The complexity of electrical systems requires components with high precision, resistance and reliability. And terminals, which are essential for the safe and efficient interconnection of circuits, are a good example of this, as they must fulfil strict technical and regulatory requirements.
ETMA has 85 years of experience in the production of metal parts for the electrical sector and, through its technical know-how, technological capacity and rigorous quality control, has become specialised in the development and manufacture of low and medium voltage solutions. In particular, and as we will cover in this article, it produces terminals for the electrical sector, integrating advanced production processes to guarantee products with high performance and durability, short response times and optimised control of the entire logistics process.
TERMINALS FOR THE ELECTRICAL SECTOR: TECHNICAL REQUIREMENTS AND CHALLENGES
Terminals play a critical role in the stability of electrical connections and are designed to withstand high electrical loads, thermal variations and adverse environments. The main technical requirements include:
- Optimised electrical conductivity to minimise energy loss and temperature rise;
- Mechanical and thermal resistance to withstand dynamic stress and extreme temperatures;
- Resistance to environmental corrosion to guarantee longevity in industrial applications;
- Compliance with international standards for safety and reliability.
The design and industrialisation of these components therefore requires knowledge of the client’s technical requirements and regulatory benchmarks, highly precise production processes and rigorous quality assurance methods, both in terms of dimensional control and specific technical tests, areas in which ETMA stands out.
PRODUCTION PROCESSES AND APPLIED TECHNOLOGIES
In the production and assembly of terminals, ETMA adopts an integrated approach that combines its unique system of 10 Integrated Production Processes, ensuring optimised, high-performance manufacturing. The main processes involved in the production of terminals include:
- High-precision metal stamping
ETMA uses high-speed presses to form metal alloys with complex geometries, guaranteeing tight dimensional tolerances and repeatability in the process.
- CNC machining for technical profiles
The introduction of machining operations makes it possible to carry out critical technical details such as high-precision fittings, threads and drilling.
- Functional surface treatments
To guarantee electrical and mechanical resistance, treatments such as zinc coating, nickel-plating and passivation are applied, adapted to the requirements of the electrical sector.
- Automated assembly and quality control
The integration of robotic cells ensures the efficient and standardised assembly of terminals, reducing cycle times and eliminating variability in the process. At the same time, ETMA carries out metrological inspections and electrical tests to validate each batch produced.
INNOVATION AND CUSTOMISED SOLUTIONS: ETMA’S DIFFERENTIALS
ETMA’s know-how in metal components is reflected in its ability to develop customised solutions for each application, with a team specialised in:
- Geometric optimisation to reduce weight, improve electrical conductivity and optimise the production process;
- Development of high-precision stamping tools;
- Implementation of Lean methodologies for production efficiency;
- Functional validation through simulation and in-house laboratory tests.
CASE STUDIES: SOLUTIONS FOR COMPLEX APPLICATIONS
The terminal is a historic product at ETMA and a clear example of the advantages the client has in hiring a company that combines the various production processes of a complete product.
By way of example, ETMA has already developed terminals for projects that required the integration of up to 10 different production processes, combining:
- Prototypes
- Tools and Equipment
- Stamping
- Cold Forging / Screws
- Wire Forming
- Heat Treatments
- Surface Treatments
- Assembly
- Inspection and Sorting
These challenges demonstrate ETMA’s ability to adapt to client specifications and the sector’s regulatory requirements, alongside several advantages, such as:
- Greater control of processes and their interaction and, consequently, greater flexibility;
- Reduced lead times, particularly in multi-process production (for example, if heat and surface treatments had to be carried out externally, the lead time would increase exponentially);
- Optimisation of costs, in terms of logistics and quality.
ETMA: YOUR STRATEGIC PARTNER IN THE PRODUCTION OF TERMINALS
The experience accumulated over the years, in this component and in similar parts or components, allows ETMA to understand the interconnection and foresee potential cascading effects between the various processes, anticipating problems and their solutions, and allowing the manufactured product to be exactly what the client needs.
This is how ETMA’s expertise in the production and assembly of terminals for the electrical sector allows it to respond with innovative and efficient solutions to the industry’s challenges.
Contact us to discuss your project specifications and develop an optimised solution for your needs.
