Here at KEB America, we produce all of our own products. From processing the raw
material to assembling the final components. And the first step along the
way is our saw, in which the raw bar stock is machined into the correct sized
slugs for machining into the piece parts for our assemblies.
From there the bar stock arrives in our machining shop,
which has three vertical mills, a lathe,
an Integrex and two multiplex machines. We're continuously adding more machines
for better capability and greater capacity. The raw bar stock is loaded
into the machine, in which case the robot is loading it for the machining and then
the finished product comes out the other side.
This is our riveting assembly
station, in which we assemble the hub and armature to a flat spring, through
riveting, to form our crucial hub armature assembly, which is critical for
our brake and clutch assemblies. And over here is our roundness tester
where we have the capability to test up to 100% of the face and outer diameter
run out to the bore of the hub.
We have our magnet assembly area, which begins
with winding the coils to form the magnets. We can wind up to 6 inch
diameter coils. And we're getting another automated winder that handles up to 8
inch coils. The next step is adding the lead wires to the coils. And then after
the lead wires are added, we insert the coils into the magnet housings and then
seal the lead wires and epoxy the coils into the magnet.
Here we have our new, automated XYZ controlled epoxy system.
After the epoxy is fully cured we test 100% of our magnets for high voltage
continuity and shorts to the magnet housing. Over here we have some work
benches for some specialty soldering for smaller more difficult applications.
And beyond that, we have our connector pin and housing assembly station, in which we
add the customer specific pins and connectors to the lead wires of the
magnets, allowing them to connect it in their application. We also have a lathe,
in which we machine our magnets, friction linings, and rotors to the correct
specifications. After that we have our new Universal Robot magnet housing
assembly area, in which we assemble the three components of our permanent magnet
housings together and then screw them together using an XYZ controlled Atlas
Copco screwdriver. We have five different torque test systems here at KEB America.
From 1 and 5 Newton meter, 200 Newton meter, 50 Newton meter, 400 Newton
meter. And beyond there we have a 2,000 Newton meter torque tester. This is our 400
Newton meter torque tester waiting to load the next break.
This is our
induction motor and gearbox assembly area, in which we assemble the induction
motors and gearboxes, prep them for paint, paint them, and test them before sending
them out to the customers. Here we have our workstations dedicated to the
assembly of our spring-set COMBISTOP brakes. All the way up from small size one,
to the size nine that you see here. And the last step of the products life
cycle is packaging and shipping to the customer.
So that's an overview of our
capabilities here at KEB America. We're continuing to add new equipment, refine
our processes, and improve our capabilities.