Manufacturing of busbars, expansion joints, grounding straps and power transmission components made of copper and aluminum
ECC energy components center GmbH
Pirmasens (DE) · Marie-Curie Straße 16, 66953 PirmasensNew on Amplifa
About ECC GmbH
ECC energy components center GmbH, headquartered in Pirmasens, specializes in the engineering and manufacturing of power distribution and high-current technology components. The company processes copper and aluminum into busbars, laminated expansion joints, grounding straps, ECC-Flex bars, braided straps and insulators – from individual components through modules to complete assemblies. Core competencies include machining as well as stamping and bending of copper and aluminum bars, and joining technology for both materials through various welding, soldering and riveting processes. In addition, surface treatments are offered such as insulation up to 20 kV, electroplated coatings (tin, nickel, silver), powder coating, wet painting and electroless nickel plating. Customer industries include the electrical industry (generator and transformer construction, switchgear), chemicals, renewable energies, mechanical engineering, basic materials and transportation. Founded in 2016 by Dipl.-Ing. Michael Klug, the company also acts as a solution provider for turnkey solutions in energy technology and has been cooperating with Promet AG in Switzerland since July 2016.
- Site
- Pirmasens
- Processes
- MIG welding (metal inert gas), MAG welding (metal active gas), TIG welding (tungsten inert gas), Resistance welding (press welding), Oxy-fuel welding, Laser welding, Friction welding, Soft soldering (≤ 450 °C)
- Materials
- Copper, Aluminum, Copper wire (bare), Copper wire (tinned), Copper laminations (tinned or bare), Aluminum (braid), Copper (braid), Insulators (silicone-free and halogen-free, self-extinguishing according to UL 94 V0)
- Certificates
- Welding supervision according to EN ISO 14731, Functional and final tests, Traceability in assembly
- Founded
- 2016
- Industries
- Electrical industry (generator/transformer construction, switchgear), Chemical industry (zinc, chlorine), Renewable energies (wind, solar, hydro), Mechanical engineering (welding machines, crane construction, robotics), Basic materials industry (glass, steel), Transportation industry (rail)
- 01
Engineering and design (CAD)
- 02
Project planning
- 03
Stamping and bending of copper and aluminum bars
- 04
Machining
- 05
Welding and soldering (joining technology)
- 06
Surface treatment and insulation
- 07
Assembly including functional and final testing
- 08
Documentation and delivery
Materials and Processes
Copper
Main material for busbars, expansion joints, grounding straps, ECC-Flex and braided straps.
Aluminum
Material for busbars, expansion joints and braids, among others with Cu/Al joining technology.
Copper wire (bare and tinned)
Used in grounding straps as meter goods or fully assembled.
Copper and aluminum braids
Manufacturing of braided straps in rectangular and round cross-sections.
Insulators (silicone-free and halogen-free)
Self-extinguishing insulators for busbars according to UL 94 V0.
Electroplated coatings tin, nickel, silver
Surface finishing via a pool of external specialists.
Powder coating and wet painting
Coating processes for customer-specific surface finishes.
Electroless nickel plating
Completes the range of surface finishing services.
Insulation up to 20 kV
Electrical insulation of busbars with high dielectric strength.
Locations
Pirmasens
DEHeadquarters, manufacturing and business operations
- Materials
- Copper, aluminum, other metallic materials
- Stamping machines
- Bending machines
- Laser cutters
- Machining machinery
- CAD systems
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| MIG welding (metal inert gas)Joining | – | – | – | – | Copper, Aluminum |
| MAG welding (metal active gas)Joining | – | – | – | – | Copper, Aluminum |
| TIG welding (tungsten inert gas)Joining | – | – | – | – | Copper, Aluminum |
| Resistance welding (press welding)Joining | – | – | – | – | Copper, Aluminum |
| Oxy-fuel weldingJoining | – | – | – | – | Copper, Aluminum |
| Laser weldingJoining | – | – | – | – | Copper, Aluminum |
| Friction weldingJoining | – | – | – | – | Copper, Aluminum |
| Soft soldering (≤ 450 °C)Joining | – | – | – | – | Copper, Aluminum |
| Brazing (≥ 450 °C)Joining | – | – | – | – | Copper, Aluminum |
| Induction solderingJoining | – | – | – | – | Copper, Aluminum |
| Flame solderingJoining | – | – | – | – | Copper, Aluminum |
| Resistance solderingJoining | – | – | – | – | Copper, Aluminum |
| Stamping and bending of copper and aluminum barsForming | – | – | – | – | Copper, Aluminum |
| MachiningMachining/cutting | – | – | – | – | Copper, Aluminum, other metallic materials |
| Welding supervision according to EN ISO 14731Testing | – | – | – | – | – |
| Engineering with CAD systems (development and design)Engineering | – | – | – | – | – |
| Project planning (organization of project execution: site survey, design, manufacturing, assembly,Engineering | – | – | – | – | – |
| Assembly including functional and final testing, C-parts management, contract manufacturingAssembly | – | – | – | – | – |
| Surface coating and finishing: insulations up to 20 kV dielectric strength, groundSurface | – | – | – | – | Copper, Aluminum |
| Electroplated coating (tin, nickel, silver)Surface | – | – | – | – | Copper, Aluminum |
| Powder coatingSurface | – | – | – | – | Copper, Aluminum |
| Wet paintingSurface | – | – | – | – | Copper, Aluminum |
| Electroless nickel platingSurface | – | – | – | – | Copper, Aluminum |
| Tinning of wires/laminationsSurface | – | – | – | – | Copper |
| Riveting (riveted expansion joints)Joining | – | – | – | – | Copper, Aluminum |
| Assembly/kitting of grounding straps (meter goods with tube terminals, pressed)Assembly | – | – | – | – | Copper |
| Manufacturing of laminated expansion joints in customer dimensions and standard dimensionsAssembly | – | – | – | – | Copper, Aluminum |
| Coating and insulating of busbarsSurface | – | – | – | – | Copper, Aluminum |
4 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Stamping machines | – | – | – | – | Pirmasens |
| Bending machines | – | – | – | – | Pirmasens |
| Machining machinery | – | – | – | – | – |
| CAD systems | – | – | – | – | Pirmasens |
Additional services
Quality
Welding supervision is carried out according to EN ISO 14731 by an International Welding Engineer (IWE). In assembly, functional and final tests as well as complete traceability of all parts and assembly steps are implemented.
| Evidence | Pirmasens |
|---|---|
| Welding supervision according to EN ISO 14731 | |
| Functional and final tests | |
| Traceability in assembly |
History
- 2016
Foundation of ECC energy components center GmbH by Dipl.-Ing. Michael Klug
- 2016
Since July 1, 2016 cooperation partner of Promet AG (Kirchberg, Switzerland); ECC acting as solution provider for Promet AG