Output tripled with FUJI: R&D Elektronik increases placement output in electronics manufacturing

E²MS service provider expands capacities heading for series production

Kelsterbach, July 27th, 2023 – The demand for high volumes is rising in electronics manufacturing – driven, among other things, by increasing digitization and the associated rise in demand for electrical components. The E²MS service provider R&D Elektronik GmbH & Co. KG, a company of the R&D Group, is adapting to this situation and establishing efficient series production processes. To this end, the company will in future be relying on placement machines from FUJI EUROPE CORPORATION GmbH (www.fuji-euro.de). With the help of three modules from the AIMEX series, the company was able to more than triple its output.

With almost 50 years of industry experience, the R&D Group is an expert in the field of electronic control technology, electronics and mechanical engineering. As a full-service E²MS provider, R&D Elektronik manufactures and develops electronic products – from prototype to series production. In doing so, R&D Elektronik pays attention to a balanced industry mix of industrial electronics, medical technology, automotive and consumer electronics.

The company already had an placement line in operation for small and medium-sized series production (100 to 1,000 units). The growing demand for high-volume production necessitated an expansion in this area. “The demand for electronic components and devices is increasing across all industries. Electronics are increasingly being used in a wide range of industrial applications. For this reason, we have significantly expanded our production capacities,” explains Theo Schelasni, plant manager at R&D Elektronik GmbH & Co. KG.

Placement in series: positioned for the future

The previous placement line, which is and will remain in operation, produces 35,000 CPH (components per hour). Recently, an additional line was installed, with three modules AIMEX IIIc, FUJI`s flexible high-mix placement machine, producing 75,000 CPH. Thus, the total output could be more than tripled in a very short time. “The FUJI placement machines are running at full speed in our production since the beginning of May 2023. The positive effects were noticeable immediately. We can now also realize larger series production and see ourselves optimally positioned for future challenges,” says Theo Schelasni.

The AIMEX IIIc all-in-one pick-and-place machine supports any type of production and changes in used package shapes. It enables the processing of smallest chip components up to large components. It allows easy ramp-up of new productions or reaction to changes in package shapes. The AIMEX IIIc model can accommodate up to 130 feeders (8mm) on one machine. It can also handle large PCBs with ease. This results in high performance and flexibility – and R&D can respond quickly to changing requirements.

NIDEC CORPORATION drives electromobility: Investment in automatic placement machine from FUJI

Automotive supplier establishes plant in Novi Sad as new Competence center for inverter production in Europe

Kelsterbach, 4. July 2023 – Kelsterbach, xx. Juni 2023 – The development of new technologies and the creation of a corresponding infrastructure is essential to meet the growing demand for electric vehicles. The NIDEC Group is therefore expanding its capacities in Serbia – among other things with a plant for the production of automotive inverters and control units. There, the automotive supplier is using the scalable FUJI placement machine NXTR, handled by FUJI EUROPE CORPO-RATION GmbH (www.fuji-euro.de). The NXTR aims to optimize product preparation and maintenance processes as well as the automation of manual placement processes for the purpose of comprehensive networking and self-optimized production.

“Inverters in electric vehicles play an essential role in increasing energy efficiency. They enable precise control of the flow of electricity by converting the direct power from the batteries into the alternating power needed for the electric motors. This enables optimal use of the available energy and reduces the loss of power during conversion,” explains Aleksandar Nestorov, Plant Manager at NIDEC ELESYS CORPORATION.

Recovering braking energy also involves the use of inverters. In conventional internal combustion engines, most of the energy generated during each braking process is lost as heat. Inverters make it possible to recirculate this braking energy back into the batteries and reuse it. This increases the vehicle’s range and the efficiency of the entire drive system.

As a logical consequence of the increasing demand for in-vehicle inverters, partly due to the tightening of environmental regulations in Europe and CO2 emission standards for automobiles, NIDEC Group has expanded its production capacity with two plants in Novi Sad. NIDEC ELESYS CORPORATION produces automotive inverters and control units on an area of 25,000 square meters.

“Novi Sad is the second largest city in Serbia and has a well-developed infrastructure that meets the needs of the automotive industry. Furthermore, the Serbian government is very interested in promoting the automotive sector. In addition, Novi Sad has a labor force of professionals with experience in the automotive industry. This is why we decided to build a plant here for the production of automotive inverters and control units, among other things,” explains Aleksandar Nestorov.

New production line for inverter production

For the construction of a new production line in this plant, NIDEC ELESYS CORPORATION has chosen different suppliers. ASYS automation systems solutions are used for the laser, printing and board handling. The Rehm Group reflow oven is also part of the line. FUJI acts as the general contractor and provides the NXTR smart factory platform for placement processes. NIDEC is the first company in Serbia using the NXTR. The state-of-the-art placement solution offers a wide range of options and scalability. It can also handle increasing volumes without any problem – even with limited space in production.

A special sensor system ensures stable and high-quality placement. The NXTR platform fully automates the feeder exchange process. Heads and other units can be replaced without tools. Predictive maintenance is enabled by self-diagnostics that prevent sudden machine stops from affecting the production schedule.

“The plant in Novi Sad is to become a major new center of competence for inverter production in Europe. At present, 50 employees are working here, later it will be 200. Solutions for automated, efficient processes – especially for repetitive tasks – are a key building block for us. FUJI’s NXTR is easily scalable and supports our goals by enabling more efficient production and providing growth prospects,” says Aleksandar Nestorov.