Precise sensor solutions for E-mobility.

Efficient and safe production at BMW Plant.

Leuze sensors perform important tasks in the cell coating line and module production at the BMW Group plant in Leipzig: They reliably detect objects and also meet high requirements, such as the detection of high-gloss surfaces. In addition, safety technology from Leuze ensures seamless safety on machines and systems. The Sensor People thus contribute to efficient processes in the automotive industry and are always on hand to support system operators in the design and implementation of sensor and safety solutions.

The site  produces both combustion engine and electric models in parallel. E-mobility requires high-voltage batteries to supply the BMW Group's electric cars or hybrid vehicles with the necessary drive energy. The automotive group also manufactures these on site. Sensor technology from Leuze makes an important contribution to an efficient and safe production line process, implemented by Schaeffler Special Machinery, the Schaeffler Group’s mechanical engineering company.

It all starts with the cell.
Three successive production steps are required from the first component to the finished high-voltage battery. Only after cell coating, module production and finally assembly is a high-voltage battery ready for use as an electric vehicle’s energy supply. Precision and reliable processes are essential at every step. Leuze supports this with sensor solutions in cell coating and module production. Cell coating is the first step in high-voltage battery production. Each battery module consists of several cells. These are delivered to BMW in large load carriers (GLT). So that the GLTs can be unloaded automatically by robot, a Leuze MLC safety light curtain secures the danger zone to prevent people from entering. Muting ensures that only the GLT can pass through. The robot always unloads 16 cells at the same time and places them on a conveyor belt. Here, horizontally installed, Leuze CSL switching light curtains detect whether the cells are positioned correctly. “The switching light curtains particularly suitable for monitoring large detection fields as they are easy to install, configure and far more cost effective than image-based systems” explains Jürgen Schweiß, KAM-Automotive and Safety Application Specialist at Leuze.

High-gloss surfaces.
Diffuse sensors from Leuze are implemented at different points: “Sensors mounted on the belt detect the presence and correct position of the cells. If they are present and correctly positioned, the process continues,” says Jürgen Schweiß. The advantage of the PRK 25C series sensors used here is that they can detect the high-gloss surface of the cells with absolute reliability and can installed even in confined spaces due to their small physical size. Despite its small size the sensor has an operating range of 16 meters. Another advantage is that the sensors can be easily adjusted for sensitivity and alignment due to their bright light spot.

A compact approach to safety.
Sensor technology from Leuze keeps an eye on every aspect of cell coating: Laser diffuse reflection sensors from the HT46CL series detect the individual cells and control the conveyor – with maximum detection reliability thanks to background suppression. Before the cells are loaded into a GLT, they are discharged through a Leuze MLC safety light curtain. Advantages of Leuze light curtains: They not only score points with their high resolution, protective field height and operating range, as Jürgen Schweiß emphasizes: “With light curtains, a compact design and short safety distances are also important. This allows them to be easily integrated into tight installation situations.”

Perfectly positioned.
Leuze laser diffuse reflection light scanners also monitor the unloading of the cells from a GLT into a module line from Thyssenkrupp Automation Engineering. Each cell also receives a “heat shield” – a protective heat insulation – which is pressed onto the long sides. Robots rotate the cells into the desired position on a circular machine. Sensors from Leuze also provide support here: PRK 25 retro-reflective photoelectric sensors detect the presence of the objects. The heat shield process runs in parallel at two stations in order to achieve a high throughput time.

From stacking to the module.
In “stacking”, as experts call the stacking of several cells to form a battery module, several cells are placed next to each other and a pressure plate is attached to each end. PRK 25C sensors from Leuze detect the height and presence of the cells and recognize whether the tool carriers are closed correctly. Sensors are also used when placing the cell contact system (ZKS) on the module. A machine lifts the entire module so that the coating on the cell base can be checked: “Here, Leuze sensors provide support for height detection and at stop positions” says Schweiß.

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@LeuzeUK @LeuzeUSA @mepaxIntPR #Manufacturing #Germany

Ultra-fast changing for ultra-fast car.

A team of students from Eindhoven University of Technology has succeeded in developing an all-electric, ultra-fast charging prototype race car. Set to roar into action at the Le Mans 24-hour endurance racing event in France, the team leveraged the advantages of Danfoss technology to solve its fluid conveyance challenges.

All-electric racing cars are not new, but how does the endurance motorsport segment join the green revolution, where events require the rapid recharging of race cars? Enter InMotion, a student team from Eindhoven University of Technology in the Netherlands which set out to develop an all-electric race car with ultra-fast charging capabilities.

Electric refueling.
To help take InMotion’s fast charging technology (called electric refueling) from concept to reality, the team reached out for technology sponsors. PowerFlex, an expert supplier of hose solutions based in Weesp, Netherlands, stepped up to the challenge. The company is a long-term Danfoss Power Solutions distribution partner.

“We saw huge potential in their ambitious project,” said Ruggero Grillo, marketeer at PowerFlex. “We believed in their goal, their underlying technology and their passion, so we were proud to support them and help accelerate the motorsport sector’s transition to a green energy future.”

The PowerFlex team was tasked with helping InMotion identify the optimal fluid conveyance solutions to meet several of The Revolution race car’s key challenges. These included minimizing heat buildup in the 58 kilowatt-hour battery pack during fast charging, enabling quick battery disconnection, and delivering efficient cooling.

Battery pack cooling.

To maintain the optimal battery pack temperature during fast charging, PowerFlex recommended the Danfoss Evercool GH001 multi-refrigerant hose and fittings due to advantages that include near-zero permeation, tight bend radius, wide temperature range, and compatibility with many refrigerants.

In addition, the Danfoss EZ Clip system for hose assemblies gave the InMotion team flexible installation options without the need to invest in costly crimp tooling, while Danfoss Hansen aluminum dry-break ADB couplings were chosen for quick and easy battery connection and disconnection without fluid loss or air infiltration.

Finally, to optimize heat distribution from the race car’s battery pack, PowerFlex provided various Aeroquip by Danfoss Performance Products, including hoses, fittings, and adapters. Throughout the project, the knowledge and experience of PowerFlex was a crucial asset in The Revolution race car’s successful development, providing InMotion with on- and off-site technical guidance, testing, servicing, and more.

“Offering a low weight-to-power ratio, high performance, and racing-level quality, the Danfoss components we chose were designed for exactly this kind of challenge — and they delivered,” stated Grillo.

12-minute charge.
InMotion’s prototype race car is now able to reach an 80% state of charge from near depletion in just 12 minutes. The installed solutions keep the vehicle as lightweight as possible, while also making it easier for InMotion to assemble or reconfigure systems. Importantly, The Revolution endurance race car remains on course to showcase the game-changing potential of fast charging at the world-famous Le Mans.

 @Danfoss @BiesheuvelSport #Automotive 

Connector for e-mobility.

Han® HPR is a globally recognised standard for connector housings which require special protection against environmental influences in power generation plants, rail vehicles or ships. To expand the connector range to cover harsh environments with limited installation space, HARTING is adding Han® HPR Compact hoods and housings to the series.

Han® HPR Compact benefits: •Smaller mounting dimensions •High flexibility due to the use of extenders, each adding 3cm of height •Time savings: shorter installations in environments with limited space •16 coding options allow safe mating process even in environments with limited space •The entire Han® B compatible connector portfolio can be used, from standard inserts to Han® HC Modular, except for the insulation body of Han® HC 650 Modular

The Han® HPR series is already a proven solution for the railway, ideal for transmitting high power, high voltage, signal or Ethernet data in exposed areas. They are suitable for bogie mounting, roof mounting and as jumper cables between carriages.

The new high-density panel footprint of the Han® HPR Compact can also provide a highly reliable alternative to plastic housing style High Voltage (HV) connectors for use on electric/hydrogen bus and truck powertrain interconnection cabling systems.

Electric drives, battery units and hydrogen fuel cells can often come into contact with potentially damaging harsh environmental conditions. Underneath a vehicle, stone damage, water and winter salt spray can occur whilst high humidity water creepage can occur along cables behind protective access panels. On the roof, high UV levels can be a particular issue. The Han® HPR Compact has been specially designed to minimise repairs and maintenance in these areas.

The Han® HPR Compact requires 20% less installation space and is 25% lighter than conventional solutions. The product is available in sizes 6, 10, 16 and 24B and has a special feature that enables the housings ‘to grow with demand’, even after installation.

Up to two frame extenders can be attached to the bulkhead mounted housing, each frame expanding the height of the enclosure by three centimetres, increasing the space available for connections and reducing cable stress.

Thanks to savings in installation space and weight, Han® HPR Compact housings also contribute towards sustainability by reducing energy consumption.