Brother machining parts solutions for electric vehicles (EVs)

The “decarbonization” trend has been progressing all over the world to achieve net zero greenhouse gas emissions, such as carbon dioxide (CO2).

The automobile industries in particular are now facing a significant turning point.

Many countries and regions are striving to accelerate the shift to gasoline-free vehicles, with targets between 2025 to 2040.

To achieve “carbon neutrality,” it is essential to implement efforts to reduce environmental burden, not only when the vehicle is running, but also throughout the vehicle’s life cycle from parts production to disposal and recycling.

“Cutting Out the Waste” “Faster by even 0.1 seconds”
Under these concepts, the SPEEDIO will continue to be essential for automobile parts machining by reducing waste that affects productivity and eliminating all other possible waste, such as in power consumption, air flow rate, and coolant volume.

Under the concept of “Cutting Out the Waste,” the SPEEDIO contributes to energy saving in production facilities, and demonstrates maximum effect for aluminum parts machining.

Overwhelming productivity, compared to #40 machining centers Energy saving performance achieved by optimal design

Energy saving technologies used in a variety of situations

Inverter case

Protects the circuit (inverter) that converts direct current to alternate current.

Facing, drilling, and tapping are mainly performed. Process integration is possible by using a rotary table.

Material: Aluminum die cast

  • The machine demonstrates overwhelming productivity in drilling and tapping.
  • Angle indexing sections can be machined effectively by using a rotary table.
  • Using the SPEEDIO can save more power than using other machining centers.

Battery case

Protects batteries mounted on EVs.

Facing, drilling, and tapping are mainly performed.

Material: Aluminum die cast

  • A large and heavy jig can be mounted as the maximum table loading capacity is 400 kg
  • Ample X/Y travels of 1,000 mm x 500 mm enable large workpiece machining.
  • Angle indexing sections can be machined using a rotary table. Using Brother’s original rotary table T-200Ad achieves fast indexing.

Gearbox

Accommodates the speed reducer that adjusts the motor rotation and transfers it to tires (drive shaft).

Material: Aluminum die cast

  • The table size of the W1000Xd1 is X1,100 mm x Y500 mm, providing sufficient jig area.
  • As drilling and tapping are performed frequently, a maximum feed axis acceleration of 2.4G can be fully utilized for this workpiece.
  • Angle indexing sections can be machined effectively by using a rotary table.

Compact motor case

Protects the EV motor.

Material: Aluminum die cast

  • Turning process and machining process can be completed with one chuck. This maintains stable accuracy in both turning and machining.
  • The M300X3’s maximum turning axis speed is 1,500 rpm.
  • Positioning is possible at the desired angle by tilting the A-axis. Lathe turning is also possible at the desired angle.

Bearing shield

Supports the EV’s motor shaft bearing. An integrated type with a motor housing and a separate type are available.

The M300X3 can be used for workpieces with an outer diameter of approx. 250 mm.

Material: Aluminum die cast

Utilizing the Y-axis travel, milling, internal turning, and slotting can be efficiently performed on large workpieces.

  • The workpiece is secured by the clamper installed on a jig plate of 350 mm in diameter.
  • Depending on the workpiece shape, a chuck can be used to clamp the outer or inner surface.
  • Use of up to the maximum speed is possible by fabricating a well-balanced jig with a low center of gravity.
  • Even when there is no machining at indexing sections, the machine may be used in place of a vertical lathe with a milling function.
  • Compared to a typical large vertical lathe, less space is required and machining speed is faster.

Electric compressor

Takes in and compresses refrigerant by securing one end of the spiral body and turning the other end.

The M200X3 can be used to produce major components of the electric compressor.

Material: Aluminum die cast

  • The maximum turning axis speed is 2,000 rpm. A built-in DD motor is used for the C-axis, enabling fast indexing.
  • Angle indexing sections can be machined easily by tilting the A-axis.
  • Turning and index-milling are performed with one chuck, enabling the machining of high-precision and high-value added products.

Pump housing

Accommodates a pump that circulates coolant to cool motors, inverters, etc. This is a key component for EVs as various parts need to be cooled.

Material: Aluminum die cast

  • The maximum turning axis speed is 2,000 rpm. A built-in DD motor is used for the C-axis, enabling fast indexing.
  • Angle indexing sections, such as inclined holes, can be machined easily.
  • Turning and index-milling are performed with one chuck, enabling the machining of high-precision and high-value added products.

Input shaft

Outputs the rotation of electric motors or gears.

Material: Cast iron

After the lathe turning process, drilling on top surface, inclined-hole drilling, and chamfering are performed.

  • Optimal for machining oil holes on shafts as the Y-axis travel is 440 mm.
  • For the M300X3, the distance between the table and top end is large, enabling drilling on the end face of a relatively long workpiece.
  • Facing and drilling on the end face are possible.There is a limit on the depth.
  • A roller gear cam is used for the tilt axis, minimizing backlash.
  • The A-axis rotates in the range of -30 to 120 degrees. The C-axis is capable of fast indexing due to the built-in DD motor.

ECU case

Accommodates electronic components to be mounted on EVs, such as sensors and computers.

Material: Aluminum die cast

  • Drilling, tapping, and chamfering are mainly performed.
  • 169mm.
  • A workpiece of this size is suitable for the S500Xd1.
  • Process integration is possible by using Brother’s original rotary table T-200Ad.

Valve

As thermal management is required for EVs, the quantity of valves increases.

Material: Extruded aluminum

  • When machining small workpieces, using a pallet changer makes the setup more efficient.
  • Optimal machine for multi-part machining that requires longer time for workpiece change.

Large valve for thermal management

Controls the EV battery temperature etc.

The S500Xd1 can be used as stepped-hole drilling and tapping are performed frequently. Forming tools of approx. 30 mm in diameter are generally used.

Material: Cast iron

  • Drilling and tapping are performed frequently by using forming tools. SPEEDIO’s tapping speed can be fully utilized for this workpiece.
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