What Innovations Are Advancing Electric Vehicle Manufacturing?

What Innovations Are Advancing Electric Vehicle Manufacturing?

by | Jan 16, 2025 | Feature Article

A translucent vehicle with all the electric systems visible

Advancements in automation and advanced testing systems are helping to fuel the innovations of electric vehicle technology and manufacturing

Few industries are so committed to constant innovation as the automotive industry. Every few years, automotive manufacturers rethink and redesign every aspect of the automobile from the ground up. In an industry where improvements on the margin yield outsized results, OEMs have a lot to gain from investing heavily in machinery that can produce high-caliber results. 

For many years now, the area of automotive manufacturing that has led research and public interest has been electric vehicles—and, by association, autonomous driver technology. These technologies often work hand-in-hand, with cutting-edge electronic vehicles incorporation advanced driver-assistance technology systems, and autonomous vehicles operating on hybrid-electric engines for fuel efficiency. 

At Convergix, we are committed to delivering automated platforms that can take your electric vehicle manufacturing and battery testing to the next level. Whether you are an OEM or a supplier, we can provide the equipment you need to remain at the forefront of automotive innovation. Here are three ways our technology is leading the way. 

#1) Advanced testing for autonomous systems 

Autonomous vehicles rely on two powerful technologies: LIDAR, which scans an environment at high speed and with enough detail to create a dynamic, real-time map of surroundings even as the vehicle is moving, and AI systems that interprets this input and responds by sending directions to the automobile. 

The safety of any autonomous vehicle is only as good as the sensors powering it. Accordingly, autonomous systems require extensive testing to ensure they are accurately mapping surrounding environments, and that they are responding quickly enough to avoid accidents. 

Very few vehicles currently rely on fully autonomous driving. However, more and more vehicles are equipped with assisted driving technology that combines autonomous systems with human control. These assisted technologies include: 

  • Adaptive cruise control 
  • Lane departure warning 
  • Blind spot detection 
  • Collision warning 
  • Pedestrian warning 
  • Traffic sign detection 
  • Parking assistance 

At Convergix, we provide advanced testing systems for autonomous and assisted driving systems. These test technologies can be incorporated into your production equipment so that you can test at any point in the assembly process to be sure your components meet the high standards required of autonomous systems. 

#2) Testing and assembly for fuel cells and batteries 

Electric vehicles draw their energy from one of two sources: batteries or fuel cells. batteries store energy and need to be recharged after a certain amount of use, fuel cells generate energy from a chemical reaction—most commonly between hydrogen and oxygen, with water as the byproduct—and as a result, require refueling to continue operating. 

Each of these technologies is currently undergoing extensive research and testing in order to improve them for electric vehicle use. Already, the advances made by these technologies have extended the range of electric vehicles while also reducing the refueling and recharge time. However, there are still major opportunities for improvement, and the EV manufacturers who find the most efficient solution stand to gain significantly in the automobile market. 

The technologies we employ during the assembly process for batteries and fuel cells include robotic handling and assembly and the application of thermal adhesives, catalyst coatings, conductive coatings, and other chemical surface treatments. 

We also have advanced testing and verification tools that can be used throughout the assembly process to ensure components meet specification standards. In fact, our battery assembly machine on display at the Rockwell Innovation Center in San Jose will be available for customers to view for the next seven years. Stop in and see for yourself! 

#3) Factory automation for EV components 

While the components for electric generation and storage power an electric vehicle, they aren’t the only parts required to make an electric vehicle run. An electric vehicle’s drive train functions differently all down the line, from the motor, which is comprised of both a rotor and a stator, to the inverter, which translates direct current to alternating current, to the drive unit, which communicates driver input from the accelerator to the inverter, thereby controlling for speed. 

Every one of these components requires its own processes for production, assembly, and testing. Our facilities can do all this, with both in-line and end-of-line testing as needed. Our assembly and test capabilities for EV drive trains include: 

  • EV motors and test stands 
  • Drive units 
  • Inverters 
  • Hybrid engines 

    We thrive off developing advanced solutions for our customers 

    The battery equipment we build for electric vehicles are also used in home battery packs, marine applications, consumer products such as headphones and hearing aids. Our automated solutions in this space are also used by the Department of Defence. The advanced testing capabilities we use for autonomous vehicle systems can be applied to other autonomous technologies as well. The assembly techniques we use for EV components are part of the toolkit we use in all our automated factory solutions. 

    Most importantly, we bring a mindset of efficiency and innovation to every project. We are always looking for ways to improve our assembly design, either by reducing the number of steps required for a full assembly, improving the production quality of components, or shrinking the footprint of the production equipment on the factory floor. 

    We are prepared to apply the same dedication to your project. If you are looking for an automation partner to design systems for your factory, contact us. We can discuss your project, our capabilities, and come to a solution that will yield the results you need. 

    CONVERGIX Automation Will Attend MD&M West 2025

    CONVERGIX Automation Will Attend MD&M West 2025

    by | Jan 15, 2025 | Event

    CONVERGIX Automation Solutions is excited to announce our participation in MD&M West 2025, taking place February 4-6, 2025, at the Anaheim Convention Center in Anaheim, California. We will be exhibiting in the ATX sector of the main floor at Booth #5400. 

    MD&M West is the premier event for medical device and manufacturing professionals, bringing together 1,700+ exhibiting suppliers showcasing the latest innovations across four key industry sectors: MedTech, Automation, Design & Manufacturing, and Plastics. With over 13,500+ verified attendees from 52 countries, this event offers unparalleled opportunities for networking, learning, and discovering the latest advancements in the industry. 

    At booth #5400, we will share our expertise in automating manufacturing and warehouse processes for the Life Sciences industry. This includes material handling, assembly, testing, machine vision inspection, and more for medical devices and pharmaceutical products. We look forward to discussing how our innovative solutions can help you: 

    • Improve efficiency and productivity: Learn how you can streamline your manufacturing processes to reduce downtime and increase your outputs. 
    • Enhance quality and compliance: Reduce errors and improve product quality with automated systems that ensure accuracy and consistency. 
    • Increase flexibility and scalability: Adapt to changing market demands and easily scale your operations to meet growing production needs.
    • Reduce costs: Minimize labor costs, improve resource utilization, and optimize your overall operational efficiency. 

    We invite you to visit us at Booth #5400 to discover how Convergix can support your business goals in the Life Sciences industry. Let’s connect at MD&M West and discuss your specific automation needs. 

    MD&M West conference information graphic

    Why Attend MD&M West? 

    There are several reasons to attend this conference, if you have a business in any of the industries mentioned above. The top reasons include:

    • Cutting-Edge Technology: Discover the latest innovations in robotics, sensors, motion control, and automated systems designed to boost efficiency and meet the growing demand for medical devices and pharmaceuticals. 
    • Industry-Leading Suppliers: Connect with leading suppliers and gain valuable insights into the latest technologies and solutions available for your specific needs. 
    • Expert Education: Participate in 100+ educational sessions, including conferences, workshops, and theater presentations, to expand your knowledge and gain valuable insights from industry experts. 
    • Networking Opportunities: Connect with industry peers, build relationships, and explore potential collaborations. 
    • Manufacturing Excellence: Gain valuable insights into best practices for optimizing your manufacturing processes, improving efficiency, and reducing costs. 
    How Factory Automation Supports the Medical Device Industry

    How Factory Automation Supports the Medical Device Industry

    by | Jan 2, 2025 | Feature Article

    Advanced Medical Printer Producing Artificial Heart Valves with Biopolymers.

    Medical devices are subject to strict regulations and high-quality control standards. Automation can help.

    The healthcare industry is among the most highly advanced manufacturing fields in the world, with tight controls and restrictions governing the development and production of medical devices at every stage. At the same time, researchers and developers in the healthcare industry benefit from manufacturing solutions that are flexible, reliable, and innovative.

    The tension in the healthcare industry between innovation and regulation has historically been difficult to balance. However, factory automation offers a resolution to some of these competing priorities by helping medical device manufacturers produce cutting-edge products that meet even the most stringent industry requirements. Here’s how:

    1. Automation offers advanced quality control measures

    Quality control is important in every industry, but in healthcare, the consequences of a flawed device can be dire. As such, advanced quality control measures are even more important.

    Automation already directly benefits production quality by enhancing standardization and removing opportunities for human error. A human operator on an assembly line will have limits to their consistency. Some inconsistencies may not have significant impacts, but others might be flaws in themselves or lead to flaws further down the production line. Automation is not only more consistent than manual production but can be optimized to a more precise tolerance level than what human workers can achieve.

    Given the quality benefits of automation in the manufacturing process, it’s only natural to apply these same processes to testing and inspection. Traditional quality control measures have used mistake-proofing techniques to prevent defects as they occur. Modern methods, such as vision technology and advanced sensors, expand the range of quality testing a company can incorporate directly into the production lines.

    2. Advanced robotics help manufacturers keep their operations flexible

    Stationary automated assembly lines have long been the standard for many high-volume manufacturers, but the downside of these assemblies is that the specialized equipment cannot easily be switched over to new uses if a production technique changes, or if market demand suddenly shifts. Given the myriad supply chain disruptions, industries around the world have faced since the onset of the Covid-19 pandemic, manufacturing flexibility is a growing priority in some sectors.

    Modern robots offer a compelling solution. With a range of effectors that can be rapidly switched during an assembly, a single robot can perform numerous operations repeatedly and consistently. Programming robots has also become more user-friendly, with some interfaces allowing an operator to easily reprogram a robot with the push of a few buttons.

    This means that robots are now able to work alongside human operators, assisting in routine tasks both on the factory floor and in other work settings.

    3. Manufacturing consistency helps devices meet FDA approval

    While flexibility around production can help manufacturers change gears in a pinch, consistency also has its benefits. Medical devices must meet various levels of FDA approval, with entirely novel devices requiring a higher standard and longer approval process than those that are similar to devices already being produced.

    If a proven production process is used to produce components of a new device, this similarity works in the manufacturer’s favor. In this way, a consistent production process not only means more reliable quality control but also a faster approval process.

    4. High-mix, low-volume (HMLV) production allows for customization

    While some medical devices are suited for production by the millions, others are complex enough that a manufacturer may only receive orders in the hundreds or thousands. For these devices, which have a high variety of components, manufacturers benefit from sophisticated automated solutions, such as those that can be provided by the latest high-end robots.

    Similarly, some medical devices need to be customized for the patient. These are the kinds of extremely low-volume products that have typically eluded automation.

    5. Production tracking helps businesses meet compliance standards

    Some medical devices require manufacturers to be able to trace the production process of individual components through each stage of the automated assembly line. This is especially true for a device that might be implanted within a human body, like a pacemaker. If there ends up being a fault with the device, then it is essential that this flaw can be traced back to its point of origin, so that any other faulty devices can be identified.

    Factory automation will fuel advances in the medical device technology of the future

    Automation has already revolutionized the medical device industry, but Industry 4.0 promises to bring even more change. Advanced simulations will give device manufacturers innovative ways to model their assemblies; IIoT and Big Data will provide new tracking tools and deeper insights into production methods, and augmented reality will transform how operators interact with equipment. 

    At CONVERGIX Automation Solutions, our expertise in the healthcare industry means we know how to meet class 10,000 cleanroom standards, GAMP regulations, and FDA regulations. Our team can work with your business to provide expert guidance in the development of automated assemblies for medical devices. Contact us today to learn more. 

    3 Main Sources of Food Contamination 

    3 Main Sources of Food Contamination 

    by | Dec 26, 2024 | Feature Article

    Hamburger patties cooking on bbq grill

    Salmonella in eggs, E. Coli bacteria in ground beef, and pesticides in infant formula are just a few contaminations since the turn of the century that have ravaged the food supply and crippled the food processing and manufacturing industries. Convergix and other equipment manufacturers work hard to ensure that contamination does not originate from the machines designed to process and package food.

    We manufacture systems that package and fill food products safely. However, food contaminants may still breach the machinery and infect the food being processed. Below is a list of the most common contamination points that you should address in your manufacturing process.

    1) Contamination from the Source

    Meat, raw veggies, eggs and milk can be contaminated with E. Coli, salmonella or other foodborne pathogens before they even reach the processing plant. These products are exposed while in or on the ground through contact with animal feces, bacterial infection, and contaminated ground water. According to the Centers for Disease Control and Prevention, eggs are often contaminated before they are deposited by the hen, due to salmonella present in the hen’s ovaries.

    2) Contact in Pre-Processing

    Slaughterhouses are notorious for co-mingling meats before and after slaughter, leading to contamination. This is because animals typically carry a lot of bacteria and germs in organs like the intestines and skin, which can easily spread to portions of meat during butchering. It is crucial to have a vigilant process to identify contaminated meat.

    Contact with pathogens can also occur during transit, especially when the food is sitting idle in the back of a hot truck. Improperly cooled or heated food only heightens the problem. Food that initially contains only a few microbes can become a teeming piece of bacterial heaven after sitting in transit for a few hours.

    3) PROBLEMS DURING PROCESSING

    Contamination during processing can involve environmental contaminants like metal shavings, pesticides and chemicals used to operate and maintain machinery. Convergix and many other companies incorporate safety measures to ensure food safety during manufacturing. However, contamination can still occur from improper maintenance, improper use of the machines and breaches in the ventilation system that leads to the processing area.

    Here are some of the more common examples:

    • Contaminated water or ice being used during the washing or packing process, especially with fruits and vegetables that are washed before packaging.
    • Bacteria can easily contaminate the surfaces that are involved during food processing, such as storage bins and processing lines.

    Most contaminants can be defeated after processing with high heat or freezing. Other types of contaminants require immediate disposal of the food. Convergix offers a wide array of services in the Consumer industry to help our customers with proper installation, maintenance and operation of all the equipment purchased. We provide solutions to improve food handling safety, including stainless steel parts, sanitation processes, and testing and detecting contamination.

    AGVs and AMRs: Your Secret Weapon for Holiday Success 

    AGVs and AMRs: Your Secret Weapon for Holiday Success 

    by | Dec 12, 2024 | Feature Article

    Black Autonomous Robotic Vehicles (AGVs) transporting goods in retail warehouse

    The holiday season, marked by events like Black Friday and Christmas, brings a surge in consumer activity. While this surge is a boon for retailers, it also presents a significant challenge. The sudden influx of orders can overwhelm supply chains, leading to delays, stockouts, and dissatisfied customers. Logistics operations, from warehousing to transportation, face immense pressure to keep up with the demand. This increased activity can strain existing resources, leading to operational bottlenecks and increased costs. 

    With heightened demand, tight deadlines, and the pressure to deliver, optimizing operations and streamlining processes becomes paramount. Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) are emerging as powerful tools to navigate these busy periods. 

    Understanding AGVs and AMRs 

    AGVs are industrial vehicles that follow a defined path, often using wires or magnetic tape. They are well-suited for repetitive tasks in structured environments. For example, they can transport pallets of goods from the receiving dock to storage locations or move finished products to the shipping area. 

    AMRs, on the other hand, are more flexible. They use advanced sensors and artificial intelligence to navigate dynamic environments, adapting to changing conditions and performing a wider range of tasks. They can independently navigate warehouse aisles, avoid obstacles, and adapt to changes in the layout. 

    Benefits of AGVs and AMRs in Peak Seasons 

    1) Increased Efficiency

    • Faster Order Fulfillment: AGVs and AMRs can rapidly transport goods within warehouses, reducing lead times and improving order accuracy. This is crucial during peak seasons when order volumes surge. 
    • Optimized Workflows: By automating repetitive tasks, these robots free up human workers to focus on more complex and strategic activities, such as quality control, problem-solving, and customer service. 
    • Improved Inventory Management: AGVs and AMRs can help maintain accurate inventory levels by efficiently moving goods between storage locations and picking stations. This reduces the risk of stockouts and overstock. 

    2) Enhanced Safety

    • Reduced Accidents: Automating material handling minimizes the risk of workplace injuries, such as strains, sprains, and collisions. 
    • Safer Working Conditions: AGVs and AMRs can operate in hazardous environments, protecting human workers from exposure to harmful substances or extreme conditions. 

    3) Greater Flexibility

    • Adaptability to Changing Demands: AGVs and AMRs can be easily reprogrammed to handle fluctuations in order volume and product mix. This flexibility is essential during peak seasons when demand can vary significantly. 
    • Scalability: As businesses grow, fleets of AGVs and AMRs can be expanded to meet increased demand without requiring significant infrastructure changes. 

    4) Cost Reduction

    • Lower Labor Costs: Automation can reduce the need for manual labor, leading to significant cost savings. 
    • Improved Space Utilization: These robots can help maximize warehouse space by optimizing storage and retrieval processes. 

    Convergix: Your Partner in Automation 

    Convergix Automation Solutions is a leading provider of AGV and AMR solutions. Our experts can design and implement a customized automation strategy tailored to your specific needs. From initial consultation to ongoing support, we are committed to helping you achieve operational excellence. 

    By embracing the power of automation with AGVs and AMRs, businesses can navigate the holiday rush with greater efficiency, safety, and cost-effectiveness. Contact Convergix today to learn more about how these innovative technologies can transform your operations.