E-Mobility Manufacturing Automation Solutions

Bihler Advantages for EV Manufacturing Equipment

At Bihler, we put our best features in every machine, letting you experience the benefits of our innovative:

High output rates: Depending on the nature of your products, some Bihler stamping and forming machines can reach output levels of over 300 parts per minute. Ensure your operations can keep up with the ever-growing nature of your industry by using the most efficient tools.

Significant material savings: Bihler believes in efficiently using your materials while producing as little waste as possible. Our e-mobility manufacturing solutions can retain lost materials during linear and radial production to maximize material usage.

Standardized, all-in-one production: Invest in new Bihler equipment or choose the modules you need to integrate our technology with your existing setup. Bihler machines are fitted with up to 70% standardized parts to work with other brands and fill the gaps in your current capabilities, from stamping and cutting to assembly and finishing.

Short changeovers: Improved efficiency means reduced downtime. Replacing modules on Bihler systems to prepare for a new production phase only takes a few minutes, allowing you to get back to work quickly.

Integrated monitoring stations: Ensure production stays up to speed and delivers products of consistently high quality with our integrated monitoring systems. This feature lets you observe production from start to finish and adjust immediately to respond to issues such as an updated specification or inaccurate measurement.

E-Mobility Manufacturing Consulting

If your electric vehicle company has an unmet need, such as an automated process for forming a part, our team can tailor standard Bihler e-mobility manufacturing solutions to address component-specific requirements. Whether this machine is your first piece of Bihler equipment or you’ve been our partner for years, an e-mobility consultation with our experts can take your manufacturing capabilities to the next level.

Our consultations help you maximize your company’s immediate return on investment. Our experts can provide more information on incorporating our easy-to-use equipment into your manufacturing process and adjusting the system’s programming to change its settings. Bihler strives to help our clients find success as safely and efficiently as possible, which we achieve through consultations, training and support services.

E-Mobility Components Manufactured on Bihler Equipment

Battery Busbars

Busbars made of copper or aluminium are decisive components of powerful battery systems and the complete power distribution in vehicles.

Depending on the component length and geometry, they are produced on the GRM-NC servo-stamping and forming machine with radial or linear forming tools. For additional value-added steps, the BIMERIC servo production and assembly system offers plenty of machining freedom.

Bihler’s equipment allows for flexible, high-volume production of busbars of varying configurations. Manufacturers can realize significant material savings – up to 50% in radial production and up to 33% in linear production with lengths of over 2000mm. Tooling is cost efficient and standardized and requires very short tool changeovers ranging from 30 minutes to 1.5 hours, and with our integrated monitoring stations, you can realize consistent production reliability and quality.

Cell Contact System for Battery

The battery powering an electric vehicle consists of a large number of individual cells that are connected to one another by means of a cell contact system. It is important to use a high-performance cell interconnect which minimizes power loss, ensures the best possible equalization between the cells and is also suitable for a fast, uncomplicated assembly.

In practice, the illustrated cell connectors are manufactured and mounted in the carrier frame on a Bihler servo production and assembly system.

Our equipment expertly handles production from start to finish. It not only fabricates the high-precision interconnects of the contact system, but also assembles them with other parts within a carrier frame. Complete assembly throughput is capable of producing four complete cell holders per minute. This equipment combines speed, precision, and comprehensive functionality, meeting the demands of professional e-mobility manufacturing environments.

Charging Plug Shielding Sleeves

Shielding sleeves protect and provide safety for both conductive and circumferential components from electrical or magnetic disturbances. Fabricated with our fine-detail servo stamping and forming machine and enhanced with our state-of-the-art LEANTOOL linear system, these sleeves exemplify craftsmanship and innovation.

Our equipment redefines precision manufacturing for delicate parts. It’s capable of producing these shield sleeves at a rate of 170 parts per minute and allows for 100% reproducible variant changes in less than 30 minutes thanks to cost-effective and highly standardized tools.

Hairpin Windings for Electric Motors

In some electric motors, conductor coils that generate the magnetic fields which are converted into kinetic energy consist of multiple windings such as this one manufactured on a Bihler hybrid stamping and forming machine with NC units.

We were able to configure our manufacturing equipment to deliver an all-in-one production system with isolation from the copper wire, notching, bending and cutting. The end result was a production rate of 100 parts per minute of these u-shaped hairpins with easy corrections when bending the wire thanks to the NC unit.

E-Mobility Manufacturing Automation Solutions