Wire forming parts for e-mobility
Our custom bending parts made of aluminum and copper are used in various electronic fields. Special machines are used for the production and shaping of the wire according to the customer's requirements. The bending material can be made of different metals like copper or aluminum. Depending on the application, however, the parts can also be further refined, for example by a surface coating.
Busbars for e-mobility
Busbars are electrical conductors used to transmit and distribute electrical power in electrical systems. They are mainly used in industrial and commercial systems as well as in modern electric vehicles. They are made of copper or aluminum with various conductor cross sections and terminal forms. Compared to conventional cables, busbars can offer a variety of advantages, such as easier installation, greater mechanical robustness and, in the case of aluminum, lower mass per length. In addition, busbars can deliver cost advantages over cables and require less maintenance, making them an ideal solution for electrical power transmission in e-vehicles.
brandgroup manufactures high-quality busbars for power distribution in the high-voltage (HV) electrical systems of battery electric vehicles (BEV).
Compared to the use of cables with the same cross-section, these flat conductors have a significant reduction in their overall height and are therefore ideally suited for space-saving integration into the architecture of modern e-vehicles. The larger surface area of the busbar also dissipates heat better than a comparable cable conductor.
Rigid busbars have a much better suitability for automatic assembly compared to the generally less stable cables, which is why they are often preferred for this purpose. Thanks to our flexible manufacturing systems, we are also able to bend complex 3D-bent busbars made of PA12 pre-coated copper or aluminum. Depending on customer requirements we can customize both cross-sections and geometries. Our vertical range of manufacture includes the complete production and testing of the conductor rail according to customer requirements.
As a leading manufacturer, brandgroup currently has the world's first system for bending PA12-coated aluminum cross-sections up to a size of 200mm2. With this technology, brandgroup is able to replace conventional copper-based busbars with more cost-effective aluminum.
Wire bending parts for electric motors in e-drive trains
Hairpin technology is an innovative winding technology for use in electric motors and generators, mainly used in traction motors for electric vehicles due to their higher efficiency and performance compared to other winding methods. The plug-in coils, also known as hairpins, are mostly made of bent and lacquered flat copper wires in U-shapes.
brandgroup is your professional partner for the production and supply of hairpins and I-pins for stators in electric vehicle traction motors.
E-machines based on hairpin stator technology thereby combine the advantages of a high slot fill factor better process stability and repeatability.
In the production of flat conductor-based plug-in coils, the brandgroup relies on a particularly flexible system technology that enables damage-free processing of all common enameled copper wires with a high number of variants. This manufacturing technology realizes the production of different hairpin designs with a constant material cross-section.
For safe removal of the coating layers at the end of the pins, the brandgroup system is equipped with an integrated system for mechanical stripping of the coating, which guarantees optimally prepared copper wire ends. This enables safe contacting in the further process sequence. With our machine technology, we are particularly geared to the production of small and medium-sized batches and thus offer our customers the opportunity to benefit from the advantages of hairpin technology at short notice and without having to make their own high investments in equipment.
The product range of brandgroup in the field of e-mobility applications also includes the production of bending parts based on copper lacquer, such as for stator connection assemblies (SABG) or coils and windings bent on the edge for use in axial flux motors.
