China’s new energy vehicle market has become the forefront of the global new energy revolution. With the support of policies and the improvement of consumer willingness, China’s new energy market has been injected with a dose of stimulant, and the automobile market is undergoing a once-in-a-century transformation. The birth of new brands, the launch of new products, and the rise of new sales models have driven irreversible changes in the industry. Competition is intensifying. From a product perspective, how can automobile manufacturers find a way out of the chaotic new energy competition? The transformation has begun, and the transformation has just begun. How can we have the password to the future?

The EMAG Group, a global leader in the metal processing industry, will be at the largest industry event of the year, CIMT 2023 (Booth: W1-B301, Time: April 10-15, 2023), with the theme of “New Energy Vehicle Parts Solutions”, integrating new processes, automation, digitalization, sustainable development and other processing elements, and focusing on displaying a number of innovative products and technologies, with the goal of helping users better cope with the multiple challenges brought about by the huge changes in the automotive industry and layout the future.

9 processes, support from the entire industry chain

As a professional company with 9 process technologies including turning, milling, gear hobbing, gear grinding, internal and external cylindrical grinding, non-circular grinding, laser welding, shrink fit assembly, and electrochemical process, EMAG is one of the few suppliers in the world that can provide a full set of process technologies and one-stop full industry chain solutions for the entire processing chain.

In response to the iterative upgrades of the drive system brought about by the rapid development of new energy vehicles, the subversive demands of automotive parts in terms of lightweight, rigidity, and precision, and the rigorous tests of automation and flexibility of processing production lines, EMAG can flexibly respond based on its own full industry chain process strength. From various gears in the reducer to different parts of the electric drive device, EMAG has customized process solutions. At the same time, based on years of R&D experience in modular and automated processing equipment, EMAG can also provide turnkey solutions for the entire processing chain.

“The automotive industry has always been one of the fields where EMAG products are most widely used and best excelled. Since the birth of the first inverted lathe in 1992, our innovative processing method that subverts the traditional concept of automation and is particularly suitable for high-precision mass production needs has been favored by many automotive parts users.” Mr. Yang Ming, General Manager of Taicang Branch of EMAG (China) Machinery Co., Ltd. and General Manager of EMAG (Chongqing) Intelligent Technology Co., Ltd., said, “Today, facing the new trend of rapid development of new energy vehicles, we have also made sufficient preparations thanks to the ‘innovation’ spirit inherent in the EMAG brand DNA. The accumulation of 9 mature processes allows EMAG to flexibly apply these technologies to machine tools and equipment, and through their mutual complementation and coordination, to meet the extensive processing needs of the new energy vehicle industry to the greatest extent.”

Core parts processing solutions, comprehensive display

The comprehensive display of multiple new energy vehicle typical parts processing solutions is the biggest highlight of this EMAG booth.

Differential housing high-speed processing solution-as the core component of the new energy vehicle drive system, the output of differential housing is continuing to increase with the hot market. Large demand, complex structure, strict processing requirements, and many difficulties greatly trouble parts manufacturers. EMAG uses modular inverted turning centers VL 4, VL 6, VT 4 and VSC 250 DD, in conjunction with the independently developed TrackMotion workpiece conveying system, to innovatively compress the processing of differential housings to 4 processes, and achieve a new breakthrough in processing efficiency with a processing cycle of 95 seconds. At present, there are nearly 100 EMAG production lines and more than 250 machine tools used in the production of differential housings worldwide, and EMAG is effectively helping users reap benefits.

Fully automatic production line for motor shafts – In this solution, one fact is clearer: EMAG’s positioning of itself is no longer just a smart equipment manufacturer, but a solution provider focusing on the entire process from blanks to finished products. Faced with the dual challenges of high production and high precision requirements for motor shafts of new energy vehicles, EMAG, relying on the process strength accumulated from rich application experience, participated in and led the design and development of the entire motor shaft processing system. This production line includes twelve main processing steps and other auxiliary processes. The connection and automation of each machine tool and workstation are realized through manipulators, truss manipulator systems and TrackMotion workpiece conveying systems.

Therefore, the motor shaft can be fully automated and completely processed under the coordination of various processing steps. In addition, this solution also has the advantage of flexibility and can be expanded at any time as the output increases, allowing customers to truly benefit from flexible and efficient production.

Innovative technology, covering more

Complete processing technology is an important support for EMAG to cope with the changes and upgrades in the processing requirements of new energy vehicle parts. At this exhibition, several innovative equipment exhibited in actual machines or prototypes also strongly confirmed this.

The first thing to introduce is the VLC 200 GT – vertical turning and grinding composite machining center, which occupies the absolute “C position” of the booth and is aimed at the new processing requirements of new energy vehicle transmission parts. It can achieve the advantages of multiple processes such as grinding and hard turning in one device, allowing it to help users shorten processing time to the greatest extent. The spindle loading and unloading concept it adopts can also easily realize automated production by connecting the shuttle channel or the circular circulation channel. The innovative gear hobbing solution, HLC 150 H, covers all relevant gear hobbing processes such as hobbing, scraping hobbing, worm milling, worm scraping, and the comprehensive process characteristics of integrated milling edges (on the same tool bar as the hob), which is an absolute all-round gear processing solution. From drive shafts and armature shafts, steering pinions to planetary gears and worm wheels, they can all be processed without burrs.

Electrochemical technology, as an important part of EMAG’s nine processes, is also a cutting-edge process that helps companies “keep the truth and be surprising”, and naturally became one of the highlights of the booth that received the most attention from the audience. Electrochemical technology, which is mainly characterized by residue-free and non-contact metal workpiece processing, is very suitable for the processing of thin-walled workpieces. It can avoid various deformations caused by traditional cutting and obtain excellent surface quality. This innovative process has great potential in the processing of some high-precision parts of new energy vehicles. EMAG’s CI 400 electrochemical machining machine (replaced by a model machine due to area reasons) provides a set of efficient processing solutions for the rotor bracket parts of the motor housing of new energy vehicles. Through the two processes of electrochemical gear “broaching” and electrochemical drilling, the rotor bracket can be completely processed without burrs. Moreover, under the condition of activating multiple cathodes at the same time, a large processing batch can be achieved according to the user’s production needs.

“Since 2022, about 65% of EMAG’s orders have come from new energy vehicles, while before 2020, this percentage was only in the single digit. It can be seen that China’s new energy vehicle industry is developing rapidly. China is the largest automobile market, the fastest growing automobile market, and the most active automobile market in scientific and technological innovation. EMAG is devoting its efforts to serving new energy customers and becoming their booster to win in China and go global.” Mr. Yang Ming concluded.
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