Machining solutions for e-mobility

Mobility is changing – the goal is a CO2-neutral future

Mobility is changing, with a focus on a carbon-neutral future and sustainability. To meet this objective, the automotive industry is working on alternative drive concepts. The electric drive is increasingly replacing the combustion engine. However, this transition won’t happen overnight. Some parts of the conven-tional drive are being further developed and the share of hybrid drives is increasing. At the same time, the production of battery powered electric vehicles is increasing rapidly and has already almost reached same the production volume as conventional drives.

As a supplier of cutting tools for the automotive industry, MAPAL incorporated the topic of sustainability into the company’s strategic orientation at an early stage. The company has transferred its expertise in machining the conventional power train to the parts to be machined in electrically powered vehicles. Only through efficient tool solutions for productive series processes can the change be shaped successfully and sustainably. MAPAL plays an important role in overcoming the challenges of e-mobility and contributing to the environmentally friendly mobility of the future.

Electrified components

Elektrifizierte Komponenten - Scrollverdichter, Elektromotor, E-Bike, Batteriewanne, Leistungselektronik

(1) Electrified drives

Electrified drives

(Hybrid and fully electric)

High-precision with large diameters

Different electric motor housings are used in vehicles with electric drives. You can differentiate between three basic types of construction. MAPAL offers innovative tool solutions for machining tasks with the housing types.

The machining portfolio is divided into three solution levels: Basic, Performance and Expert. The optimal solution is provided depending on the number of pieces, requirements and investment.

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(2) Electrified auxiliary units

Electrified auxiliary units

(Thermal management)

Spiral shapes with tolerances in the μm range

Not only the drive and energy storage systems are affected by the electrification of
vehicles, but also some auxiliary units. An example of this is the electric refrigerant compressor (scroll compressor).

Three specific machining operations:

High precision spiral shapes
Precise bearing bore
Recesses for sealing elements

(3) Energy supply

Battery tray and power electronics in CAD representation

Energy supply

(Storage, control, charging)

Machining complex, thin-walled housings vibration-free

MAPAL offers the appropriate tools with the optimal machining strategy for the various housing variants for batteries and power electronics. The powerful tool portfolio includes PCD and solid carbide tools.

Different housings:

Extruded profile (Battery cases)
Die-cast housing (Power elektronics)

(4) Electrified micromobility

Electrified micromobility

(Example: e-bike)

High-precision even on a small scale

The very thin-walled housings made of aluminium or magnesium must be manufactured with tight shape, running and position tolerances. The high precision guarantees the tangible comfort of the drives for e-bikes.

Combination tools for maximum efficiency:

Bearing and position bores in one go
Drilling and milling combined in one tool

Mapal Services - Engineering, Logistic, Maintenance, Training

With the engineering service module, MAPAL guarantees fast, precise and safe manufacturing. Further savings potential can be tapped in the area of logistics and maintenance. And in the area of training, MAPAL ensures that the specialist know-how it has gathered is transparently and completely available to the customer – this gives customers a decisive lead over their competitors.

All of the services offered by MAPAL focus on optimal processes and comprehensive support on the way to Industry 4.0. The goal is to always significantly assist the customer in achieving smooth, productive and economical manufacturing.

Advantages:

Solutions for complete workpieces including tools, devices, NC programs and commissioning
Complete process design and implementation from a single source
Fast and flexible on-site support worldwide
Efficient and cost-optimised tool technology
Optimum coordination of tool, workpiece, equipment and machine
Highest product quality, process reliability and cost-effectiveness right from the start
Fast throughput from planning to implementation with maximum planning security