WCA September 2023

Technology News

Technology investment boosts cleanroom capabilities William Hughes, a specialist manufac turer of springs and wire components, has enhanced the capabilities of its 80m 2 Class 7 cleanroom with its investment in a digitally controlled Ultrawave Neon 60 ultrasonic cleaning system. As well as being used internally, the cleanroom is offered as an advanced subcontract facility. Shaun Tattershall, special processes manager at William Hughes, said, “The cleanroom has evolved over the years since we acquired ultrasonic cleaning company AC Services, in 2015.

Said to be the only one of its kind in the UK, it is being regularly utilised by manufacturers in the aerospace, medical and hydraulics industries, where it is used for the cleaning and packing of small-batch, precision-machined and fabricated parts to meticulous standards. William Hughes can also undertake the assembly of units involving more than one component in a cleanroom environment.

“To keep up with industry demands and evolving legislation we have invested in new contemporary technology which of- fers the levels of performance expected by some of the most demanding industrial sectors. The careful handling of every part entrusted to our care is a central philosophy of this service.”

The new Neon machine, which is Class I Medical Devices compliant to MDR (EU) 2017/745, complements existing assets and capabilities in the ISO 14644 1 accredited cleanroom, which include further solvent and aqueous cleaning systems, a UV-inspection dark room and various cleaning verification systems, such as filtration studies, NVR testing and microanalysis.

William Hughes Ltd www.wmhughes.co.uk

Extrusion line for the insulation of hairpin wire Around the world, researchers and engineers are looking for ways to make e-mobility more convenient for everyday use. 800V systems for electric cars are increasingly common, and will overtake 400V systems in the coming years. more viable. It has become attractive for automotive applications due to its favourable speed-torque behaviour and high fill-factors. These qualities help to minimise energy losses and improve the overall efficiency and reliability of the electric motor.

With its newly developed hairpin extrusion line, Rosendahl is providing a production process for insulating hairpins using highly resistant polymers. This technology will make advanced hairpin insulation accessible to a broader range of manufacturers. The compact RA-I extrusion line is equipped with Rosendahl’s high temperature extruder technology and a specially developed crosshead for flat conductors. The complete conductor processing unit is mounted on a base frame to maintain tight tolerances in production. From payoff to take-up, each line component is carefully synchronised to meet the high demands of the rectangular hairpin wire. To attain its distinctive shape, a hairpin needs to be bent multiple times. Its insulation must always adhere firmly and withstand high voltages. The strong material properties that are required for that can be found in high-performance plastics such as PEEK (polyether ether ketone). The processing of these polymers requires an understanding of the underlying process, and high precision. To achieve uniform wall thickness, the rectangular copper conductor requires exact guiding and material distribution. The end product of Rosendahl’s extrusion solution is a uniformly insulated copper wire, carefully wound layer by layer onto a reel, ready for the next production stages in hairpin manufacturing.

Doubling the voltage of electric cars has several advantages. Higher voltage leads to lower current, resulting in less heat generation. A more compact design with thinner and smaller cabling and electrical components in the vehicle becomes possible, leading to a lighter and more efficient car overall. It also significantly reduces charging times. Hairpin technology, a winding method for stators in electric motors, will play a key role in making 800V systems

In the majority of modern applications, hairpins are still enamelled. However, extruded hairpins have shown their value in the premium and sports car sectors. The breakdown voltage achieved with extrusion surpasses enamelled insulation by several times, and ensures a safe and reliable power supply, even at higher voltages. Extrusion also outperforms conventional enamelling in terms of production speed and energy efficiency.

Rosendahl’s hairpin extrusion crosshead

Rosendahl Nextrom GmbH www.rosendahlnextrom.com

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September 2023