CUSTOMIZED SOLUTIONS

CUSTOMIZED PRODUCT DEVELOPMENTS AND ENVIRONMENTAL SIMULATIONS

In our current world, where technical standards are changing faster and faster, our demands and needs are developing continually. If you want to be successful today, you need to adjust to this trend and continually improve your own performance. This is also our demand to ourselves that we follow in order to continually improve and develop our customer base. True to our motto of “Customized Solutions”,

SOLUTIONS MADE TO MEASURE

Founding of company

“brehmermechatronics” is founded as a

commercial agency in Wiehl-Kleinfischbach

Extension/relocation to Oberwiehl

“brehmermechatronics” develops mechatronic products for the vehicle industry

Construction of the environmental simulation

laboratoryQualification of control units

Certification according to DIN ISO 9001

BMWI sponsorship projectFirst research projects

we process our customers‘ wishes in a targeted manner, developing many different solutions for many different areas in close cooperation with our customers. The many diffe-rent projects have enabled us to develop our know-how continually and offer customer-specific developments as well as their qualification in our internal accredited environmental simulation lab.

Our passion for vehicles is particularly reflected in the Classic Automobile area that is still relatively new for us. On the order of a renowned German automotive manufacturer and in cooperation with it, we reconstruct and procure any imaginable part from electrical components to bumpers to decorative strips. Quality and detailed reconstruction are essential for collectors and enthusiasts. This is not only

CLASSIC PARTS

because the results must be genuine, but also in order to preserve value.

With our business relationships and supplier contacts of many years, as well as the resulting experience in various areas, we are able to support our customers here every day in a timely and competent manner.

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Renamed as “Brehmer GmbH & Co. KG”

Deloitte Award

Brehmer is one of the 50 fastest growing

companies in Germany

Just-in-time supplier

brehmermechatronics becomes qualified automotive supplier and starts first Just-in-time delivery

Successful 3rd brehmermechatronics TechDay

3CUSTOMIZED SOLUTIONS | THE COMPANY

1. Feasibility

2. Economic efficiency

3. Requirements specification

4. Safety

5. Projects plan

6. Testing

7. Series Product

1st brehmermechatronicsTech-Day

DAkkS accreditation

Successful accreditation of the environmental simulation lab

brehmermechatronicsshows numerous

Products at the „bauma“

Project: CHMSL

One particularly challenging project was presented to us by one of our customers from the area of vehicle lighting. For historical reasons, it comes from the area of vehicle lighting with plastic injection moulding and light bulbs. The current trend of vehicle lighting, however, goes towards LED lighting, the customer did not have any experience of this. This was made worse because also our customer had no experience in electronics or circuit development. In addition to the elaborate EMC-compatible circuit development with switching controllers, the layout genera- tion, ESD-compatible development and design of the PCB was particularly elaborate. Heat management of the PCB placed special challenges to us, due to the small space available.

CUSTOMIZED SOLUTIONS: CUSTOMER-SPECIFIC PRODUCT DEVELOPMENT

During development, we had to deal with interfering switching transients that lead to EMC fault emissions. These result from control of the LEDs with a switching controller. The effect turned out to be particularly problematic in the third brake lamp, since this is installed close to the radio aerial of the vehicle while unimpaired function must be ensured nevertheless. Due to our committed and highly specialised emplo-yees, we were able to master these challenges to our custo-mer‘s utmost satisfaction.

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As a long-term development partner for the automotive and industrial vehicle industry, we have been able to collect many years of experience in various areas. From a homogeneous lighting in the vehicle area through EMC-compatible switching development to a pioneering battery management. We have always been able to develop the best economical and technical solutions for our customers. Some of our well-structured projects are presented below.

Various versions of the vehicle lightingfrom the project “CHMSL”

5CUSTOMIZED SOLUTIONS | PROJECT EXAMPLES

Another example of our diverse options in the area of development is the project for the charge button display element, which we developed, qualified and industrialised. This project is a typical example of integrated challenges in contemporary project development. The special challenges of this project were in the incompletely specified provisions of the customer who ex-pected highest quality at the lowest costs in the shortest possible period of time. The function integration of mecha-nics, electronics, lighting technology, haptics and tightness was just as demanding. Since there was no comparable solution on the market, a new development was needed. Resulting from this, our customer approached us with the challenge of de-veloping a module that has the following characteristics:

→ Two buttons that must be backlit and have an indicator LED to display the charge condition→ A robust housing that is able to resist the environmental influences in the outside area.

Under consideration of the existing customer application, we prepared a solution, created the first prototypes and detailed them for our client. We closely (co-operated) with our customer to continually detail the end product and develop it further under consideration of the individual specialist departments. One main problem was the very limited installa- tion space, which resulted from the specified application. This made it impossible to physically map some require-ments. Our long-term and close relationship with the custo-mer nevertheless enabled us to successfully develop and implement the final component. The time pressure made for a very precarious situation at commencement of the project. Our great network of close relationships with development and production partners was decisive here, enabling us to implement the corresponding serial startup in the demanded time. The serial startup could be implemented with small- series tools from the in-house “family base forms”. In the end, this led to a highly IP-protected unit that is able to

securely conduct and switch even the smallest currents (signals) throughout the service life. This is decisively based on protected brehmermechatronics technology. The lighting was designed homogeneously and according to the custo-mer‘s narrow tolerances. Developed as a cost-efficient solution for our client, the corresponding technology can be transferred to other, more complex modules as well, thus representing an attrac-tive solution for other customers. Alternative output stages in applications that offer more installation space are con-ceivable as well. Bus systems such as CAN or LIN as well as output drivers can be installed also to directly switch loads.

Project: Electromobility, display element charge button

Charging button on the in-house test bench and in the customer‘s application

Project electromobility, LED module

The market for electrical cars is a market that is developing continually and rapidly particularly in our current times. For this reason, one of our customers from the vehicle industry approached us and charged us with a development that is intended exclusively for electrical cars. The solution de-veloped and delivered by us had the task of visualising the current charging status or condition for the user. However, this display was to be installed in the external area close to the charging socket instead of inside the vehicle. This place-ment poses special challenges regarding the robustness of the product to be developed in order to ensure a long service life. Furthermore, there were challenging demands such as homogeneous lighting or absolute water-tightness. In order to implement a corresponding solution, it was necessary to not only focus on the electronic develop-ments; we also had to include the materials to be used, as well as the final production processes. We implemented the required tightness with a special 2K PU casting. In order to process such materials and the resulting material pair, the corresponding experience is of enormous importance. In this area, we have always been able to rely on our employees‘ experience from many different areas of development and material technology, as well as our production partners. The in-house accredited environment simulation lab turned out to be of special benefit here as well. It was used to perform a broad range of the most extreme tests for all materials and products accompanying development. The required lighting directly contributed to several engineering disciplines. The tolerances of the LEDs resulting from the production process demanded particularly intense project support and recurring tests. Not only colour fluctu- ations but also brightness and various other physical tole-rances had to be evaluated. Our calculations thus led to a number of different PCB versions. In order to compensate

for the LED tolerances, up to eight bills of material were compiled for one and the same product. This enabled us to develop a product that completely meets our customer‘s requirements and that enabled us to further increase our own pre-existing experience.

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LED module as a complete unit

LED-module lighting ring

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Many ideas of the brehmermechatronics developers come from the area of research. Since there is not always a commercial promoter, we occasionally use promotion of innovative, medium-sized enterprises from the Federal Ministry of Economics and Energy (Bundesministerium für WirtschaftundEnergie; BMWi). This has enabled us to imple-ment the smart chain link project, called the “I-chain”.

This smart chain link measures the elongation in the weakest link of the chain and transfers the data with RFID- technology or by low energy Bluetooth. This way, chain failure will be indicated to the user in time to prevent failure of the application. In the meantime, there have been the first customers from the area of motor sports who are interested in this development.

Project: Industry 4.0 – smart chain link “I-chain”

CUSTOMIZED SOLUTIONS | PROJECT EXAMPLES

Project: Industry 4.0 – “Sensor M22”

Developed specifically for tomorrow‘s industry, our capaci- tive “Sensor M22” with its high protection type lives up to the demands of future industry applications. It is a pionee- ring brehmermechatronics product that is already highly popular due to its divese application options and that is subject to continuous further development.

Smart chain link “I-chain”

Capacitive “Sensor M22” with various lighting modes

brehmermechatronics has been dealing with battery-related challenges for years. The company holds design patents for electro-mechanical battery disconnection switches, a patent for „battery management systems“ and exclusive patent use for ”alternator synchronisation“. Battery monitoring modules developed by us show the current charge status of the battery on the drive‘s display. A highly integrated E-management system was developed as early as 2007. Another highly complex product is the ”electronic battery main switch“ („elektronischer Batteriehauptschal-ter“; in short: eBHS) project, combining a control unit with several sensors in a single device. The control unit developed by us controls bistable vehicle relays that disconnect the batteries from and connect them to the on-board grid.

This includes:→ Connecting and disconnecting the batteries and the vehicle‘s on-board grid

→ Monitoring the jump-start socket for polarity reversal and prevention of activation in case of error→ Monitoring the battery‘s SOC (State of Charge) → Integrated micro-mechanical inclination sensor to detect the vehicle position→ Intrinsically safe circuit according to Exib: Intrinsically safe circuit for use in potentially explosive environments→ Communication with other control units→ High EMC stability according to military standards

In this case, our task was not only the development of the ECU (Electronic Control Unit), but also finding or developing the matching relays inside it to fully meet customer require- ments. This highly interesting project required us to bring out our entire performance range. In this specific case, this meant not only developing the actual solution but also veri- fication of the completed product in our accredited lab, which enabled us to completely satisfy our customers.

Project: Battery management for hazardous goods transport EX PROTECTION: eBHS – electronic battery main switch

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Not only the high vibration demands but also the high current resilience for the relay of max. 1,000 A for several minutes had been specified by the customer. This project also has a battery monitoring stage as a special feature that is part of the electronics. In the solution developed by us, highly precise special ICs were used to conduct various measurements on the battery to continually monitor the battery‘s charge status. This enables the user to continually monitor the battery‘s status to detect threatening discharge at an early stage. The user is thus always able to reliably take the vehicle into operation. The integrated inclination sensor also detects the vehicle‘s inclination and disconnects the battery from the vehicle in a fraction of a millisecond if the vehicle exceeds the critical inclination angle. At the same time, a message is sent to all other control units of the vehicle to enable them to react. Our eBHS also feeds the intrinsically safe circuits for the emergency off buttons installed in and on the vehicle that are also used in potentially explosive areas, e.g. for hazardous

goods transports. If an emergency-off event is detected, the battery will also be „diconnected“. The current explosion protections according to ATEX require a special feed for the emergency off circuits named. In order to implement compli- ance with these provisions consistently, a production moni-tor was installed specifically for production of this control unit. This ensures that no sparks can form at the emergency off outputs in any case. This not only serves to protect the application but also and in particular for protection of the user. With a permanent view of the extreme EMC provisions and the very high mechanical requirements, we implemented the solution (comprehensively and on time) for our custo-mer. This enabled us to present him with a solution that fully meets the specific mechanical vibration demands and the high IP protection needs. The cast unit is completely water- tight and submersible to meet the strict requirements. This highly complex product enabled us to further intensify our experience in various areas. We are certain that we will be able to use this experience successfully on future projects.

9CUSTOMIZED SOLUTIONS | PROJECT EXAMPLES

Electronic battery main switches in different development stages and in application

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11CUSTOMIZED SOLUTIONS | TEST METHODS

Does my product meet the customer‘s requirements? How long-lived is it? How does it react to the many diffe- rent, at times very severe environmental influences? How do I get the certifications I need for my product? These are only some of the questions that must be asked in order to develop a high-quality product. Since quality is a very important factor for us, we have set up our inter-

ENVIRONMENTAL SIMULATION LAB FOR HIGHEST DEMANDS

nal accredited environmental simulation lab in which our experienced employees submit our products and those of our customers to many different tests every day. Our employees make use not only of many years of expe- rience and state-of-the-art technology, but in particular also of their motivation to offer the best advice to our customers.

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Setup of the environmental simulation lab

Setup of an additional climate test chamber

Expansion by another climate test chamber

for the shaker test bench

OUR TEST METHODS:

Expansion by another ESD test bench

Environmental tests Tests according to: • DIN EN 60068-2-1, DIN EN 60068-2-2, DIN EN 60068-2-14, DIN EN 60068-2-30, -2-67, -2-78, DIN EN 60068-2-38

Vibration testsTests according to: • DIN EN 60068-2-1, DIN EN 60068-2-2, DIN EN 60068-2-14, DIN EN 60068-2-30, -2-67, -2-78, ISO 16750-3, IEC 60068-6, IEC 60068-64, IEC 60068-80, LV124, MIL STD, DEF STAN 59

Temperature testsTests according to: • DIN EN 60068-2-1, DIN EN 60068-2-2, DIN EN 60068-2-14, ISO 16750-4

Thermography tests• Thermal imager Fluke TI25• “Hotspot“

Dust test chamber• Tests according to DIN 20653

Water test chamber• Tests according to DIN 20653

Mechanical tests of electrical components, switches, sensor, controls:• Linear drive / Rotary drive• Lifetime tests by means of state-of-the-art data acquisition

13CUSTOMIZED SOLUTIONS | TEST METHODS

Acquisition and commissioning of another climate test chamber

with a volume of 400 L and tensile test bench

Accreditation pursuant to ISO 17025

New climate test bench with a capacity of 350 l

Successfulsurveillance audit

and other test standardsfor our laboratory

Investment in state-of-the-art technologies in »high current

and high-voltage range«

Drop-test bed • Tests according to LV124 • Tests according to different customer specifications

Universal testing machine LPS ZDT 3-X500• Single-spindle: 3kN - 500 mm movement range• Resolution force measurement 0,1 N• Resolution path measurement 0.0001 mm

Chemical Consistency • Resistance tests of materials according to chemicals• Chemicals are specified by the customer

Maximum current tests • Tests according to ISO 16750-2

Datalogging• Up to 1MS/s• Up to 200 channels

ESD-testsTests according to: • ISO 10605, IEC 61000-4-2, TL82466, M3284

For detailed information on our testing methods, please download our brochure on the accredited environmental simulation laboratory.Simply scan the QR code or order a print sample at labor@brehmer.gmbh.

Download Brochure

Find an overview of customers already relying on our solutions below. We see this small table as a pleasant confirmation of our working method and continuous inspiration to keep up enthusiasm for our work – on both sides.

OUR CUSTOMERS

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If you have a question or an idea, if you wish to receive more information or would like to get to know us – in short: If we have aroused your interest, then simply get in touch with us.

YOUR CONTACTS

15CUSTOMIZED SOLUTIONS | YOUR CONTACTS

Moritz SchmidtB. Eng. Mechanical Engineering

ManagementHead of DevelopmentPhone: +49 2262 727 17-16

Dennis BlättermannDipl.-Ing. Electronic

Managing Director

Phone: +49 2262 727 17-22

Robin Brehmer

ManagementHead of Sales & ClassicPhone: +49 2262 72717-20

Visit our website for more information and news atbrehmermechatronics.com or download our catalogue.

Website Catalogue

ALWAYS UP TO DATE!

Brehmer GmbH & Co. KGWilhelm-Grümer-Weg 2251674 Wiehl Germany

phone +49 2262 727 17-0fax +49 2262 727 17-11

info@brehmer.gmbhbrehmermechatronics.com

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