EXPERT Transformatorenbau GmbH...In 2006 was purchased separately from the former EXPERT Maschinenbau GmbH ... 100% quality control of all components ... – Power 100 kVA – Size

EXPERT Transformatorenbau GmbH High Current Applications│ Resistance Welding │ Heating Current Sources

EXPERT Transformatorenbau GmbH

│High Current Applications

│Resistance Welding

│Heating Current sources


Industriestr. 6a

64653 Lorsch

Tel: +49 6251 86906 0

Fax: +49 6251 86906 10

E-Mail: [email protected]

www.expert-trafo.de



19.04.2013 2

Located south of Frankfurt

Privately owned company

50 year old tradition in the development and manufacturing of

water-cooled high current transformers and rectifiers

35 employees

$10.3M Sales (2014)

Global Supplier

Industries serviced: – Automotive

– Machine building

– Process technology

– Plant manufacturing

– Ceramics

– Railway

– Solar industry


Company‘s history

19.04.2013 3

1961

1967

1990

2006

2012

2015

Founded in 1961 as EXPERT Maschinenbau GmbH in Lorsch by

Hans Jäger and under EXPERT Inc. in Detroit

Delivered the first transformers in 1967

Transformer manufacturing was an integrated part of the

EXPERT Maschinenbau GmbH

Helped develop international standards in the field of resistance

welding transformers

Developed MFDC transformer technology 1990

In 2006 was purchased separately from the former EXPERT

Maschinenbau GmbH

2012 move to new manufacturing facilities


International

19.04.2013 4

Direct and indirect supplier of products all over the world

Marketed and serviced through agents and resellers in: – China

– South Korea

– UK

– Italy

– France

– US

– Brazil


Core competencies

19.04.2013 5

High volume production of MFDC transformers for automotive

industry applications

Product range in customized transformers from 5 to 1,500kVA

and more

Vertically integrated manufacturing

100% quality control of all components

Joint specification development with existing customers – Automotive industry

– Plant manufacturing

– Machine builder

– Welding control companies

– Final customers

Development of new markets in the field of high current water

cooled applications – Renewable energy

– Railway

– Electro mobility

– Process technology


19.04.2013 6

Turn-Over

0 €

1.000.000 €

2.000.000 €

3.000.000 €

4.000.000 €

5.000.000 €

6.000.000 €

7.000.000 €

8.000.000 €

9.000.000 €

10.000.000 €

2007 2008 2009 2010 2011 2012 2013 2014

5.138.571 €

6.336.547 €

3.802.657 €

6.136.571 €

7.388.705 € 7.407.764 €

6.451.504 €

9.445.188 €


19.04.2013 7

Sales by markets 2012 - 2015

89,53%

7,11% 1,67%

0,01% 0,32%

1,35%

Europe

Asia

N America

Australia

Africa

S America


19.04.2013 8

Product mix 2012 - 2015

Type Quantity % of total Quantity Turn over % of turn over

MFDC 18347 87,27% 22.911.519 € 77,18%

Gun transformer AC 1132 5,38% 1.045.685 € 3,52%

Process transformer 587 2,79% 2.601.270 € 8,76%

Fixture type transformer 318 1,51% 1.057.471 € 3,56%

Pulse transformer 290 1,38% 1.145.957 € 3,86%

Multi welding transformer 237 1,13% 417.077 € 1,40%

Special transformer 92 0,44% 344.139 € 1,16%

Suspended transformer 13 0,06% 30.278 € 0,10%

3 Phase rectifier units 7 0,03% 133.929 € 0,45%

Total 21023 100,00% 29.687.323 € 100,00%


Customers

19.04.2013 9

EXPERT is an approved international supplier to various

manufacturers including automotive, appliance, and machine

manufacturers

Active customer base of more than 500 customers

More than 900 different transformer types have been sold since

2006

Product range of more than 2,000 different transformers,

reactors, inductors, and chokes …

All product data since 1967 is readily available

HFDC transformers for robot and machine applications

MFDC transformers for continuous and pulsed applications such

as seam welding, high current Butt and Flash welding, and

resistance heating.

http://www.fct-systeme.de/


19.04.2013 10

Development and Design

Products conform to various international standards and

specifications

Design optimization of electrical, mechanical and thermal

parameters utilizing mathematical computation and simulation

software

3D CAD designs with models available

Life cycle modelling for MFDC transformers

Development of customer specific solutions

Prototyping

Continuous technological development


19.04.2013 11

Manufacturing

Manufacturing capability from single units to large volumes

Metal processing

Joining technologies

Powder coated high current secondary cooling coils

Primary coil insulating and winding

Epoxy resin encapsulation

Final assembly

100% Quality control tested – Leak testing of cooling circuit up to 175 PSI

– High voltage and isolation resistance tested

– Heating tests


19.04.2013 12

Water cooling benefits

Use of water cooling to reduce size – 4 times higher cooling capacity than air

– Heat transfer from the copper secondaries to water is approx. 1,000 times more

efficient than to air

Transformers and coils can be designed much smaller – Important weight and size reduction

Direct and indirect cooling – Water channels inside of the secondary coils (direct cooling)

– Thermal transfer of heat from the primary coils to the water cooled secondary

coils (indirect cooling)


19.04.2013 13

Products

High current sources for resistance welding – AC transformers, MFDC, pulse transformers, 3-phase DC rectified units

Process transformer of high power – Conductive heating, annealing and melt processes, customer specific solutions

High power chokes – Filter chokes, storage chokes, singe and three phase, power line matching

Supported welding technologies – Spot welding (steel, high strength steel, aluminium)

– Projection welding

– Seam welding

– Capacitor discharge welding

– Butt welding

– Flash butt welding


19.04.2013 14

High current sources for resistance

welding - AC

AC transformers for robot welding guns of the automotive

industry based on customer and industry specifications

AC transformers for applications such as: – Grating welders

– Spot welding

– Projection welding

– Seam welding with low induction

Continuous current up to 70 kA per transformer

Product range from 5 to 1,200 kVA

More than 600 types


19.04.2013 15

High current sources for resistance

welding - DC

MFDC units for welding guns, machine style, and fixture type

units

Modular MFDC series available for a wide range of applications

Transformers for pulsed and continuous operation

Frequency range from 1 to 10 kHz

3 phase rectified units (50 / 60 Hz)

Power range from 5 to 1.500 kVA (50% d.c.)

More than 150 types


19.04.2013 16

MFDC technology – a comparison

Standard AC transformer (50 Hz) – Power 100 kVA

– Size 550 x 235 x 184 mm

– Weight 113 kg

MFDC transformer – Power 123 kVA

– Size 315 x 160 x 127 mm

– Weight 24 kg


MF2 series – 75kVA (8,4V), 5,0kA I2p, 1 diode per branch

– 106x150mm, 15,5kg

MF3 series – 111kVA (9,3V), 6,5kA I2p, 2 diodes per branch

– 125x160mm, 24,4kg

MF4 series – 123kVA (9,3V), 7,2kA I2p, 1 diode per branch

– 125x160mm, 24,5kg

MF8 series – 107kVA (8,9V) , 6,5kA I2p, 1 diode per branch

– 106x150mm, 16,5kg

MF10 – 10kHz, 121 kVA (11,1V) , 6,0kA I2p, 1 diode per branch

– 106x150mm, 13kg

19.04.2013 17

MFDC, HFDC Product Range


Pulse transformers für capacitor discharge welding

Energy range from 5 to 120 kJ

Pulse currents up to 1000 kA

More than 35 types

19.04.2013 18

Pulse transformers


19.04.2013 19

Resistance Heating transformers

Resistance heating of:

Ovens

Melting pots

Valves for glass and ceramic industry

Glass, ceramic and carbon manufacturing

Product range from 3 to1000 kVA

More than 350 design styles


Water cooled chokes for high current applications – Filter chokes

– Storage chokes

– Interphase transformer

Use in inverter and converter systems for grid connection

Smoothing choke for plating equipment

Transformers for inductance heating

19.04.2013 20

Other Applications


21.06.2013 21

And why EXPERT?

Over 50 years experience in latest design and manufacturing

techniques

Experience being involved in developing standards and

regulations to industry trade associations as well as large

manufacturers

Application specific design criteria capabilities

Approved for use at most global automotive manufacturers

Quality system conformance

Competitive pricing

Global supplier


19.04.2013 22

Closing

THANK YOU!

Documents

EXPERT Transformatorenbau GmbH...In 2006 was purchased separately from the former EXPERT Maschinenbau GmbH ... 100% quality control of all components ... – Power 100 kVA – Size