are designed in the tool in accordance with the required tolerance values and quality criteria.
An economical complete solution
Our one-stop store solution enables fast reactions and scalability as well as a lean and globally roll-outable production concept without unnecessary external service providers.
Fully integrated socket concept with R&D
Various metal inserts with different diameters are used to ensure stability and mounting on the vehicle. The assembly concept developed includes the overmolding of the various metal bushings via press-fit, inlay assembly and vibration welding or ultrasonic assembly. Depending on the construction situation or the requirements for the metal insert, the most economical and efficient process is selected.
Potential for errors in binding seams minimized
When two enamel fronts meet, so-called weld lines are formed as a result of the process. The rapid cooling of the flow fronts results in inhomogeneous joints, which become visible as surface defects in the form of a flow line and represent a weak point under mechanical loads in the injection molded component. However, we can counteract this in terms of development and design.
Thanks to filling simulations, we move the weld lines to areas that are not visible and prone to breakage. At the same time, we counteract the formation of such surface defects by increasing the injection speed, reinforcing the material with glass fibers (PA66 GF35) and adjusting the wall thicknesses.
# Next Gen Projects
Together we create Next Gen Solutions.
“We know the production side and have the development expertise. Only those who understand both sides and bring them together will be able to demonstrate a competitive edge.”
Chief Sales Officer
