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POWER RAILS

  • POWER RAIL CLIPTED

    Material:
    Any material possible
    Printing material: PA12
    Temperature resistance: 130 C°

    Use:

    All areas in which insulated busbars are used (automotive/e-mobility, electronics, energy technology, photovoltaics, etc.).

    Advantages:

    • Fully automatic assembly of the insulation clips possible
    • Complex bus bar geometries can be isolated
    • Consistent insulation thickness in multi-component construction
    • Materials with flame retardancy can be implemented
    • No special cleaning process is necessary before installing the insulation
    • No troweling of the bus bars necessary
    • Flexibility and short response times for geometry changes/product updates

  • POWER RAIL

    USE
    E-booster for Porsche Taycan (first car with 800 volt battery voltage)

    ADVANTAGES Shorter charging times Same performance with twice the voltage - means thinner and therefore lighter cables.

    MATERIAL / COATING CU-ETP silver-plated

  • INTERMEDIATE CIRCLE

    USE
    Capacitor assembly as energy storage for industrial trucks

    ADVANTAGES Simple construction of busbar + busbar - with insulation and resistance welds

    MATERIAL / COATING CU-HPC silver-plated

  • FILM CAPACITOR

    USE
    Module for holding the intermediate circuit capacitor

    ADVANTAGES
    Foil insulation with heat conduction to cooling plate; Stacks for connection to capacitor. Semi-automatic assembly of the entire assembly with foil laminate and electrical tests, HV and TE testing

    MATERIAL / COATING Cu materials ; aluminum; various foils / tinned

  • POWER RAIL

    USE
    Power modules for renewable energies such as wind power and solar energy. The power modules convert alternating current into direct current. This means that the modules can be controlled with little power and pass on a large output.

    ADVANTAGES
    One tool for three load connection variants. The selectively coated raw material can be used for all 3 variants. Several items are produced per punching stroke (falling multiple times).

    MATERIAL / COATING Se-Cu58 (Cu-PHC) selectively nickel-plated

    Information brochure Storm rails
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    STAMPINGS

    OUR LATEST AUTOMATION

    AUTOMATION

    STAMPINGS

    • EXTERNAL CONDUCTOR

      USE
      Charging batteries in electric vehicles up to 450 kWh, enables safe power transmission of 420 A

      ADVANTAGE
      Shield plate to ensure electromagnetic compatibility

      MATERIAL / COATING Stainless steel selectively tinned

    • ROUND PLUG

      USE
      Charging plugs for electric vehicles

      ADVANTAGES
      1000 charging cycles; high current-carrying capacity, cheaper to produce than turned parts in larger quantities

      MATERIAL / COATING K75 silver plated

    • HOUSING SHIELD

      USE
      Serves as EMC shielding on cables

      SPECIAL FEATURE Thermoformed item with several levels

      MATERIAL / COATING CuZn30 silver-plated

    • ROUND CONNECTOR ASSEMBLY

      USE

      These connectors are mainly used in auxiliary equipment such as electric heating systems, air conditioners, DC/DC converters and battery charging.

      This connector provides excellent shielding and is available in straight and angle designs. Despite their small size, these connectors achieve a current carrying capacity of approx. 60 A at 85 °C.

      SPECIAL FEATURE

      The item consists of 2 parts, which are pre-punched in a separate punching process, sent to the electroplating process and then finished punched in a finishing punching unit and married to each other

      MATERIAL / COATING

      Cu-ETP, CuCrSiTi
      Nickel + silver plated / tin plated + silver plated

    • POWER RAIL

      USE
      E-booster for Porsche Taycan (first car with 800 volt battery voltage)

      ADVANTAGES Shorter charging times Same performance with twice the voltage - means thinner and therefore lighter cables.

      MATERIAL / COATING CU-ETP silver-plated

    • PUNCHING GRID INCLUDING SUPPLIED ELOPINE

      REQUIREMENT
      Construction of a high-precision punching tool with the possibility of implementing many different customer connections and further processing options.

      IMPLEMENTATION
      For this purpose, a universal tool was built for Danfoss. With the help of this tool it is possible to map different variants. Both selectively refined soldering pins and selectively coated press-in zones made of high-performance alloys can be fed into the assembly tool. The highly sophisticated contacting elements are produced in a separate stamping process and fed to the stamped grid already refined.

      MATERIAL / COATING Base material punched grid: CuSn0.15 sel. Ni + Sn EloPin: K55 sel. Ni + Sn Solder pin: CuSn0.15 sel. Ag

    • INTERMEDIATE CIRCLE

      USE
      Capacitor assembly as energy storage for industrial trucks

      ADVANTAGES Simple construction of busbar + busbar - with insulation and resistance welds

      MATERIAL / COATING CU-HPC silver-plated

    • ROUND PLUG

      USE
      HV fuses for PDUs (Power Distribution Unit) are used in electric vehicles.

      ADVANTAGES
      HV fuses in a lightweight plastic housing are waterproof and vibration-proof and have an HVIL (High-Voltage Interlock) lock. These fuses or the corresponding insert can be easily replaced without opening the component housing.

      MATERIAL / COATING CuCrSiTi silver-plated

    • FILM CAPACITOR

      USE
      Module for holding the intermediate circuit capacitor

      ADVANTAGES
      Foil insulation with heat conduction to cooling plate; Stacks for connection to capacitor. Semi-automatic assembly of the entire assembly with foil laminate and electrical tests, HV and TE testing

      MATERIAL / COATING Cu materials ; aluminum; various foils / tinned

    • POWER RAIL

      USE
      Power modules for renewable energies such as wind power and solar energy. The power modules convert alternating current into direct current. This means that the modules can be controlled with little power and pass on a large output.

      ADVANTAGES
      One tool for three load connection variants. The selectively coated raw material can be used for all 3 variants. Several items are produced per punching stroke (falling multiple times).

      MATERIAL / COATING Se-Cu58 (Cu-PHC) selectively nickel-plated

      Information brochure stamped parts
      Info brochure press-in zones
      Stamping technology machine park
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      STAMPINGS

      TOOL TECHNOLOGY

      Manufacture of high-performance stamping tools for production at your site or at ours. Individual tools according to customer requirements, user-friendly tool design and the conception and implementation of complete systems with press, tool and handling system are standard for us.
      Tool technology information brochure
      Machinery toolmaking
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      TOOL TECHNOLOGY

      PAYMENT WORK

      • Holding unit

        PROCESSING STEPS: Milling / Hardening / Surface grinding / Wire EDM / HSC milling
        MATERIAL: Tool steel
        SURFACE QUALITY: Functional area Ra 0.2µm
        AREA OF APPLICATION: Gripper for assembly technology

      • Embossing stamp

        PROCESSING STEPS: Milling / hardening / surface grinding / wire EDM / HSC milling / sinker EDM
        MATERIAL: Powder steel
        SURFACE QUALITY: Functional area Ra 0.05µm
        AREA OF APPLICATION: Embossing die in a progressive composite tool

      • Gripper segment

        PROCESSING STEPS: Milling / hardening / surface grinding / wire EDM / HSC milling / sinker EDM
        MATERIAL: Tool steel
        SURFACE QUALITY: Functional area Ra 0.05µm
        AREA OF APPLICATION: Automation gripper

        KLEINER supports you in your daily work. We can deliver individual stamps and inserts to you within a short period of time. We check the feasibility with you in advance. Of course, this also applies to parts that have not previously been manufactured by KLEINER.

        Through framework agreements you will receive spare parts within a very short time. We always have the most important parts in stock. Everything “express”. Without any storage costs. Extra cost? Only for express shipping!

        ERODE

        EDM is a key technology for the production of complex precision parts.

        GRIND

        We process various materials made of steel and hard metal using CNC grinding. The advantages of grinding over other types of machining are the good machinability of hard materials, the high dimensional and shape accuracy (tolerance class IT 5 to 6) and the low waviness and roughness (Rz = 1 to 3 μm) of the ground surface.

        HIGHSPEED-FRÄSEN

        Highly precise in the μ range. Even complex three-dimensional contours can be easily produced using HSC. Another plus is the quick and precise production of electrodes. The milling of cobalt-bonded materials is also a key strength of HSC milling.

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        PAYMENT WORK

        Contact person for punching technology
        Hans-Jürgen Schüpf
        Phone 07231-60720
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        Contact person for tools and contract work
        Kevin Engel
        Phone 07231-60720
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