Electric Mobility Electric Motor Assembly & End of Line Testing Solutions. Electric Motor. Test Systems. ThyssenKrupp System Engineering

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1 Electric Mobility Electric Motor Assembly & End of Line Testing Solutions Electric Motor Test Systems ThyssenKrupp System Engineering

2 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 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- components, plant and factory planning. Our main scope of supply is the design, manufacturing and commissioning of turnkey lines out of one hand. Stator Rotor Final End of Line Test Assembly of coils Impregnation Assembly of contact ring Assembly of magnets Assembly of laminations with shaft Balancing and magnetizing Pre- of bearings Adjustment of components Final and finish Isolation test Leak test Functional test Customer advantages: From coil pre 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 2 3

3 Assembly solutions for electric mobility Assembly line for high speed traction motor We plan our 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 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 Stator 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

4 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 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 Testing solutions for electric motors: 6 E-Motor End of Line test benches Customized 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 Software engineering 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 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 Battery 7

5 ThyssenKrupp System Engineering /2015