Electric Vehicles are disruptive in more ways than we think. It’s not just the change of fuel, but a re-engineering of an entire value chain. From a mixing and dispensing technology view, adhesives will replace the traditional welded and riveted parts in the electric vehicles. At the same time, there is a demand for serving several new applications such as sealing in batteries, specialised dispensing in rotor motors, adhesive dispensing in composite or new age materials and much more.
For the last few years, Twin Engineers has enabled several applications for the Electric Vehicles using cutting-edge solutions.
Dispensing technology for the heart of EVs
Magnets form the heart of the motors in Electric Vehicles. Recently, the team at Twin Engineers developed an Epoxy dispensing Machine for sealing a set of magnets in the rotor of EV motor.
Void-free sealing with under vacuum dispensing
The job involved dispensing of 2 Part Epoxy (shot size of 150 gm) inside the cavity of the rotor holding the magnets. The sealing operation prevents the magnets from displacement under the rotational forces inside the motor. Accurate filling of quantity, mixing ratio accuracy are highly critical to ensuring the proper functioning of the EV motor. The material was dispensed under vacuum to ensure void-free sealing of multiple magnets through the deep cavity inside the rotor.
Meeting the specific needs of the process
Twin’s team designed the dispensing set-up by a careful consideration of the smallest details expected to be at play in the application. Starting from the selection of materials in the machine to programming the dispensing path, everything was designed to meet the highly specific needs of the process.
Charged for a high-speed production
Twin’s team helped the customer to achieve the desired cycle time, thus ensuring a high-speed production for a critical process. The Machine, build on Twin’s Intellomix platform comes with important interlocks for process parameters to ensure absolutely no deviation in end product quality.
Twin has been a partner to develop mixing and dispensing technology to some of the largest OEMs and Suppliers of Electric Vehicles in India. If you are looking for an expert partner in developing parts or components for Electric Vehicles that use sealants or adhesives, speak to one of Twin’s representatives to explore new possibilities.
Euro VI necessitates several fundamental changes in technology for Two Wheelers. To comply to the Euro VI norms, Two Wheeler manufacturers are likely to phase out CDIs and Carburettor whose functions will be carried by the new Magneto coil designs and ECUs.
When one of world’s top Auto-Electronic manufacturer was looking for a reliable solution to dispense single component epoxy on the winding (12 to 18 poles) of its newly designed Magneto coil, it selected Twin’s Machine for the job.
The process uses a single component epoxy in order to insulate and bond the winding and prevent its fly-off under high rotational forces. With a decade-long relationship and a strong reputation earned from Twin’s previous projects, the Client entrusted the task of developing the machine for this new application to Twin’s team.
The single component Epoxy Dispensing Machine equipped with dual-head Robotic Dispensing, designed by Twin, serves the specific needs of the application including accurate shot size and desired cycle time. The dual dispensing heads on the Machine improve the productivity of the process by enabling simultaneous dispensing in two coils. The highly compact design, coupled with the most advanced controls has helped the client to save space and costs while providing total assurance to achieve the product quality, as desired.
Over the last two decades, Twin has developed specialized mixing and dispensing machines to cater to over 120 applications in a variety of electronic and electrical products.
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Twin’s Fluid Filling Machine for 2 Wheelers comes with a unique design, featuring double filling guns, to significantly reduce cycle time!
One of the world’s largest auto-parts manufacturer for 2 Wheelers selected Twin’s Fluid Filling Machine for Shock Absorber Oil. To meet the Client’s requirement and production goals, Twin developed the machine based on a unique design, which includes 2 Filling Guns, used simultaneously, to fill the shock absorber oil.
The double filling guns on the Machine significantly improved the cycle time of the filling process, as compared to other similar designs previously considered by the Client. The Machine offers shot size ranging from 20 ml to 80 ml in order to cater to the range of shock absorber variants.
The compact design enables easy and quick loading of the components, further reducing the cycle time of the filling process. The Machine comes with two Fixtures to hold the components and can be operated by a single Operator.
Further, on Client’s request, Twin also offered the option to fill two variants of the shock absorbers with different shot sizes (mounted on separate fixtures), in a single cycle. This meant a throughput as required on the assembly line with optimal productivity.
Twin’s Fluid Filling Machines are used for a variety of applications in 2/3/4 Wheeler and HCVs. The applications include Radiator Coolant filling, AC Charging Stations, Urea/Ad-Blue Filling, Power Steering Oil Filling, Diesel Filling, Engine, Axle, and Transmission Oil Filling.
Transformer manufacturers are well aware that the domestic and export market has turned highly competitive. Customers want the best at the lowest possible cost. And you as a company know that quality cannot be compromised. The transformer casting process is an area where challenges have existed for long. The casting process, for transformer manufacturers, is a key cost center and also holds the key to the quality of products.
You know that the casting process has to be done with complete precision and accuracy. Whether it’s weighing the materials, maintaining exact temperature control or ensuring the accuracy of the mixing ratios, each step in the casting process demands a specific requirement.
With this, the casting process is prone to several challenges including material wastage, poor process control, sub-optimal productivity and more. While automation of the casting process is the go-to-solution, the initial investments and operational costs of the current solutions could be highly prohibitive.
The Challenge Today
Typically, the current method for large-scale manufacturing of Transformer uses a “fixed” setup for the material preparation and casting process. This often involves separate and fixed stations where resin and hardener are prepared and mixed to be carried using fixed pipes until the clamping stations. One of the reasons for high initial investment is due to the higher complexity of the fixed set-up which requires the piping and material handling, preparation, mixing and dispensing/casting stations to be laid out in a very specific manner for efficient operations.
The use of fixed stations and pipelines to transfer materials lead to several disadvantages:
- High upfront investment owing to design complexities, equipment costs, and a layout that demands more space
- Very high installation costs due to a long drawn out process of installation, and commissioning efforts, often running into months
- Severe limitations on modification of the layout
- Relatively higher cost of cleaning and maintenance owing to the fixed design
- Much higher operational costs due to the need to continuously run the process as necessitated by its design
While the fixed layout has its benefits, clearly, there is huge room for improvement to reduce the investments and operational costs.
The Innovative Solution
We have come up with a simple solution. Our Epoxy casting plant can be used successfully in the manufacturing of Open Cast components or can be easily attached to clamping stations in the APG (Automatic Pressure Gelation). Our innovative, portable system for APG helps companies achieve efficiency using optimised process economics. With this system, preparation and dispensing processes can be performed simultaneously and also independent of each other. There is no need to run the entire plant continuously. This is a plug-to-use system, is movable and can be operated by a single, skilled operator.
It has a Hopper sieve to collect the pre-heated silica and a magnetic vibratory separator that removes the metallic and foreign particles from the fillers. Its screw conveyor carries the fine particles to the resin and the hardener tank separately. It has an intake data display that is displayed on the HMI which maintains all the production data record and is logged in for all future references. The portable meter mix dosing system is mounted on a portable trolley that can be easily moved between the clamping stations. The shrinkage compensation cylinder in the system ensures that there is no material loss inside the mould by providing the necessary gelation pressure.
Some of the most complex problems sometimes have the simplest of solutions. Our solution has a small footprint and makes sure that our clients are able to create high-quality products that meet global standards. It offers them the flexibility they need because of the system’s portable nature and also gives them the benefits of a low operational cost and yet high-quality set-up.
Our solutions are designed in Germany and manufactured in India using the best quality products and have been used by customers across 15 countries to improve the productivity, quality, and cost-effectiveness of their mixing and dispensing process.
Connect with us at firstname.lastname@example.org – we may have a similarly innovative solution for you too!
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