Production and testing system for CSC modules in e-mobility
Panasonic produces complex CSC modules in various sizes for the e-mobility division of car manufacturer BMW. These control the correct charging and discharging in the vehicles. As critical components, their manufacture therefore requires the highest technical precision and multiple checks of each production step. In close cooperation with Panasonic and BMW, HEITEC Slovensko developed and installed a complex nine-part production and testing line, the reliability and efficiency of which has already led to further orders.
Technical data
- TS2 Bosch Rexroth automatic chain conveyor as main conveyor system<
- 2 traverse units, 8 centring units
- System completely encased in aluminium and polycarbonate
- 5 pneumatic valve terminals
- PLC: Siemens S7-1516
HMI: 2x Siemens KTP1200 Comfort (station 1 and 4)
Realisation
The production of the CSC modules is a complex multi-stage process with completely different requirements depending on the station. For example, the thickness and position of the adhesive paste applied automatically by the fully automatic dispensing system must be constantly checked using a 3D measuring system, ultrasonic weld seams must be monitored and documented and the correct positioning of all components must be ensured in every production step.
As BMW insisted on manual stations for loading and unloading as well as cable fastening, the inspection cameras must also monitor and log the work of the human employees during production and use appropriate sensors to indicate when intervention is required.
Stations at a glance
- Loading and unloading
Operated by a human operator. Sensors check the position of the inserted product and return visual signals.
- Dosing system
Fully automatic station. Application of the paste in three rows, the position and quantity of which is checked by a 3D measuring system.
- Inserting the printed circuit boards
Fully automatic station. Automatic feed unit and 2-axis manipulator system position the PCBs, which are checked by a camera.
- Attaching the cables
Operated by a human operator. The multi-part camera inspection system checks the correct installation and position of the cables and sends visual signals back to the operator.
- Application of the covers
Fully automated station. Two-axis manipulator system and a vacuum suction cup apply the cover to the CSC module.
- Ultrasonic welding
Fully automatic station. A 2-axis manipulator positions the module, which is fixed in place by a double ultrasonic welding unit. The camera inspection system checks and records the welding points.
- High voltage test
Fully automatic station. HW+SW of the test unit based on IPC during the test. A label is then applied to the product.
- Function test
Fully automatic station. HW+SW of the inspection unit based on IPC in the inspection test.
Camera inspection
Fully automatic station. Final inspection of the produced unit via 6 cameras with up to 1.6 megapixels.
Customer benefits
Due to the high degree of reliability of the system described, this was the second of its kind that we had the honour of developing for the production of BMW e-cars. Like all HEITEC systems, it is future-proof thanks to its modular design and can be modified at any time in the event of changes to production specifications or new legal or technical requirements.
This means that HEITEC partners Panasonic and BMW are well equipped for the lively e-mobility market for years to come.
