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Electro Vehicle Connector Case

Complexity made easy

Connector production is an assembly process requiring several components:
  • Base plate
  • Insert
  • Slider
  • Pin
In order to produce these parts, we of course need some electrodes and EDM processes. The total process includes parts to be produced on 3- and 5-axis milling, wire EDM and sinker EDM machines. Material handling with so many parts presents a high production risk and the chances of making a mistake are high.
Complexity made easy

The Makino solution: Sliders and pins

Long distances with squared shapes: these parts are typically for wire EDM machines. We need a solution that can handle wires down to 0.07 mm with a reliable wire-threading system and no wire breaks, even in poor flushing conditions.

In addition to this, the number of components to be produced justifies automation. In this case Makino used an automation system provided by Ingenia Automation.
The Makino solution: Sliders and pins

The Makino solution: Base, inserts, electrodes and finishing of pins

Base and inserts 

For base and inserts we used an F5 machining centre that delivers excellent pitch accuracy and surface quality.

Graphite and copper electrodes

For the electrodes we used a Makino D200Z, our reference machine for 5-axis volumetric accuracy and surface quality. Its ability to switch from graphite, copper and steel makes it the ideal machine for switching between different jobs.

Finishing of the pins

As the pins are extremely precise, we need an extremely stable machine, especially in the Z axis. The machine chosen was the Makino Sinker EDM EDAF3, which allows us to cut to Z0 position without iteration. Moreover, its high speed and acceleration in side machining make it the ideal machine for this application.

We mentioned above the large number of electrodes needed. So how do we connect all the systems? In this case we used an Erowa Robot Dynamic solution. With their JMS system we were able to handle the electrodes from the D200Z.
Erowa Robot Dynamic