{"id":7432,"date":"2023-10-20T11:58:42","date_gmt":"2023-10-20T09:58:42","guid":{"rendered":"https:\/\/www.cleanlaser.de\/?page_id=7432"},"modified":"2023-10-20T11:58:42","modified_gmt":"2023-10-20T09:58:42","slug":"entlacken-in-der-elektromobilitaet","status":"publish","type":"page","link":"https:\/\/www.cleanlaser.de\/de\/entlacken-in-der-elektromobilitaet\/","title":{"rendered":"Entlacken in der Elektromobilit\u00e4t"},"content":{"rendered":"

[vc_row el_class=”bg-gray subpage-section”][vc_column][vc_row_inner content_placement=”middle” el_class=”container”][vc_column_inner][vc_column_text]<\/p>\n

Pr\u00e4zises und r\u00fcckstandsfreies Entlacken in der Elektromobilit\u00e4t<\/strong><\/h1>\n

 <\/p>\n

Ob zur Kontaktierung oder zur Herstellung elektromagnetisch vertr\u00e4glicher geschlossener Geh\u00e4use, die Elektromobilit\u00e4t fordert neue kosteng\u00fcnstige, reproduzierbare Entlackungstechnik. Mit Hilfe pr\u00e4ziser laserbasierter Entlackung ist es dabei nicht nur m\u00f6glich Batteriegeh\u00e4use aus Aluminium oder verzinktem Stahlblech punktuell zu entschichten, sondern auch Kupferlackdraht r\u00fcckstandsfrei zu entlacken. Die blanken Kupferdr\u00e4hte sind damit optimal f\u00fcr den weiteren L\u00f6t- oder Schwei\u00dfprozess in der Stator-Produktion des Elektromotors vorbereitet.<\/p>\n

Batteriegeh\u00e4use entlacken<\/strong><\/h2>\n

Batteriek\u00e4sten zur Aufnahme der Batteriemodule sind in der Regel aus zahlreichen Einzelteilen gef\u00fcgt, um die empfindlichen Batterien im Falle eines Unfalls sicher vor Besch\u00e4digung und der damit einhergehenden Brandgefahr zu sch\u00fctzen. Nach dem Einbau werden diese Batteriemodule dicht verschlossen, damit keine Feuchtigkeit eindringen kann. Auch elektromagnetische Strahlung darf nicht mehr in die Batterie gelangen. Ein wirkungsvoller Schutz und eine Verbesserung der elektromagnetischen Vertr\u00e4glichkeit (EMV) lassen sich durch elektrische Kontaktierung des Batteriegeh\u00e4uses zum Deckel erzielen. Dabei muss zudem die Korrosion solcher \u201eblanken\u201c Kontaktfl\u00e4chen vermieden werden. Au\u00dferdem ist eine sichere Massekontaktierung zur Stromableitung der Batteriemodule technisch notwendig.<\/p>\n

Die Clean-Lasersysteme GmbH (cleanLASER) hat zur elektrischen Kontaktierung verschiedene L\u00f6sungen entwickelt. F\u00fcr die Komplettbearbeitung gro\u00dfer Batteriek\u00e4sten eignet sich vor allem die cleanCELL, ein modulares Komplettsystem.<\/p>\n

Bauteile aus verzinktem Stahl oder Aluminium lassen sich abh\u00e4ngig von der Beschichtungsart und der Schichtdicke mit bis zu 30 cm\u00b2 pro Sekunde entlacken.<\/p>\n

Bei Aluminium erfolgt eine automatische Begrenzung der Entlackung durch die Reflektion am \u201eblanken\u201c Metall. Bei Stahlblech besteht die Herausforderung darin, die Zinkschicht, die sich unter dem KTL-Lack auf dem Stahlblech befindet, zu erhalten und somit vor Korrosion zu sch\u00fctzen. Dabei ist es mit der Lasertechnik m\u00f6glich, den Lack auf verzinkten Bereichen so schonend zu entfernen, dass die Zinkschicht nicht gesch\u00e4digt wird. Zugleich lassen sich gestanzte Bereiche wie z.B. Schraubl\u00f6cher aussparen, denn hier muss oft die Innenseite eines Bohrlochs beschichtet bleiben, um keine Startpunkte f\u00fcr Korrosionssch\u00e4den zu erzeugen.<\/p>\n

Da die Bearbeitung der Batteriegeh\u00e4use und -deckel einerseits positions- und konturgenau erfolgen muss, andererseits aber m\u00f6glichst kein Programmieraufwand bei der Anwendung entstehen soll, entwickelte cleanLASER die Software \u201econtourSCAN\u201c. Durch die integrierte CAD\/CAM-Schnittstelle wird die pr\u00e4zise Entlackung aus den Zeichnungsdaten mit ein paar Mausklicks erzeugt.<\/p>\n

Die contourSCAN-Technologie kann sowohl mit den cleanCELL-Standard-Automationssystemen als auch mit den daraus abgeleiteten cleanGANTRY-Systemen eingesetzt werden. Mit diesen hochgenauen Portalanlagen ist die Bearbeitung gro\u00dfer Bauteile und Baugruppen reproduzierbar und qualit\u00e4tskontrolliert m\u00f6glich.[\/vc_column_text][vc_single_image image=”4709″ img_size=”medium”][vc_column_text]<\/p>\n

F\u00fcgevorbehandlung<\/strong><\/h2>\n

Eine weitere Anwendung ist die F\u00fcgevorbehandlung von Geh\u00e4usebauteilen aus Aluminium zur Klebevorbehandlung. Dabei l\u00e4sst sich der Laser auch auf unbeschichtetem Material effektiv einsetzen. Durch die Modifikation wird die Oberfl\u00e4che f\u00fcr die Anbindung der Kleb- und Dichtstoffe vorbereitet und somit eine gute Haftung der FIPG- und CIPG-Dichtungen erzielt. Au\u00dferdem eignet sich die Oberfl\u00e4chenreinigung und Modifikation mit dem cleanLASER f\u00fcr strukturelle Verklebungen. Durch eine gezielte Ver\u00e4nderung der kristallinen Struktur z.B. bei Aluminium ist eine Absenkung des elektrochemischen Korrosionspotenzials und somit eine dauerhafte Klebefestigkeit auch f\u00fcr crashbelastete Strukturen m\u00f6glich.<\/p>\n

Aber auch die Nachbehandlung von Schwei\u00dfn\u00e4hten z.B. f\u00fcr die Abdichtung mit Hei\u00dfbutyl oder MS Polymeren kann mittels Laserreinigung kontaminationstolerant und prozessstabil erzielt werden. Das Laserverfahren ist immer dann von Vorteil, wenn eine \u201eblanke\u201c Metalloberfl\u00e4che frei von Organik und Beschichtungen eine Voraussetzung f\u00fcr den Folgeprozess darstellt, wie z.B. zur KTL-Beschichtungsvorbereitung von K\u00fchlerkomponenten im Thermomanagement der Batterie oder auch f\u00fcr die Schwei\u00dfvorbehandlung im Allgemeinen.<\/p>\n

Vorteile des Laserverfahrens sind die nachweislich sehr guten Haftungseigenschaften und Klebfestigkeiten, die Steigerung der Korrosionsbest\u00e4ndigkeit, eine dauerhafte stabile Abdichtung sowie die Crashfestigkeit.[\/vc_column_text][vc_column_text]<\/p>\n

Absaugung und Prozessabsicherung<\/strong><\/h2>\n

Zur r\u00fcckstandfreien Bearbeitung geh\u00f6rt auch eine effiziente Absaugung, mit der die abgetragenen Lackpartikel gesammelt werden. Damit l\u00e4sst sich eine 24\/7 Nutzung der Anlagen mit minimierten Wartungsunterbrechungen erzielen.<\/p>\n

Es stehen zudem Prozessabsicherungsl\u00f6sungen f\u00fcr die Laserentlackung von Batteriekomponenten zur Verf\u00fcgung. Diese umfassen neben der Technologie zur Absicherung der Anlagentechnik, wie z.B. zur Messung der Laserleistung, auch Messsysteme zur Ergebnisabsicherung. Das sind beispielsweise auf Kameratechnik basierende vergleichende Systeme, die inline jederzeit in der Lage sind, die Bauteilbearbeitung mit entsprechenden Referenzteilen zu vergleichen. Diese und weitere Prozessparameter sowie Messdaten lassen sich \u00fcber entsprechende Schnittstellenstandards (z.B. OPC UA) f\u00fcr den Datenaustausch mit Betriebsdaten-Erfassungssystemen (BDE) bereitstellen.[\/vc_column_text][vc_column_text]<\/p>\n

Kupferlackdraht<\/strong><\/h2>\n

Bei der Fertigung von Elektromotoren werden Kupferlackdr\u00e4hte mit speziellen Isolationsbeschichtungen aus Kunststoffen verwendet. Typischerweise sind das temperaturbest\u00e4ndige Kunststoffe wie Polyamid (PA), Polyamidimid (PAI) oder Polyetheretherketon (PEEK). Auch eine Kombination mehrerer Kunststoffe ist m\u00f6glich. Die Beschichtungen dienen zur Isolation und zum Schutz der Kupferleitungen. Um nun optimale Schwei\u00df- und L\u00f6tergebnisse des Kupfers zu erhalten, muss die Isolationsbeschichtung partiell entfernt werden. Diese Entlackung l\u00e4sst sich mit mechanischen Methoden oder wesentlich reproduzierbarer und prozesssicher mit der wireLINE von cleanLASER ausf\u00fchren.[\/vc_column_text][vc_single_image image=”5274″ img_size=”medium”][vc_column_text]<\/p>\n

wireLINE zur effizienten Drahtentschichtung<\/strong><\/h2>\n

Bei der Fertigung von Statoren kommen vor allem im Bereich der E-Mobility lackierte Kupferleitungen zum Einsatz. Diese sind zur Isolation gegen Kurzschluss mit einem Lack oder einer Isolierung gesch\u00fctzt.<\/p>\n

Beim Entlacken zur Schwei\u00dfvorbehandlung wird das Rohmaterial von der Rolle zugef\u00fchrt und der beschichtete Draht f\u00fcr die Wicklung je nach Leistung und Bauart des Motors in St\u00fccke von typischerweise 100 bis 800 mm L\u00e4nge geschnitten, so dass daraus Pins entstehen. Diese geraden I-Pins bzw. zu Halbschlaufen gebogene Hairpins werden dann in die gelochten Statorbleche eingesteckt. Um daraus eine geschlossene Wicklung zu erstellen, muss man die Halbschlaufen miteinander verl\u00f6ten oder verschwei\u00dfen. F\u00fcr eine optimale Verschwei\u00dfung werden die Enden der Pins entlackt. Idealerweise erfolgt das bereits inline am durchg\u00e4ngigen Draht, sodass nach dem Schnitt in der Mitte der Entlackungsstelle zwei abisolierte lackfreie Drahtenden entstehen.<\/p>\n

Die Anforderungen seitens der Industrie an die Drahtentschichtung sind vielf\u00e4ltig: Allseitige Entlackung, vollst\u00e4ndige Lackfreiheit sowie hohe Reproduzierbarkeit bei schwankender Lackschichtdicke. Der Entlackungsprozess sollte au\u00dferdem kontaminationsfrei sein, und dass bei hoher Taktzeit und minimierten Kosten.<\/p>\n

cleanLASER hat daher die festk\u00f6rperlaserbasierte Systeml\u00f6sung wireLINE entwickelt, die eine Bearbeitung \u00fcber eine gro\u00dfe L\u00e4nge des durchlaufenden Drahtes im Bereich von ca. 300 mm Arbeitsbereich erlaubt. Die Entlackung erfolgt nachweislich r\u00fcckstandsfrei mit einer Rest-Fluoreszenz (RFU) < 5. Diese Messung korreliert mit einer organischen Kontamination und stellt sicher, dass der Lack auch vollst\u00e4ndig entfernt ist.<\/p>\n

Der Drahtquerschitt wird durch die Reflektion des Laserstrahls am Kupfer dabei nicht messbar reduziert.<\/p>\n

Die wireLINE<\/a> DIRECT L\u00f6sung bestrahlt den Draht direkt mit vier Optiken und vier Lasersystemen. Sie eignet sich besonders f\u00fcr wechselnde Drahttypen und bietet eine hohe Flexibilit\u00e4t f\u00fcr verschiedene Drahtquerschnitte. Die Taktzeiten sind durch die relativ hohe Gesamtlaserleistung, die fortw\u00e4hrend bei der Vorschubbewegung auf den Draht (\u201eon-the-fly\u201c) einwirkt, sehr kurz. Bei einem Draht mit bis zu 4 mm Kantenl\u00e4nge und einer 90 \u00b5m PA\/PAI Beschichtungsst\u00e4rke liegt die Taktzeit z.B. bei nur 0,6 Sekunden.<\/p>\n

Somit l\u00e4sst sich der Draht durch die bewegte Bearbeitung (auch mit variabler Geschwindigkeit) um bis zu 40 % schneller abtragen als mit bisherigen Laserverfahren, die den stehenden Draht bearbeiten. Dabei konnte die Laserleistung um 70 % gegen\u00fcber konventioneller statischer Laserbearbeitung reduziert und der damit einhergehende Energieverbrauch deutlich gesenkt werden. F\u00fcr das o.g. Beispiel ergeben sich bei einer angenommenen Nutzungsdauer von nur sechs Jahren und einem Stator mit ca. 150 Hair-Pins Entlackungskosten von lediglich 0,5 \u20ac pro Stator bei einer Jahreskapazit\u00e4t von \u00fcber 150.000 Statoren.<\/p>\n

\u00c4hnlich wie f\u00fcr die Batteriek\u00e4sten bietet cleanLASER auch f\u00fcr die Drahtentlackung<\/a> passende Absaugtechnik, die an Draht und Lackanforderung angepasst ist, sowie komplement\u00e4re Prozess\u00fcberwachungsl\u00f6sungen an.[\/vc_column_text][vc_single_image image=”7439″ img_size=”medium”][vc_column_text css=”.vc_custom_1697795660340{border-radius: 2px !important;}”]Jetzt mehr \u00fcber Anwendungen im Bereich der Elektromobilit\u00e4t<\/a> erfahren:<\/p>\n

+49 2407 90970<\/strong> oder schreiben Sie uns an info@cleanlaser.de<\/a><\/strong>.<\/p>\n

Sie k\u00f6nnen auch gerne unser Kontaktformular<\/a> <\/strong>nutzen.[\/vc_column_text][\/vc_column_inner][\/vc_row_inner][\/vc_column][\/vc_row]<\/p>\n<\/div>","protected":false},"excerpt":{"rendered":"

[vc_row el_class=”bg-gray subpage-section”][vc_column][vc_row_inner content_placement=”middle” el_class=”container”][vc_column_inner][vc_column_text] Pr\u00e4zises und r\u00fcckstandsfreies Entlacken in der Elektromobilit\u00e4t   Ob zur Kontaktierung oder zur Herstellung elektromagnetisch vertr\u00e4glicher geschlossener Geh\u00e4use, die Elektromobilit\u00e4t fordert neue kosteng\u00fcnstige, reproduzierbare Entlackungstechnik. Mit Hilfe pr\u00e4ziser laserbasierter Entlackung ist es dabei nicht nur m\u00f6glich Batteriegeh\u00e4use aus Aluminium oder verzinktem Stahlblech punktuell zu entschichten, sondern auch Kupferlackdraht r\u00fcckstandsfrei zu […]<\/p>\n","protected":false},"author":2,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-7432","page","type-page","status-publish","hentry"],"acf":[],"rankMath":{"parentDomain":"www.cleanlaser.de","noFollowDomains":[],"noFollowExcludeDomains":[],"noFollowExternalLinks":true,"featuredImageNotice":"Das angezeigte Beitragsbild sollte mindestens 200x200 px gro\u00df sein, damit Facebook und andere Social-Media-Websites es 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