MANUFACTURING SOLUTIONS FOR E-BIKES Components with ECM technology
SOLUTIONS FOR E-BIKE MOTORS with ECM technology The popularity of e-bikes is on the rise all over the world. If we look at the sales figures in just Europe, there is a clearly identifiable trend: CONEBI (Confederation of the European Bicycle Industry) expects e-bikes to have a 50% market share within the next 10 years. With this market share, millions of components will need to be efficiently manufactured, some in conditions that cannot be achieved using traditional manufacturing technologies (see below). ECM technology is perfect to meet these demands.
Rotor ++ Deburring the gear
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Transmission Shafts ++ Deburring the gear
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++ Broaching the external gear ++ ECM drilling
Gear Wheels ++ Deburring the gear
++ Broaching the internal and external gear
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Benefits of ECM Technology for Thin-Walled Components For years the hollow shaft has been established as the axle for the crank system in order to reduce the overall systems weight. However, the traditional chip removal process is challenging with this system because of the special configuration of the workpiece. The workpiece is hardened which means rising tool costs, and the low wall thickness of the hollow shaft can result in warping. With the ECM process, these issues are not a problem. Both the borehole and the external gearing can be cut after hardening using ECM – with no burrs or workpiece deformation. This means that no additional finishing processes are necessary.
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ECM – ELECTRO-CHEMICAL MACHINING Electro-chemical machining (ECM) from EMAG ensures highly efficient production processes. The ECM process removes metal through electrolysis: The workpiece becomes the positive anode, and the tool becomes the negative cathode. An electrolyte solution flows between the two pieces, removing metal ions from the workpiece. This creates a quasi-negative to the geometry of the tool with a reproduction accuracy of less than 20 µm – and all with minimal tool wear. Based on this principle, the EMAG ECM experts have developed machining process and machines used around the world, by a variety of different industries. The flexible layout of ECM machines means that all processes can be combined and scaled.
ECM DEBURRING
Tool (cathode) Electrolyte
Power source
Workpiece (anode)
PROCESS TIME 20 – 50 SECONDS
++ Chamfering and deburring in a single process ++ No secondary burr formation ++ Optimal rounding of edges ++ Perfect surface quality ++ No finishing required ++ Multiple deburring in a single process step
ECM BROACHING ++ Hard broaching is possible ++ Radial and axial machining possible ++ Absolutely zero burrs ++ Thin-walled components can also be machined ++ Broaching with no stress or tension ++ Cost-efficient machining (tool costs) ++ Edge rounding possible ++ Multiple components in a single work cycle
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FEED SPEED 0.01 –6 MM/MIN
ECM DRILLING
FEED SPEED 0.5 – 8 MM/ MIN
++ No drilling caps, chips, or burr formations ++ Reliable ++ Long drilling cathode service life ++ Multiple boreholes possible at the same time ++ Hard and soft machining ++ No interrupted cutting ++ Drilling and rounding in a single step
ADDITIONAL ECM WORKPIECE EXAMPLES
The drive units of all leading manufacturers contain sleeves, gear wheels and shafts.
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CI – COMFORT INTEGRATED
Excellence for deburring, drilling and broaching The CI series is the perfect entry level system into ECM. The CI machine features a compact machine design - the machining area, control cabinet, control system and electrolyte management system, are all installed on a single machine frame. This compact design gives the CI an overall small machine footprint, allows it to be transported with just a forklift and makes it easy for integration into nearly any manufacturing environment.
HIGHLIGHTS Maximum Precision and Flexibility
++ Stainless steel frame ++ Quick and easy upgrade to full automation
Integrated Siemens panel with S7-300 control system Scalable generator / pulse technology Central machining area extraction unit
++ Option: CI-DUO - two machining areas Process Monitoring of all Machining Parameters
++ pH value control ++ Conductivity monitoring ++ Pressure and temperature control Compact Design
++ Machine dimensions 98 x 78 x 94 in ++ Integrated electrolyte management system ++ Can be moved with a forklift Minimum Floor Space Requirement
++ 60 ft2 includes CI 400 + ECM filter Flexible Generator Technology
++ DC / Pulse ECM technology ++ Flexibility for pulse options ++ Single cathode control ++ Single cathode monitoring ++ Automatic cathode cleaning during the process
++ Fast short-circuit shutdown to minimize tool costs
Forklift transport possible All parameters are monitored by a control unit Machining area 43 x 35 in 6
Integrated electrolyte management system
OTHER SOLUTIONS FOR E-MOBILITY Example: Machining of Rotor Brackets
1 ECM broaching Gear 1
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2 ECM broaching Gear 2
ECM Drilling
Rotor brackets are components in electric motor housings and their production numbers are continuing to rise. The machining requirements for rotor brackets are the same as those previously described for e-bike components. To meet these requirements, ECM is the perfect solution.
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SIMPLE
++ Burr-free machining
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VARIABLE
++ Soft and hard machining
++ No chips
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STURDY
++ Thermally neutral machining
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ZERO FORCE
++ No mechanical stress /
deformation of workpieces with thin walls
++ No micro-cracks ++ No white layer
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FAST
++ Simultaneous machining of multiple workpieces
++ Multiple cathodes active at the same time
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Subject to technical changes.
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