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EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
EXPERT Transformatorenbau GmbH
│High Current Applications
│Resistance Welding
│Heating Current sources
EXPERT Transformatorenbau GmbH
Industriestr. 6a
64653 Lorsch
Tel: +49 6251 86906 0
Fax: +49 6251 86906 10
E-Mail: [email protected]
www.expert-trafo.de
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
EXPERT Transformatorenbau GmbH
19.04.2013 2
Located south of Frankfurt
Privately owned company
50 year old tradition in the development and manufacturing of
water-cooled high current transformers and rectifiers
35 employees
$10.3M Sales (2014)
Global Supplier
Industries serviced: – Automotive
– Machine building
– Process technology
– Plant manufacturing
– Ceramics
– Railway
– Solar industry
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
Company‘s history
19.04.2013 3
1961
1967
1990
2006
2012
2015
Founded in 1961 as EXPERT Maschinenbau GmbH in Lorsch by
Hans Jäger and under EXPERT Inc. in Detroit
Delivered the first transformers in 1967
Transformer manufacturing was an integrated part of the
EXPERT Maschinenbau GmbH
Helped develop international standards in the field of resistance
welding transformers
Developed MFDC transformer technology 1990
In 2006 was purchased separately from the former EXPERT
Maschinenbau GmbH
2012 move to new manufacturing facilities
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
International
19.04.2013 4
Direct and indirect supplier of products all over the world
Marketed and serviced through agents and resellers in: – China
– South Korea
– UK
– Italy
– France
– US
– Brazil
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
Core competencies
19.04.2013 5
High volume production of MFDC transformers for automotive
industry applications
Product range in customized transformers from 5 to 1,500kVA
and more
Vertically integrated manufacturing
100% quality control of all components
Joint specification development with existing customers – Automotive industry
– Plant manufacturing
– Machine builder
– Welding control companies
– Final customers
Development of new markets in the field of high current water
cooled applications – Renewable energy
– Railway
– Electro mobility
– Process technology
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 6
Turn-Over
0 €
1.000.000 €
2.000.000 €
3.000.000 €
4.000.000 €
5.000.000 €
6.000.000 €
7.000.000 €
8.000.000 €
9.000.000 €
10.000.000 €
2007 2008 2009 2010 2011 2012 2013 2014
5.138.571 €
6.336.547 €
3.802.657 €
6.136.571 €
7.388.705 € 7.407.764 €
6.451.504 €
9.445.188 €
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 7
Sales by markets 2012 - 2015
89,53%
7,11% 1,67%
0,01% 0,32%
1,35%
Europe
Asia
N America
Australia
Africa
S America
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 8
Product mix 2012 - 2015
Type Quantity % of total Quantity Turn over % of turn over
MFDC 18347 87,27% 22.911.519 € 77,18%
Gun transformer AC 1132 5,38% 1.045.685 € 3,52%
Process transformer 587 2,79% 2.601.270 € 8,76%
Fixture type transformer 318 1,51% 1.057.471 € 3,56%
Pulse transformer 290 1,38% 1.145.957 € 3,86%
Multi welding transformer 237 1,13% 417.077 € 1,40%
Special transformer 92 0,44% 344.139 € 1,16%
Suspended transformer 13 0,06% 30.278 € 0,10%
3 Phase rectifier units 7 0,03% 133.929 € 0,45%
Total 21023 100,00% 29.687.323 € 100,00%
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
Customers
19.04.2013 9
EXPERT is an approved international supplier to various
manufacturers including automotive, appliance, and machine
manufacturers
Active customer base of more than 500 customers
More than 900 different transformer types have been sold since
2006
Product range of more than 2,000 different transformers,
reactors, inductors, and chokes …
All product data since 1967 is readily available
HFDC transformers for robot and machine applications
MFDC transformers for continuous and pulsed applications such
as seam welding, high current Butt and Flash welding, and
resistance heating.
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 10
Development and Design
Products conform to various international standards and
specifications
Design optimization of electrical, mechanical and thermal
parameters utilizing mathematical computation and simulation
software
3D CAD designs with models available
Life cycle modelling for MFDC transformers
Development of customer specific solutions
Prototyping
Continuous technological development
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 11
Manufacturing
Manufacturing capability from single units to large volumes
Metal processing
Joining technologies
Powder coated high current secondary cooling coils
Primary coil insulating and winding
Epoxy resin encapsulation
Final assembly
100% Quality control tested – Leak testing of cooling circuit up to 175 PSI
– High voltage and isolation resistance tested
– Heating tests
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 12
Water cooling benefits
Use of water cooling to reduce size – 4 times higher cooling capacity than air
– Heat transfer from the copper secondaries to water is approx. 1,000 times more
efficient than to air
Transformers and coils can be designed much smaller – Important weight and size reduction
Direct and indirect cooling – Water channels inside of the secondary coils (direct cooling)
– Thermal transfer of heat from the primary coils to the water cooled secondary
coils (indirect cooling)
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 13
Products
High current sources for resistance welding – AC transformers, MFDC, pulse transformers, 3-phase DC rectified units
Process transformer of high power – Conductive heating, annealing and melt processes, customer specific solutions
High power chokes – Filter chokes, storage chokes, singe and three phase, power line matching
Supported welding technologies – Spot welding (steel, high strength steel, aluminium)
– Projection welding
– Seam welding
– Capacitor discharge welding
– Butt welding
– Flash butt welding
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 14
High current sources for resistance
welding - AC
AC transformers for robot welding guns of the automotive
industry based on customer and industry specifications
AC transformers for applications such as: – Grating welders
– Spot welding
– Projection welding
– Seam welding with low induction
Continuous current up to 70 kA per transformer
Product range from 5 to 1,200 kVA
More than 600 types
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 15
High current sources for resistance
welding - DC
MFDC units for welding guns, machine style, and fixture type
units
Modular MFDC series available for a wide range of applications
Transformers for pulsed and continuous operation
Frequency range from 1 to 10 kHz
3 phase rectified units (50 / 60 Hz)
Power range from 5 to 1.500 kVA (50% d.c.)
More than 150 types
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 16
MFDC technology – a comparison
Standard AC transformer (50 Hz) – Power 100 kVA
– Size 550 x 235 x 184 mm
– Weight 113 kg
MFDC transformer – Power 123 kVA
– Size 315 x 160 x 127 mm
– Weight 24 kg
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
MF2 series – 75kVA (8,4V), 5,0kA I2p, 1 diode per branch
– 106x150mm, 15,5kg
MF3 series – 111kVA (9,3V), 6,5kA I2p, 2 diodes per branch
– 125x160mm, 24,4kg
MF4 series – 123kVA (9,3V), 7,2kA I2p, 1 diode per branch
– 125x160mm, 24,5kg
MF8 series – 107kVA (8,9V) , 6,5kA I2p, 1 diode per branch
– 106x150mm, 16,5kg
MF10 – 10kHz, 121 kVA (11,1V) , 6,0kA I2p, 1 diode per branch
– 106x150mm, 13kg
19.04.2013 17
MFDC, HFDC Product Range
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
Pulse transformers für capacitor discharge welding
Energy range from 5 to 120 kJ
Pulse currents up to 1000 kA
More than 35 types
19.04.2013 18
Pulse transformers
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 19
Resistance Heating transformers
Resistance heating of:
Ovens
Melting pots
Valves for glass and ceramic industry
Glass, ceramic and carbon manufacturing
Product range from 3 to1000 kVA
More than 350 design styles
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
Water cooled chokes for high current applications – Filter chokes
– Storage chokes
– Interphase transformer
Use in inverter and converter systems for grid connection
Smoothing choke for plating equipment
Transformers for inductance heating
19.04.2013 20
Other Applications
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
21.06.2013 21
And why EXPERT?
Over 50 years experience in latest design and manufacturing
techniques
Experience being involved in developing standards and
regulations to industry trade associations as well as large
manufacturers
Application specific design criteria capabilities
Approved for use at most global automotive manufacturers
Quality system conformance
Competitive pricing
Global supplier
EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources
19.04.2013 22
Closing
THANK YOU!