eldec LLC

3355 Bald Mountain Rd, Ste 30
Auburn Hills,  MI  48326-4312

United States
  • Booth: C13406

 Press Releases

  • Simple, intuitive control of the heating process, similar to a smartphone.

    Induction technology is used for a variety of tasks, such as hardening, preheating, joining or brazing, across a number of industries. With this technology, these processes are faster, more precise, and more energy efficient than other heating methods, allowing users to benefit from a more cost-effective process. The induction specialists at EMAG eldec are adding to this success with the new ECO LINE EEi² series of generators. They have focused on the operation, since “EEi²” stands for “EMAG eldec Intuitive Interface.” This interface is as easy to operate as a smartphone when the generator is used as a standalone solution. However, this series also used as an energy source within many production systems. This is where the well-established Siemens control technology comes in, as it ensures effortless connection to higher-level Siemens control units. For the first time ever, eldec Quality Control (eQC) modules are integrated in the proven ECO-LINE series for greater production reliability.

    The areas that induction heating can be implemented are vast, and generally implemented wherever materials and components are heated. Whether it’s brazing processes on copper, aluminum, and brass profiles (or similar materials), efficient surface hardening on things like pressing tools and gears, or precise heating of stator frames prior to joining the stator – the process always showcases its strengths. For example, only the desired area is heated to the precisely defined temperature. Energy efficiency is improved with this process because less energy needs to be transferred to the part during heating, and discharged from it during cooling. The process is also perfectly reproducible because the amount of energy required is very precisely defined.

    The generators that EMAG’s subsidiary eldec, headquartered in Dornstetten near Freudenstadt in Germany, have produced for over 30 years have a very important role as an energy source for induction. These are often models from the proven ECO LINE generator series. The series provides flexibility in configuration with a continuous power rating ranging from 5 to 150 kW (MF version) or 5 to 75 kW (HF version), it is virtually maintenance-free and features single or multiple outputs, as desired. With this, it can be fit into any environment, and will require very little space. “These particular strengths of the ECO LINE will obviously still apply in the future,” says Stefan Tzschupke, Head of Business Development Generators at EMAG eldec. “However, we are now taking a decisive step in development with the ECO LINE EEi², since the new generation’s operation is much more intuitive—comparable to a smartphone. Additionally, we’re also integrating a Siemens PLC in the ECO LINE series for the first time to enable easier connection to higher-level systems. Last but not least, we’re integrating an entire optional bundle of eldec quality control modules that fully monitor and document the induction process as is expected from an industry 4.0 solution. In summary, one could say that we’re driving the ECO LINE into the future.”

    Controlling it all like an app

    The most noticeable change with these developments is obviously the new touchscreen display that lends this series its name. It displays the main parameters of the induction process, such as power, frequency, current, voltage, and temperature, with clear bar charts and percentage values. All needed data can be acquired with just a glance. Menu items along the sides give users access to setup options and additional information. For instance, there are eight different timers, each with running times ranging from 0.1 to 9,999 seconds, and storage space for managing up to 500 recipes. “We made a deliberate choice to make the interface for this software look like a smartphone app since everyone is familiar with them by now. Consequently, the operation of these generators has been drastically simplified, which in turn benefits process reliability when running as a standalone process,” emphasizes Tzschupke.

    Siemens control unit makes integration easy

    The South German induction specialists also kept integration into production systems in their minds—this has always been of particular importance for the ECO LINE. The robust devices can be customized for very different applications. Users benefit from short-circuit-proof transistor technology, precisely controlled application of energy, and high efficiency. At EMAG eldec, all generators are produced to order: The core component of the generator, the resonant circuit, is specifically designed for the customer’s process.  The specialists are thus able to guarantee that the process is configured for optimal operation and runs as efficiently as possible—which is tremendously important for the overall production system. “In the end, we only deliver optimally configured devices that have been tested on the component. This wins over many customers,” adds Tzschupke. “This also explains why, for the ECO LINE EEi², we are using Siemens programmable logic controller for the first time: Many customers, for instance in the machinery industry, also use Siemens solutions for their overall control system. The integration of the ECO LINE EEi² thus becomes a much easier process.”

    eQC: perfect process monitoring

    A third innovation in the EEi² series, compared to previous ECO LINE devices, is the optional integration of eQC. The individual solutions build on and complement one another, and together, they guarantee customers an extensively monitored hardening and heat treatment process. This includes the eQC Flux and eQC RFID modules, for example. The former is used to measure the actual voltage at the base of the inductor. This is an ideal measuring point, because tool and component geometry as well as other factors influence the magnetic flux, which can be measured at the base of the inductor. eQC Flux thus provides much better information about the amount of energy that actually “reaches” the tool. For instance, this helps to detect whether the component has not been positioned correctly or if the inductor is damaged. This data can also be used to very precisely monitor component heating. The eQC RFID solution equips the tool with an RFID chip that is read using a read-write unit before production starts. The machine subsequently not only “knows” whether the right inductor has been used, but also the tool status and any manufacturing tolerances. 

    “As a whole, we’ve put together a particularly powerful and future-proof package with the ECO LINE EEi²,” concludes Stefan Tzschupke. “Users benefit from high efficiency, stable processes, robust technology, and simple usability. We’re convinced that this level of quality will win out in the marketplace.”

    More about EEi²

    More about eQC

  • There are various challenges in the field of electromobility or, to be exact, in industrial production for electromobility. The drive train must meet very high requirements in terms of precision, weight optimization, new environmental standards, etc. Laser technology offers perfect solutions for this. EMAG LaserTec shows how machinery manufacturers approach these tasks with a wide range of laser applications, which it has developed in recent years. From laser welding of highly complex drive components to laser cleaning of components to laser metal deposition for brake disks, EMAG shows the diversity of the machining operations that can be performed by or with laser beams. 

    The importance of laser welding in car manufacturing has been increasing significantly for years, and not just in car body production. Many components “under the hood” – or, more accurately, in the drive train – benefit from the precise and fast process. Laser welding is likewise increasingly used in the manufacture of electric motors, for example with copper or aluminum compounds, especially in the electric drive and in the battery. Laser welding is also perfect for rotor shafts. When machining these “lightweight rotor shafts,” users benefit from the EMAG LaserTec specialists’ extensive experience with components. The company is a world leader in laser systems for the manufacture of powertrain components. 

    Mechanical engineering meets laser

    High-precision and complex welds are only possible if the beam guidance system and the clamping of the workpiece are also highly precise. In other words, knowing how to clamp and machine a workpiece with the required control is essential for industrial production. These are typical topics faced in mechanical engineering, where not only the process itself, but also the complete infrastructure of the relevant user must be considered. How do the parts get to the machine, and in what condition? How is the machine loaded and unloaded? What is the downstream process? These are all aspects that influence the process reliability and must be taken into consideration. Consequently, modern production laser-welding systems like the EMAG ELC series, which fully satisfy the above requirements, have a lot more in common with machine tools than with typical welding systems.

    Machines for laser cleaning

    Producing flawless welds still requires proper preparation of the workpieces: High cleanliness requirements for the workpieces also apply when welding with a solid-state laser. Residues, like those from coolants, lead to faults like pores or cavities in the weld and need to be removed by reliable processes before welding. After many years in which washing the workpieces in a tunnel washer was standard practice, so-called laser cleaning now offers an alternative. The team at EMAG LaserTec recognized this early on, and for years has been relying on its own laser cleaning machines to enable the best possible welds.  For the cleaning, an ablation process is used, in which brief but very powerful (> 10 kW) laser pulses are applied to the workpiece surface. Pulsed laser radiation is applied to a surface with high pulse peak power. The material instantly evaporates and only a very thin layer is heated in the process. Many types of impurities or coatings can be removed from a component pulse by pulse in this manner – from coolants or oils to oxide and graphite layers to rust, paint, and phosphate layers. The technology is also used to suitably prepare surfaces for subsequent work steps (e.g. “roughing”). In short, the process is extremely flexible and very energy efficient.

    Laser metal deposition

    EMAG LaserTec has developed two more new machines for laser applications. They can be used for coating brake disks, for example. Modern brake systems have always generated (too) many fine dust particles. Now there is a new challenge: The brakes on electric cars are used less frequently, since recuperation of the motor produces enough braking effect. When a brake disk is unused for long periods, it may even start to rust. The solution is coated brake disks, which are impervious to wear and corrosion. No fine dust is produced here – at least not by the disk. For the manufacture of such a brake disk, EMAG’s machine portfolio now includes the ELC 450 LMD and the ELC 500 DUO LMD for reliable laser metal deposition. With this method, a bond layer and the hard metal layer on top of it, for example, are applied to the brake disk by means of a laser welding process. Therefore, almost no material is lost.

    A look at the details of the machine reveals exactly how this process works. The machines are equipped with either 1 or 2 (DUO) turntables. The component passes through the process two to four times, depending on the requirement for the coating system. 

    What are the requirements for laser metal deposition?

    Process reliability is integral to industrial production. The operator must have the entire process under control. For laser metal deposition, in detail this means:

    ·       Measuring the weight of the raw part

    ·       Preparing for laser metal deposition: There are numerous ways of doing this, for example laser cleaning or preheating the components, etc.

    ·       Laser metal deposition: Apart from the actual laser metal deposition, quality monitoring and control systems are extremely important. Examples:

    o   Monitoring and controlling the workpiece temperature

    o   Active coating thickness measurement

    o   Active weld pool monitoring

    o   Checking the powder stream caustic network

    o   Calibrating the powder delivery, etc.

    The actual manufacturing process is much more complex than simply getting to grips with the technology. Mechanical engineering involves meeting the highest quality requirements, across thousands of parts, day in, day in. And consideration must also be given to the downstream steps. Not only to how the machined parts are transported onwards, but also to the process step that logically follows. In the case of the coated brake disk, the surface also needs to be ground. EMAG has developed a machine for this too, with the result that EMAG truly can offer the complete process chain from machining of castings to laser metal deposition to grinding. 

    This broad practical and technological knowledge allows EMAG, and in particular EMAG LaserTec‚ to offer customer-specific solutions based on standardized processes. At the same time, the company ensures cost-effective production processes in combination with the presented laser applications through perfect coordination of the mechanical engineering, the technology and the associated software. These are key USPs of EMAG LaserTec. Learn more about EMAG LaserTec equipment and capabilities.

    Discuss your project with us at FABTECH. We'll be in booth C13406 with our sister company, eldec LLC.

  • When it’s time to repair or replace your induction heating coils, contact eldec LLC. Not only can we repair eldec coils, we can also repair coils manufactured by our competitors or manufacture replacement coils based on the old design. Typically, we do prototype runs to demonstrate our expertise and to meet our customers' expectations. Since short lead times and on time delivery are critical to your operation our current backlog is well positioned to allow a quick turnaround when you're in a pinch. If you need a completely new inductor designed, we do that well, too.  Learn more at inductionheatingexperts.com.

    eldec will exhibit at FABTECH in booth C13406 at the McCormick Convention Center in Chicago, Illinois. Give us a call at (248) 364-4750 and let us know you’re coming.