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PRODUCTION AND ASSEMBLY LINES FOR
ELECTROMOBILITY
TECHNOLOGICAL CHANGEin vehicle powertrains
Breaking new ground together To be able to offer you the best products for your vehicle manufacturing facility, our focus, as a future- facing family-owned company, is on developing state-of-the-art technologies and system concepts. No matter whether for conventional or electrified powertrains – we supply highly innovative production and assembly systems.
The electrification of vehicle powertrains continues apace. The more stringent regulations governing CO2 and nitrogen oxide emissions, coupled with the scarcity of crude oil expected over the medium term, is increasing the demand for electrically powered vehicles and thus prompting automotive design engineers to develop new drive concepts.
GROB recognized this change at an early stage. We are already capable of supplying complete production and assembly lines for e-drive components and can showcase successfully realized reference projects.
Micro | Mild | Full hybridPetrol | Diesel | Gas
HYBRIDCOMBUSTION ENGINE
BATTERY FUEL CELL
FROM THE CONVENTIONAL DRIVE TO THE ELECTRIC DRIVE
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Benefit from a partnership with us. Worldwide sales and service branches safeguard the availability of systems around the globe. We are at your service – from the conceptual design to the planning through to the implementation of your electric drive production plants.
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GROB – Your central contact for turn-key projects worldwide GROB offers you an integrated concept for tomorrow's components through its modular, flexible and scaleable electric powertrain solutions. Our core competence in the mechanical engineering and automation sector guarantees our customers first-class, dependable system technology. GROB is your central contact for realizing worldwide turn-key projects in electromobility. Thanks to our many years of experience, we also fully integrate partners' components into the overall system to ensure convincing levels of functionality and performance.
Complete turn-key solutions from GROB mean you can bank on efficient, future-proof and sustainable solutions tailored to your needs. GROB stands for reliability, availability and efficiency. Benefit from our long-standing experience and extensive network.
Our range of services for the electromobility sector GROB offers its customers comprehensive state-of-the-art products and services. Because we have all competencies and core processes in-house, we can quickly respond to developments, changes and new schedules.
• Support for designing and dimensioning the e-machine• Prototype engineering• Development and verification of production processes• Staff training• Guaranteed quality along the value creation chain
BATTERYE-MACHINE
• Cell assembly• Module assembly• Pack assembly• Housing production
(machining)
• Stack assembly
FUEL CELL
• Stator assembly• Rotor assembly• Mechatronics• Final assembly• Motor and gearbox housing
production (machining)
CT and digital X-rays for quality monitoring in the GROB laboratory
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High-output manufacturing and assembly lines for the production of your automobile electric drive The flexible dimensioning of manufacturing lines and assembly and test stations according to your particular requirements guarantees you economic production with the highest yields.
E-DRIVESystems for assembling electrified powertrain components
4
5
Benefit from the process and system knowledge we incorporate into all our machines and systems. Furthermore, by expanding our manufacturing expertise in the electromobility sector and consistently implementing our strategy, we are ensuring an ever-growing product range for your production facility of tomorrow.
Electric drive production and assembly with GROB Electromobility is one of our key future sectors. GROB offers a broad range of modular and process-reliable system technology for assembling stators, rotors, e-machines through to the complete e-axle. State-of-the-art technologies and new manufacturing concepts allow us to stay abreast of electric motor industrialization. At the same time, we support our customers' growth, innovative strength and long-term success.
As an innovative family-owned company, GROB is an ideal partner with a broad range of expertise and capacities in machine tool and special-purpose machine industry, and in the industrialization of new manufacturing technologies.
GROB services for the e-machine sector We deliver integrated, reasoned processes for your electric motor production.
GROB machining line for HOUSING PRODUCTION
GROB assembly line for STATOR PRODUCTION
GROB assembly line for E-MACHINE PRODUCTION
GROB assembly line for ROTOR PRODUCTION
GROB assembly line for E-AXLE PRODUCTION
Source: VW AG
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We offer you a wide range of systems for various winding processes. According to your requirements, four different winding technologies are currently available for which we can already offer you newly developed, tried and proven systems, as well as production lines.
ELECTRIC MACHINESpecific systems for various winding technologies
66 Automatic winding and insertion station
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Various winding technologies with round and rectangular wire
HAIRPIN
INSERTING TECHNOLOGY
CONTINUOUS HAIRPIN
NEEDLE WINDING
GROB Mindelheim scope GROB Italy S.r.l. scope
The various winding processes at a glance GROB develops and produces machines and systems for the large-scale manufacture of electric motors. At our sites in Mindelheim and Turin, we are working on the various winding technologies for round and rectangular wires – depending on drive and motor size.
The product range spans from stand-alone, semi-automatic machines through to fully automated turn-key projects for our customers from the automotive industry. Competence, quality and speed are the basis of our customized solutions and future developments.
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Stator production with hairpin technology GROB offers an extensive product range for hairpin stators in various sizes. An innovative bending concept creates extreme flexibility and diversity without tool change for a batch size of 1.
ELECTRIC MACHINEStator assembly systems
WIRE PROVISIONING
PREPARING AND PRESS-FITTING THE HAIRPIN RIM
SLOT INSULATIONPRODUCING THE HAIRPINS
WIDENING AND TWISTING THE HAIRPIN
Station: Cutting the hairpins
Station: Provisioning the wire and producing the hairpins
Station: Welding and inspecting the contact bridge
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CUTTING THE HAIRPIN
DISMOUNTING THE WELDING TEMPLATE
IMPREGNATION CHECKWELDING THE HAIRPIN
WELDING AND INSPECTING THE CONTACT BRIDGE
Station: Widening and twisting the hairpins
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Stator production with insertion technology For decades now, GROB Italy has been offering insertion technology with round wire and can thus offer its expertise for realizing your projects with fully automated manufacturing stations.
ELECTRIC MACHINEStator assembly systems
WINDING AND INSERTING
IMPREG-NATION
LACING/KNOTTING
INSERTING THE SLOT INSULATION
INTER- MEDIATE FORMING
FINAL FORMING
ELECTRICAL INSPECTION OF THE STATOR
Station: Flyer winding
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Station: Template-based winding
Template-based winding The coil is created when the round wire is wrapped around a rotating template.
Flyer winding The coil is created when the flyer carrying the round wire rotates around a stationary template.
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Stator and rotor production with needle winding GROB Italy develops systems for needle winding technology with round wire that are capable of producing both stators and rotors. The prototypes for these machines are already available.
ELECTRIC MACHINEStator and rotor assembly systems
Station: Prototype for needle winding
WIRE PROVISION
MAKING THE CONNECTIONS
INSERTING THE SLOT INSULATION
WINDING THE INDIVIDUAL COILS
IMPREG-NATION
ELECTRICAL INSPECTION OF THE STATOR/ROTOR
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Stator production with continuous hairpin The advantages of the continuous hairpin lie in the economic feasibility of high numbers of slots with large inside diameters. This technology makes small wire cross-sections easily manageable and eliminates the need for complex circuitry.
Station: Press-fitting the wire mat
WIRE PROVISION
IMPREG-NATION
PRESS-FITTING THE WIRE MAT
SLOT INSU- LATION
MANUFACTURING WIRE MAT
WELDING/ CONTACTING CHECK
Flat windingSword winding
GROB offers two processes for producing the wire mat for the continuous hairpin:
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We offer innovative system concepts for assembling battery cells, battery modules and battery packs. In addition to production systems for e-machines, GROB also supports you in designing systems for the manufacture and assembly of energy storage systems.
BATTERYEnergy storage system assembly systems
1414 Modular battery module assembly system
15
Assembly lines for battery systems Intelligent production technologies are major contributors to the urgently required cost reduction of lithium-ion batteries. Many years of experience from assembly technology and the proximity to the customer industry help GROB develop and produce highly automated production lines for energy stores. The greatest challenges are the increasingly shorter innovation cycles and the rapid transformation in business and industry. GROB has already developed a modular and scalable system, which satisfies the high requirements for cycle time, safety, quality and costs for the assembly of battery modules and battery packs.
Only the interplay between high-quality materials, capable production equipment and efficient manufacturing processes achieve technical feasibility and economic success. For this reason, GROB is verifying and developing innovative production solutions to facilitate the competitive and sustainable volume production of battery systems.
Battery production process and services in the battery technology sector
* Current status: Under pre-development | ** Current status: In-house developments realized
SYSTEMS for fully automated cell assembly*
ELECTRODES & SEPARATOR
SYSTEMS for battery module assembly**
PROCESS STEPSPROCESS STEPS PROCESS STEPS
SYSTEMS for battery pack assembly**
1. Pre-assembly
2. Insulation and bracing
3. Electrical contacting
4. Final assembly
5. Inspection
1. Separating
2. Stacking
3. Contacting
4. Packaging
5. Filling
1. Module integration into battery housing
2. Thermal integration
3. Electrical integration
4. Final assembly
5. Inspection
INPUT OUTPUTOUTPUT/ INPUT
OUTPUT/ INPUT
BATTERY MODULE BATTERY PACK
Source: OPEL AG
Source: AUDI AG
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POUCH CELL/ PRISMATIC CELL
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New system concepts for manufacturing fuel cells From the first idea to the conceptual design through to series-capable production, our customers benefit from the individual implementation of their systems, and receive comprehensive advice from a single source in the process.
FUEL CELLAdvance development of fuel cell assembly systems
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GROB services for the fuel cell technology sector The fuel cell is a promising technology within electromobility, and a key area of focus for our research and development activities. For the assembly of components in the vehicle fuel cell drive, GROB offers innovative and automatable manufacturing and assembly lines that guarantee a high degree of flexibility, precision and reliability.
Process steps for fuel cell stack assembly
Source: AUDI AG
SYSTEMS for fuel cell assembly
MEA & BPP
SYSTEMS for fuel cell stack assembly
PROCESS STEPSPROCESS STEPS
1. MEA and BPP pre-assembly
2. Applying & curing sealant
3. Applying MEA
4. Assembling and joining cells
5. Checking for leaks
MEA: Membrane electrode assembly
BPP: Bipolar plate
1. Stacking
2. Joining the stack
3. Fixing the stack
4. Assembling media connections
5. Checking for leaks
6. End-of-line inspection
INPUTOUTPUT/ INPUT
OUTPUT
FUEL CELL FUEL CELL STACK
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Source: Lohmann
Source: FST
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Tried and proven manufacturing and assembly concepts – adapted to meet the challenges of the electric drive In the design of manufacturing lines involving machine tools, assembly solutions and automation solutions, we always consider your complete process to be able to offer the best in terms of quality, productivity and reliability.
MACHINING AND GEARBOX ASSEMBLY Systems for housing machining and gearbox assembly for the e-drive
Machining with the tried and proven GROB know-how
Turn-key assembly line for the e-axle drive
Our new F-machine series, comprising the G500F, G500FS, G520F and G600F machine versions, is designed specifically for meeting the requirements of machining frame structure parts, chassis parts and auxiliary frames, as well as battery housings.
Thanks to the innovative swivel head on the G600F with a 180° swivel range, even large components can be machined in every angular position, making this machine the ideal solution for machining complex part structures.
We have been delivering customized assembly lines for meeting high type and quantity flexibility requirements from a single source since 1982.
We also use this know-how for assembling electrified powertrain components, such as the axle drive and mechatronic components.
GROB assembly line for E-AXLE DRIVE PRODUCTION
Shaping the future together Together with our customers worldwide, we want to develop and shape the future of electromobility on all levels.
BECOME ONE OF OUR VALUED REFERENCE CUSTOMERS!
ASIA
SOUTH AMERICA
NORTH AMERICAEUROPE
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www.grobgroup.com
ASIADalian, China
Beijing, China
Shanghai, China
Yokohama, Japan
Seoul, South Korea
Haiphong, Vietnam
Hyderabad, India
SOUTH AMERICASão Paulo, Brazil
NORTH AMERICABluffton, Ohio, USA
Detroit, Michigan, USA
Querétaro, Mexico
EUROPEMindelheim, Germany
Buttigliera Alta, Italy
Birmingham, Great Britain
Hengelo, Netherlands
Senlis, France
Steinhausen, Switzerland
Poznań, Poland
Győr, Hungary
Moscow, Russia
B. GROB DO BRASIL S.A.São Paulo, BRAZILTel.: +55 11 4367-9100E-mail: [email protected]
GROB MEXICO S.A. de C.V.Querétaro, MEXICOTel.: +52 442 713-6600E-mail: [email protected]
GROB POLSKA Sp. z o.o.Poznań, POLANDTel.: +48 728 646000E-mail: [email protected]
GROB JAPAN K.K.Yokohama, Kanagawa, JAPANTel.: +81 45 414-3390E-mail: [email protected]
GROB SYSTEMS, Inc. Bluffton, Ohio, USATel.: +1 419 358-9015E-mail: [email protected]
GROB MACHINE TOOLS U.K., Ltd.Birmingham, GREAT BRITAINTel.: +44 121 366-9848E-mail: [email protected]
GROB HUNGARIA Kft.Győr, HUNGARYTel.: +36 96 517229E-mail: [email protected]
GROB KOREA Co., Ltd.Seoul, SOUTH KOREATel.: +82 31 8064-1880 E-mail: [email protected]
GROB MACHINE TOOLS(CHINA) Co., Ltd.Dalian, P.R. CHINATel.: +86 411 39266-488E-mail: [email protected]
GROB BENELUX BVHengelo, NETHERLANDSTel.: +31 74 3490207E-mail: [email protected]
GROB RUSS-MASCH GmbHMoscow, RUSSIATel.: +7 495 795-0285E-mail: [email protected]
GROB VIETNAM L.L.C.Haiphong, VIETNAM
E-mail: [email protected]
GROB ITALY S.r.l.Buttigliera Alta (TO), ITALYTel.: +39 011 9348292E-mail: [email protected]
GROB FRANCE S.A.R.LSenlis, FRANCETel.: +33 375 290 470E-mail: [email protected]
GROB MACHINE TOOLS (CHINA)Co., Ltd. Beijing BranchBeijing, P.R. CHINATel.: +86 10 6480-3711E-mail: [email protected]
GROB MACHINE TOOLSINDIA Pvt., Ltd.Hyderabad, INDIATel.: +91 40 4202-3336E-mail: [email protected]
GROB-WERKE GmbH & Co. KGMindelheim, GERMANYTel.: +49 8261 996-0E-mail: [email protected]
GROB SYSTEMS, Inc. Detroit, Michigan, USATel.: +1 419 3589015E-mail: [email protected]
GROB SCHWEIZ AGSteinhausen, SWITZERLANDTel.: +41 79 8692941E-mail: [email protected]
GROB MACHINE TOOLS (CHINA)Co., Ltd. Shanghai BranchShanghai, P.R. CHINATel.: +86 21 3763-3018E-mail: [email protected]
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