Advanced Sealing Technology for E-mobility.

The automotive world is getting electrified, driven by environmental legislation, public opinion and newcomers to the market. By the year 2020, EU legislation limits CO2 emissions for newly registered cars to a maximum of 95 g/km, and further reductions are expected afterwards. With the trend of vehicle electrification, the need for high power density in electric motors is increasing in order to increase efficiency and achieve optimal packaging.

High power density has a high effect on the thermal management of the electric motor with increasing demand for rotor cooling. Rotor cooling systems require dynamic sealing in high speed and durable conditions, exceeding physical limits of conventional sealing products.

The high power density also requires high rotational shaft speeds to deliver the required power output, which leads to challenging conditions for sealing the electric motor from the reduction gear oil.

For this purpose, EKK developed the GlideX™ Surface Textured Electrical Motor Seal (EMS) and Reduction Gear Seal (RGS).

The GlideX™-EMS and -RGS enable electric motor and reduction gear manufacturers to cross physical limits and utilize high rotational shaft speeds and active rotor cooling, without having to be afraid of high friction and leakage.

EKK GlideX™ seals are based on mechanical seals, using advanced surface texturing technology that enables microscopic flow control in the dynamic sealing faces. This technology breaks the boundaries of the reciprocal relationship between friction and leakage, enabling the reduction of both sealing parameters. Test results verified the reduction of both properties to an unreached sealing performance, with zero leakage capability and over 90% less friction compared to conventional seals.

Stamping and Ultrasonic Cleaning Facilities

The stamping department of EKK Eagle Simrax has six state-of-the-art presses of the AIDA brand. With the DSF servo drive we stamp a diversity of production series. The presses range from 110-160 tonnes and speeds up to 150 strokes/minute are achieved. We work in a clean and safe working environment and are able to manufacture products of high-end quality.

Quality and environmental related standards, such as IATF 16949, ISO 9001 and ISO 14001, hold no secrets for us and are a part of our daily production routines.

In terms of stamping and the related cleaning, we offer:
- Six AIDA DSF servo presses, 110 tonnes and 160 tonnes

Material thickness from 0.05 to 2 mm;
Maximum strip width of 140 mm;
Maximum strip length of 1500mm;
Horizontal belt run-off material input capabilities.

- Two automated (alkaline) Finnsonic cleaning lines - ultrasonic cleaning incl.
- Full quality control, testing and measuring capabilities

Sealing Technology.

The mechanical seal technology is a sum of mechanical engineering and physical property technology. More specifically, the core of the mechanical seal technology is the tribology (friction, wear and lubrication) technology used to control the surfaces where the stationary and rotary rings slide against each other.

Mechanical seals with improved functionality will not only prevent the liquid or gas handled by a machine from leaking to the outside, but also improve the operating efficiency of the machine, helping save energy and prevent environmental contamination. Moreover, in some cases rotating machines handle media that, in the case of leakage, can lead to a dangerous situation. Therefore mechanical seals need to be reliable through manufacturing backed by solid engineering expertise.

Eagle Industry works on product development, making the optimal use of our proprietary measurement and analysis technologies:

Analysis technology: Thermal and structural analyses of mechanical seal face materials.
Measurement technology: Micro-torque testing of small shaft seals, rotation and visualization testing of large shaft seals.

Pulsation Dampening.

Every day, EKK lives by the awareness that loyalty and partnership are our reason for existence. This has always fuelled our commitment to quality and innovation, in synergy with our automotive partners. Presently, we take pride in developing products focused on increasing fuel economy, reducing carbon footprint and enhancing the driver’s and passenger’s comfort at the same time.

One of our innovations is the Pulsation Damper: an ingenious device with great effect. Our challenge was to minimize pulsations of fuel supply inside high-pressure fuel pumps in direct injection fuel systems. These pulsations cause vibrations, result in noise and stress other system components.

Through fuel system behavioral analysis and trial we came up with a unique structure based on previously in-house applied process-technology and material know-how. A specially designed metal pressurized container is sealed by an internally developed welding technique. Based on these features the product is able to withstand the force of the pressure inside. The resulting combination of technical features was patented and so a lightweight but heavy-duty and durable product was born.

The benefits are significant; maximum pulsation reduction with minimum vibration production, providing much higher level of comfort for the driver. Additionally, more consistency in the injected fuel amount resulting in a more stable combustion, thus lower emissions and higher fuel economy.

A clever design, due to its versatility; besides it being able to be installed directly in the fuel pump, with a minimum of redesign needed, we also offer an OEM or aftermarket solution; a version that can be easily installed in the fuel system after production.

Our patented Pulsation Damper offers not only more quietness to you as a driver, but also your car produces less environmental noise and CO2 which will be much appreciated by the world around you.