The level of innovation behind these efforts is exemplified by passenger car transmissions, whose gear wheels and related components are manufactured by the millions and require optimized designs. To ensure that manufacturing processes run smoothly and efficiently, engineering specialist EMAG, employs high-tech solutions such as laser welding to realize spectacular results.
The differential transmission is a key component in vehicles and is manufactured millions of times over. Already perfected, is it possible to make the design even lighter? Engineers believe so and have created a simple, yet highly effective weld joint that is used by German auto makers to replace the previous threaded connection between differential components. This reduces the amount of material required, which in turn lowers the unit price of such a high-volume assembly. The weight of the differential housing is also reduced by approximately 1.2 kilograms. "This reduction is nothing short of impressive in the automotive world," explains Dr. Andreas Mootz, Managing Director of EMAG Automation.
Process integration ensures efficient production
But how is the welding work carried out? After all, enormous production quantities are involved. Automated ELC equipment from EMAG is used to manufacture the transmissions. The machine starts by loading components, then presses them together and welds the gap. Additional processes may also be carried out depending on the component handled. Each gear wheel is finished in just twelve seconds, and all differential components are fully welded in no more than 40 seconds. "Laser welding is key here and integrates technology that controls the laser beam with exacting precision," explains Mootz.
A world leader in transmission components
The welding specialists at EMAG enjoy a long history of success. Today, all renowned auto makers use laser welding in their manufacturing processes. German engineering companies also benefit from the recent market trend, which has resulted in an increased demand for gear wheels thanks in part to the dual-clutch transmission. This trend extends to conventional manual gearboxes as well, many of which integrate more gear ratios than before to further lower fuel consumption.
Janine Christoph | EMAG Leipzig
Enhanced ball screw drive with increased lifetime through novel double nut design
23.01.2018 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH
Scientists from Hannover develop a novel lightweight production process
27.09.2017 | IPH - Institut für Integrierte Produktion Hannover gGmbH
Breakthrough provides a new concept of the design of molecular motors, sensors and electricity generators at nanoscale
Researchers from the Institute of Organic Chemistry and Biochemistry of the CAS (IOCB Prague), Institute of Physics of the CAS (IP CAS) and Palacký University...
For photographers and scientists, lenses are lifesavers. They reflect and refract light, making possible the imaging systems that drive discovery through the microscope and preserve history through cameras.
But today's glass-based lenses are bulky and resist miniaturization. Next-generation technologies, such as ultrathin cameras or tiny microscopes, require...
Scientists from the University of Zurich have succeeded for the first time in tracking individual stem cells and their neuronal progeny over months within the intact adult brain. This study sheds light on how new neurons are produced throughout life.
The generation of new nerve cells was once thought to taper off at the end of embryonic development. However, recent research has shown that the adult brain...
Theoretical physicists propose to use negative interference to control heat flow in quantum devices. Study published in Physical Review Letters
Quantum computer parts are sensitive and need to be cooled to very low temperatures. Their tiny size makes them particularly susceptible to a temperature...
Let’s say the armrest is broken in your vintage car. As things stand, you would need a lot of luck and persistence to find the right spare part. But in the world of Industrie 4.0 and production with batch sizes of one, you can simply scan the armrest and print it out. This is made possible by the first ever 3D scanner capable of working autonomously and in real time. The autonomous scanning system will be on display at the Hannover Messe Preview on February 6 and at the Hannover Messe proper from April 23 to 27, 2018 (Hall 6, Booth A30).
Part of the charm of vintage cars is that they stopped making them long ago, so it is special when you do see one out on the roads. If something breaks or...
15.02.2018 | Event News
13.02.2018 | Event News
12.02.2018 | Event News
16.02.2018 | Information Technology
16.02.2018 | Health and Medicine
16.02.2018 | Physics and Astronomy