Summary
- Busbars are essential components found in EVs and EV charging hardware with different requirements in manufacturing
- WAFIOS develops specialized machinery for wire and tube processing, including machines for busbar production
- BMF series by WAFIOS is suitable for compact busbars in vehicles with space constraints, offering tight radii and flexibility
- WAFIOS offers TWISTER machines for extra-long busbars with large conductor cross-sections for e-mobility applications
- WAFIOS provides automation solutions for busbar bending machines to increase productivity, enhance quality, and reduce costs
Article
Busbars are essential components in various electrical equipment, including electric vehicles (EVs) and EV charging hardware. However, not all busbars are the same, as different requirements, dimensions, and geometries need to be taken into account during the manufacturing process. WAFIOS, a company specializing in machinery for the wire and tube processing industry, offers a range of machines designed to produce different types of busbars to meet specific production needs.
The BMF series from WAFIOS is ideal for manufacturing compact busbars, especially those found in vehicles with limited space. These machines utilize patented tool technology that allows for tight radii with a thin profile, as well as the flexibility to modify the alignment of busbar ends through twisting. Additionally, WAFIOS’ patented rotary roller infeed unit, present in all wire bending machines, ensures maximum production speed. For the production of longer busbars with a large conductor cross-section, WAFIOS offers the TWISTER 25 and TWISTER 35 machines, originally designed for the tube-bending sector and now adapted for e-mobility applications.
WAFIOS provides end-to-end automation solutions for additional operations in the busbar manufacturing process. These solutions include punching various geometries, ultrasonic welding, feeding in and mounting connector parts, labeling busbars, and discharging them onto workpiece carriers or transport belts. These features are aimed at enhancing productivity, improving quality, and reducing the cost per piece. The incorporation of automation solutions like EasyRobot facilitates the handling of busbars seamlessly, with full integration into the bending machines, as stated by Jörg Eisele of the WAFIOS Executive Board.
Insulation stripping is a crucial step in busbar processing to ensure a clean surface without any residue from the insulating material. WAFIOS offers mechanical insulation stripping as an alternative to CO2 laser stripping, emphasizing its cost-effectiveness and ability to reduce cycle times by over 40%, leading to a higher output rate from the entire machine system. The insulation stripping system in WAFIOS’s BMF 60 and BMF 90 busbar machines features seven axes and two milling units, providing maximum flexibility. The CNC insulation stripping device allows for the production of any combination of stripped sides at the busbar end, based on the connection situation of the busbar.
Overall, WAFIOS specializes in providing machinery for wire and tube processing industries, including tools for manufacturing a wide range of busbars tailored to specific production needs. Their machines, such as the BMF series and TWISTER models, are designed to handle various busbar dimensions and requirements, offering flexibility and high production speed. Additionally, WAFIOS offers automation solutions for additional operations in busbar manufacturing, enabling manufacturers to enhance productivity, quality, and cost-effectiveness. With a focus on mechanical insulation stripping to ensure clean surfaces and increased output, WAFIOS is a leading provider of busbar processing solutions for the growing demand in the e-mobility sector.
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