The challenge
The European market leader for connection solutions between battery and motor in electric vehicles was faced with the challenge of meeting high demands with regard to the quality of components while also keeping costs under control.
To maximize the performance of dynamic electric vehicles, current-carrying components must be made of pure electric copper. This material is very expensive, difficult to machine and also fairly soft. This can cause components to deform easily, leading to damage that can impair their function.
The special nature of the task
In this specific case, a component for connecting the battery and electric motor with a rectangular outer geometry and a convex front surface had to be manufactured as cost-effectively as possible.
The Dakoko solution
Dakoko decided to have a special material produced that already has the correct outer geometry. The finished component is then turned on a sliding headstock lathe. The non-rotationally symmetrical areas that cannot be turned are milled using directly driven tools. Complete production in one processing step ensures both consistent quality (no multiple clamping) and the lowest possible process costs.
Details that make the difference
As a global company, Dakoko was able to develop a solution that combines the advantages of all Dakoko locations.
The raw parts are manufactured at the Dakoko site in China. One of the largest copper producers, with whom Dakoko maintains excellent relations. is located near the plant. This facilitated an agreement for the chips generated in the production process at Dakoko to be re-melted directly at the manufacturer on very good terms – in the same quality as the original raw material. This has resulted in significant price advantages.
The raw parts are also automatically inspected 100 % for damage in China. To prevent damage during handling, the feed is carried out by a robot. The components are then coated in Germany by one of the world’s leading coaters. This allows us to achieve the highest coating quality and consistency without damaging the components.
The customer is supplied on a weekly basis from the central Dakoko warehouse in Villingen Schwenningen. Despite the global supply chain, there are no disadvantages for the customer in terms of their own inventory or order planning times.
Benefits for the customer
- Optimal quality thanks to automated 100% monitoring
- Optimal costs thanks to a global solution