Carbon Brushes and Brush Systems State-of-the-art Technology for ...

Carbon Brushes and Brush SystemsState-of-the-art Technology for AutomotivePower net-fed Electric MotorsSchunk Business Unit Automotive

The Business Unit AutomotiveThe Automotive Field –the “Motor of Development”Core Competency:Automotive EngineeringThe worldwide demand for and thequality requirements placed on carbonbrushes and complete brush systemsfor the automotive industry has steadilyincreased in recent years. For thefuture, we anticipate more and moreand higher and higher expectationsin this field.Technical challenges, such as continualimprovement of comfort and safety, theintroduction of the 42 volt power net,as well as higher and higher demandsplaced on the level of interference suppressionin electrical motors used inautomobiles, are also becoming a“motor of development” for the automotiveindustry in the area of carbonbrushes and completebrush systems.This applies to innovative materials andoptimal design shapes for carbonbrushes, carbon brushes with fittingsor complete units with holders, as wellas for complex systems for electricalstandard features and safety equipmentand comfort features in nearlyall models of the leading automobilemanufacturers worldwide.Through years of cooperation with ourpartners in the automotive industry, weknow the special needs of this market.To us, core competency in automotiveengineering does not only meanworking together with our customers inthe area of design, rather it also meansconsistently producing top quality overlong periods of time.We accompany our customers throughthe entire development and productionprocess. This includes:material recommendationssupport for the optimal design ofcomponentsdetermination of the most efficientmethods of productionoffers for individual logisticsolutions.

Top Quality Through SynergyOur goal is to achieve absolute topquality for our customers. Therefore,we have brought together a teamof the most highly qualified specialistsfor carbon brush materials and componentknow-how at the AutomotiveBusiness Unit. Hence, in recent yearsfive companies with special knowledgewere merged into the AutomotiveBusiness Unit:Schunk Kohlenstofftechnik GmbHHoffmann & Co. Elektrokohle AGGerhard PraezisionspresstechnikGmbHSchunk Modultechnik GmbH,SchmittenMember in an InternationalTechnology GroupThe Schunk Automotive Business Unitis part of the multinational SchunkGroup, which employs some 7,000people worldwide and generates annualsales of 625 million Euro. The Schunkgroup is represented by 80 subsidiariesin 25 countries on 5 continents.As a customer of the AutomotiveBusiness Unit, you will automaticallyprofit from the innovations of theresearch and development projects ofour other business units, such ascarbon components for fuel cells, carbonpistons for combustion enginesand CFC materials for high-performancebrake discs, to name a few.Schunk Modultechnik GmbH,Ganderkesee

Your Development PartnerContinual Development up to theProduction StageAs the Automotive Business Unit,we have been working together withengineers, developers and productdesigners from the automotive supplyindustry for years. Together with ourpartners, we have taken part in manyinteresting projects from the first ideathrough to the production stage.We offer special know-how in the followingareas:Concrete Support for Your WorkYou can considerably increase the efficiencyof your product developmentby working together with our developmentteam and test lab. We help youto recognize and eliminate potentialsources of errors and faults as early asthe structural design phase.If desired, we can also advise youat this early stage on the most costefficient production method.development of materials compliantwith EC-Directive on End-of-LifeVehicles (2000/53/EC)noise reduction in commutative systemselectromagnetic compatibilityOur Central Development Departmentoffers you access to our chemistry andphysics labs with their modern analyticalmeasuring methods. We supportyou when making noise and oscillationmeasurements, as well as when measuringthe degree of interference suppression.carbon brushes for42 volt power netsmodule solutions with integratedinterference elimination and speedcontrollersIn our electrical lab, we carry out performancemeasurements and durabilitytests in accordance with customersengineered specifications.development of commutative systems.

Our Design Department works withPro-Engineer, IDEAS and AutoCAD systems,among others.Upon request, we can manufacturefunction samples on short notice.Teamwork from the Word “Go”The best teamwork begins as earlyas the idea phase, since this is wherethe paths are laid. In this early phase,we can give you a lot of tips and recommendationsto optimize your plans.Ideally, teamwork should begin withthe following steps:Climatic chamber made by Weiss-Klimatechnik (Schunk Group). Regulationof humidity between 10 % – 95 % is possible,the temperature can be adjusted from– 40 °C to +180 °Ccustomer enquirynew parts meetingfeasibility studyfeedback with the customerCAD/preliminary drawingsubmission of offer.Starter test benchwith integratedtorque measurement,simulationof the start processof a combustionengine using anelectronically controlledservomotor

Production, Process Security, QualityAs a Global Player, We Can Be onLocation for You WorldwideCarbon Brushes and Brush Systemsin Large-Series ProductionWith 13 production sites worldwide,we are one of the global players in theproduction of carbon brushes forpower net-fed electric motors andready to install brush systems.For the standard electrical features, weproduce components for the followingelectrical motors:startershydraulic press,power: 250kN, fullyautomatic with twindie for double layercarbon brushesWe strive to locate our production andlogistics facilities to be as close as possibleto the locations of our customers.We use semi- and fully-automated systemsand can manufacture manually aswell, if necessary.alternatorsengine cooling fans (ECF)heating ventilation air condition(HVAC)windshield and rear window wipersfuel pumpswater pumps.For the safety features we producecomponents for:ABS/ASR/ESPseat belt tightenersheadlight wiperselectro-hydraulic brakes (EHB).

For the area of comfort, we developand produce brushes with and withoutholders as well as brush systems for:window lift motorsseat adjusterssun-roof driveselectric clutch systemspower steeringsservo fly press, accuracy 0.001 mmproduction hall with modularautomatic rotary tableselectrical power locksside mirror adjusterspower antennas.For environmental protection, we developand produce components for:catalytic converter fansthrottle controls.“Made by Schunk” MeansTop QualityIn the entire Automotive Business Unitwe have a clearly defined quality commitmentand a solidly institutionalizedquality management system.Our individual companies are certifiedin accordance with ISO 9001 andsome are also additionally certifiedwith QS 9000 and VDA 6.1.All standard quality planning, approvaland release processes are carried outwithin the framework of a well establishednew parts project-management.These include, for example, AdvancedProduct Quality Planning (APQP),Failure Mode and Effect Analysis (FMEA)and Production Parts Approval Process(PPAP) in accordance withQS 9000 or Initial Samples InspectionReport (ISIR) in accordance with VDA.automatic linear grinder LIN NT 2 and rotary table, fully automaticmachining of carbon brushes

High-Tech Products for Safe Current TransmissionAt the Automotive Business Unit wesupply the leading automotive suppliersworldwide with carbon brushes,holders and ready to install brushcards. A few product samples from ourportfolio are portrayed below.Assemblyfor Wet RunningFuel Pumpscarbon brushesand plastic holdercomplete with connectorCarbon Brushfor AirConditioningFanscurved PTScarbonbrushes,for especiallydesigned brushholdersCarbon Brushfor CatalyticConverter Fansaxially pressedwith pressed onhead for springcentering, groundrunning surfaceand welded shuntendCarbon Brushfor Heating Fansradially pressed,cross shaped headgroove, cable enddoubly welded,ground runningsurface2-ComponentStarter Brushfor demandingcommutationCarbon Brushfor EngineCooling Fanwith an offsethead for bipolarmotors, specialdesign for clampfastening usinga leaf spring,welded shunt endand ground runningsurfaceassembly consistingof carbon brush andsuppressor (choke) forwet running fuelpumps

EHD Brush SystemBrush System – Interference-Suppressed with SensorsModule for AutomaticTransmissionsAs a component of the electrical powersteering pump, the EHD brushsystem contributes directly to drivingsafety in car design. In order to optimallyuse resources, the current carrieris made of a single part which incorporatesinnovative shaping technology.State-of-the-art injection technology,combined with electronics in thebrush system. TPE sealing, injectionmolding and soldering fully automated.Temperature range between– 40 °C /+85 °C. Due to a variable-basissystem, use in several different typesof vehicles is possible.Brush system with sensors, high durabilityof carbon brushes, temperaturerange between – 40 °C /+85 °C. Use ofthe System contributes to the bypassingof the clutch function in vehiclesand ensures output capacity when useddirectly in a motor.Brush Systems for ABS MotorsVVT Brush SystemL 100 Brush RockerPlastic composite part, base modulemade of polyamide 50 % GF withsilicone seal molding, fully automatedmanufacture of the basis module.New manufacturing method replacesthe assembly method with ordinaryO-rings previously used. Temperaturerange between – 40 °C /+120 °C.Extremely compactly built VVT brushsystem, in combination with other componentsforms the variable valve control.The VVT brush system proves itsperformance at acceleration ofup to 40 g and temperatures of over150 °C.Brush Systems with Circuit Boardfor Window Lift MotorsHas proven itself a million times –the L100 brush rocker combines fullautomation with the highest degreeof variability. Due to the intelligent, patenteddesign, the support plate withthe integrated plastic brush boxes, includingthe closure valves which arelater needed, can be produced as onepart. Due to the optimal forward re-sistance,a cost efficient control of therotational speed can be realized.Plastic composite part, basis modulemade of polyamide 30 % GF withThermoplastic Elastomers (TPE) sealmolding. Fully automated manufactureof the basis module. Automatic testingof the mobility of the carbon brush,spring force, Hall IC.

Logistics and CommunicationSchunk Automotive Business Unit:We are here for you and we are gladto answer your questions.We Have Everything under Controlin the Area of Logistics AlsoIn the area of logistics and communications,we guarantee our customersa smooth and efficient flow of goodsand information.We offer our customers individualpackaging solutions which best suit therespective assembly requirements: e.g.intelligent packaging alternativessuch as rolled blister-foil packagingfor automated, uncontaminatedand precision placing of components.A packaging alternative from theelectrical and semi-conductor industryfor the placement of circuit boardsusing pick and place assembly units.The designation of goods is ensured byusing barcode labeling (VDA) productstickers.If you would like to place your orderonline, Electronic Data Interchangeis available at Schunk Automotive foryour convenience.Rolled blister-foil packaging forautomated, uncontaminated andprecise positioning of components.This method of packagingoriginated in the electrical andsemi-conductor industries.

Schunk Kohlenstofftechnik GmbHRodheimer Strasse 5935452 HeuchelheimGermanyTelephone: + 49 (641) 608 - 0Telefax: + 49 (641) 608 -1223e- Mail: infobox@schunk-group.comHoffmann & Co. Elektrokohle AGAu 624832 SteegAustriaTelephone: + 43 (6135) 400 - 0Telefax: + 43 (6135) 400 -10 or -12e- Mail: office@hoffmann.atwww.hoffmann.atSchunk Modultechnik GmbHSeelenbergerstrasse 1aD-61389 SchmittenTelephone: +49 (60 84) 9 45-0Telefax: +49 (60 84) 9 45-155e-Mail: smt-info@schunk-group.comSchunk Modultechnik GmbHIndustriepark 7D-27777 GanderkeseeTelephone: +49 (42 22) 43-0Telefax: +49 (42 22) 43-21e-Mail: smt-info@schunk-group.comGerhard PräzisionspresstechnikGmbHRingstrasse 2391619 ObernzennGermanyTelephone: + 49 (9844) 97 11- 0Telefax: + 49 (9844) 97 11- 50

14.02e/2002Schunk Business Unit Automotive GmbHRodheimer Straße 5935452 HeuchelheimGermanyTelephone: + 49 (641) 608 - 0Telefax: + 49 (641) 608 -1488www.schunk-group.com