HAHN Automation Group develops turnkey-solution for DC/DC Converter
The customer required a fully automated production line for DC/DC Converter assembly, including a material supply system directly connected to their intralogistics.
A direct voltage converter, also known as a DC/DC Converter, is an electrical circuit that converts a direct voltage supplied at the input into a direct voltage with a higher, lower or inverted voltage level.
#Automotive #DCDC #Production #AssemblyLine
- Full-automatic Production Line
- Automated Material Supply
- Integrated E-Test
Challenge
A key challenge was managing four different ferrite-based contact variants, each requiring exact positioning and handling. The overall process complexity included multiple high-precision steps such as 2K gluing, TIM dosing, insulation foil application, plasma cleaning, and EOL testing.
Additionally, the inserts had to be joined precisely into the housing mold. Ensuring seamless coordination of all steps while maintaining short cycle times demanded a highly reliable and integrated automation approach.
Developing a Solution
The HAHN Automation Group engineered a fully automated line incorporating a range of advanced core technologies, including plasma cleaning, thermal interface material (TIM) dosing, 2K gluing, foil application, and electrical testing of connectors. The system features precise insert placement into the mold and a custom buffer solution for smooth process flow.
An AGV-less material handling concept was developed and connected directly to the customer’s logistics system—ensuring continuous, hands-free material supply. Drawing on extensive experience in all requested process steps, and supported by in-house development resources for both plasma and foil application, HAHN ensured optimal performance and long-term reliability.
