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TRUMPF smart factory example fpr e-mobility applications

Automated production solutions for electromobility

Manufacturing e-mobility components has some challenges. One central key to success is the coordination of the entire production process. From raw material handling to cutting, forming, bending sheet metals and laser welding the finished part – TRUMPF analyzes existing production processes and plans completely new production lines together with you.

The emphasis is on optimum utilization of resources, short cycle times as well as high profitability and simultaneous great flexibility. Intelligent TRUMPF sensor systems monitor the entire process and provide the best production results and traceability for each individual part. We are convinced: we have the production technology for electromobility with automated production processes and networked systems.

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TRUMPF solutions for your e-mobility application

Battery tray

TRUMPF machine systems process flat sheet metal by laser cutting, bending, punching dies and laser welding to create a leak-tight battery tray – depending on the requirements, this can also be done within a fully automated process. Seamless documentation, repeatability and traceability are a matter of course. Our experts will advise you from design to production and even beyond.

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Battery tray cover plates

The cover plate is the enclosed protective housing for the battery module, power electronics and cooling unit. It must therefore fulfill the stringent requirements in terms of gas-tightness (helium leak test) and crash safety. Our machine tools in the area of 2D laser cutting and bending and our punch combination systems offer the optimum solution for this. TRUMPF lasers also make it possible to weld the bend joints so that they are gas-tight, and they facilitate precision cleaning of the flange for joining and adhesive preparation for the cover.

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Battery system cooling

TRUMPF offers flexible production technologies for manufacturing different cooling concepts for battery systems. This ensures consistent temperature distribution in the module and pack. Whether plate heat exchangers, pipes or punch press profiles – with TRUMPF laser technology, you can rely on media-tight weld seams for components made of aluminum and stainless steel.

TRUMPF application battery pack segmentation

Frame construction for separation

A stable frame made of aluminum is used to safely position the battery pack in the battery tray. TRUMPF machines such as the TruLaser Tube or TruMatic flexibly produce the reinforcement or separation segments of the individual modules. Thanks to our OCT seam position control and monitoring as well as our programmable focusing optics from the PFO range, you will obtain highly precise overlap and fillet seams – quickly and with absolute process reliability.

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Accident and assembly structure of the battery system

Battery system manufacturers achieve a crash-optimized concept with adapted edge and tube designs. You will benefit from our TruLaser Tube machines with highly productive and precise tube and profile cutting. You will also weld without flanges with TRUMPF laser technology. Our scanner weld solutions and laser hybrid welding also provide a high level of tightness.

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Underride protection for the battery system

High-precision welded seams effectively protect the energy storage from intrusion. Furthermore, TRUMPF lasers play to their strengths when welding on the reinforcement.

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Automated production process for manufacturing battery packs

Flexible and scalable – this is what an automated system looks like

With TRUMPF production systems, you will manufacture components in highly flexible and fully automated processes. Even components with high precision requirements are no problem thanks to sensor-based process control during sheet metal processing. Even components which are conventionally deep-drawn can be manufactured economically and highly flexibly with TRUMPF production systems.

TRUMPF smart factory solutions process draft

Your Smart Factory solution: you set the requirements – we provide the finished system

TruStore 3030 an TruLaser 5030 mit LiftMaster Store und SortMaster

Hardware

Take advantage of the great variety of our entire TRUMPF machine portfolio. Even though every single one of our machines is excellent on its own, we always keep our eyes on the big picture. We interlink and automate your individual processes and machines with clever automation components and material buffers.

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Software

You can trust our software portfolio: enjoy optimum monitoring of the laser sources' and systems' states with Condition Monitoring. TruTops Monitor is used to monitor the production and productivity, while you keep an overview of the complete material flow with TruTops Fab.

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Services

We analyze and optimize your component in workshops with laser-optimized design in mind. Then our Smart Factory consultants plan your entire production lines and organize the set-up directly at your site. You can rely on our comprehensive application consulting and our technical support, for example when starting the production.

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The advantages of TRUMPF

Automated production solutions

TRUMPF customers appreciate our comprehensive way of thinking. We will give you a complete package with all production steps perfectly coordinated, all from a single source. We combine the expertise of all our core competencies for you, meaning we can offer you intelligent automated production solutions. Whether bending, cleaning, welding, marking or connecting dissimilar materials – TRUMPF facilitates a completely integrated solution for all these individual applications across the process chain, for example in the production of battery trays. Comprehensive networking also facilitates seamless component traceability and barrier-free development of the individual processes for the consolidated process chain.

Reliable, highly productive systems

Take advantage of our decades of experience as a market leader in mechanical engineering, combined with our extensive process and industry expertise in automotive engineering. You benefit from our competence in the application for different part processes and their technical implementation as systems. Our laser systems, inter-machine communication and new sensor technologies facilitate the continuity of the process chain and constant quality monitoring.

Manufacturing with process reliability and seamless documentation

With comprehensive system and software solutions, TRUMPF offers the necessary process reliability as well as seamless documentation of the production history. Our TruConnect product portfolio contains innovative solutions for Condition Monitoring and paperless manufacturing.

TRUMPF technical service and consultation

We support you – during operation and beyond. Our TRUMPF experts are ready to offer you intensive process consultation and application support, so you reduce your start-up expenditure as much as possible.

Maximum productivity at all times

The Condition Based Services increase the technical availability of your laser systems. Use dashboards to visualize the state of the machine - Smart View Services. The TRUMPF Condition Monitoring Center evaluates sensor data and detects failure risks.

Relevant information - at a glance

You receive relevant data concerning your laser using the Data Based Services. The OPC-UA interface provides important information for this purpose. The Quality Data Storage 2 software also makes it possible to record data synchronously to the process.

What are the actual applications where TRUMPF can offer you practical support?

Would you like to see the advantages of flexible sheet metal processing for battery pack manufacturing for yourself? Visit us at TRUMPF on-site in our showroom and make the most of the consulting services of our experts:

Advice for the design of sheet metal parts

What potential is still hidden in your parts? Find out in our workshops and seminars on part optimization in sheet metal and tubes.You will gear your parts toward success with our consolidated expertise in sheet metal design – and save money as well. Economically constructed parts are the key to efficient manufacturing, require fewer process steps and pave your way toward networked production.

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Production of prototypes made of sheet metal

Customised customer parts are manufactured in TRUMPF precision machines and are checked to ensure they meet the material requirements. We identify the optimization potential in the production of your part along with you. The goal: we will optimize and manufacture selected parts which you can directly implement into your designs and manufacture more cost-effectively.

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Customized automated production systems

Use the expertise and years of experience of TRUMPF to your competitive advantage. TRUMPF experts plan entire new production lines for you in line with the greenfield strategy or adapt your existing production lines in the best possible way to new manufacturing situations and the challenges of electromobility together with you. You are on the road to success with custom-fit planning of your production - intelligently networked from the very beginning. You will benefit from our treasure trove of decades of experience in sheet metal processing and our pioneering role in Industry 4.0.

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The TRUMPF Customer Center

We ensure TRUMPF products are an all-embracing experience for our customers. The entire sheet metal process chain – from programming to laser welding – is represented in our most up-to-date product portfolio which is shown in our Customer Center, opened in 1987 and expanded in 2020.

You can have machines from different technologies demonstrated to you here. We offer standard product demonstrations as well as customer parts presentations. Generation of time studies, feasibility checks and creation of sample parts are also some of the core tasks of the Customer Center.

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Tackling the challenges of e-mobility together

Would you like to know how we can provide your production with optimum support on your path to electromobility? Make an appointment directly with our internationally active branch managers. They are happy to advise you concerning our customized complete packages and facilitate new production technologies for the new mobility.

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Smart Factory

With the modular networking solutions from TRUMPF, we help our customers to create a continuous flow in their production facility, thereby arranging their entire production process with increased transparency, flexibility, and cost-effectiveness within the framework of Industry 4.0.