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KUKA Assembly & Test and KUKA Systems (China) Co., Ltd. are providing assembly systems and test equipment worldwide. We develop, plan, design and manufacture systems and automation equipment for the efficient assembly of series products such as electric drives, motors, inverters, engines, cylinder heads, transmissions, axles, brakes, and steering systems as well as the corresponding inspection and test equipment.
The powertrain is associated with unbridled power that is optimally transferred to the road, bringing a unique propulsion to life. It is always made up of many components that generate and transmit torque from the engine to the drive axle in the vehicle.
The mobility sector is currently undergoing significant changes: the classic combustion engine will be replaced by electrification in the next few years. The future belongs to electromobility.
As one of the world’s leading suppliers of automation solutions, we are masters in designing flexible and efficient assembly systems and test systems. We always have our finger on the pulse and develop customized state-of-the-art automation concepts tailored to your requirements and needs. Our many years of experience and extensive expertise make us a specialist for assembly and test solutions for all powertrain components – regardless of whether they are classic internal combustion engines, hybrids, electric or hydrogen drives. In addition to development, our service portfolio includes the planning, design and manufacture of robot-assisted and digitalized automation solutions for the efficient assembly of series products, such as engines, cylinder heads, transmissions, axles, brakes and steering systems, as well as the corresponding inspection and test equipment. Supplemented by services such as process planning, simultaneous engineering, customer training and after-sales service, KUKA is your full-service provider.
Electromobility will replace the internal combustion engine in a much shorter time than planned. Developing new vehicle and drive concepts in such a short time and producing them on an industrial scale is a Herculean task. We are very pleased to support our customers in this respect with state-of-the-art assembly and test systems for electric drives.
Assembly: From the idea to series production
Fast and economically efficient assembly, top quality and perfection are our goal.?We leverage our systems to develop, design, optimize, qualify, manufacture and assemble forward-looking solutions. Our specialized knowledge and high level of vertical integration allow us maximum flexibility.
Engine assembly is one of our specialties: our portfolio includes individual machines for valve clearance adjustment, assembly lines for cylinder heads or engine blocks, through to complete line systems for all engine components.
We develop and manufacture assembly lines for the production of:
Electric drives (also with integrated EOL and/or test bay)
Electric drive units (EDU), such as rotors etc (pre-assemblies)
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Benefit from our decades of expertise in mechanical and systems engineering and jointly develop the optimal production system for your product and your individual requirements together with us. To achieve this, we use tested and proven processes and innovative technologies. We offer customized?automation solutions?from industrial robots to complete production lines – all from a single source. From the pre-series to series production, we configure, modular, turnkey production systems available worldwide – tailored to any level of automation and cycle time.
We implement flexible and scalable manual, semi-automatic and fully automatic assembly systems for your production.
We accompany you and your products from the development phase to production in order to turn perfectly coordinated automation solutions into reality.
KUKA System China provides efficient solutions of assembly and test in the field of automotive powertrain, E-motor assembly and E-drive assembly and testing, with rich successful applications based on complete process technologies.
We are well-versed in the assembly of transmissions and axles for cars and trucks.
Numerous automakers around the world are already producing a variety of drive trains on our assembly lines.
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We develop and manufacture assembly lines for the production of:
Hybrid transmission (MHEV, PHEV)
Front and rear axles including automatic wheel alignment and camber setting
Wheel carriers
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We can implement a customized assembly system for you too, with which you can manufacture your products more efficiently.
The fundamental goal of the iteration of electric drive system technology is to improve power density and efficiency, thereby increasing the range of new energy vehicles. High power density is the development direction.
Flat wire motors can increase efficiency, power density, heat dissipation, and NVH capabilities by increasing the slot filling rate. At the same time, they achieve higher production automation and significant advantages.
The complete manufacturing process of a Hair Pin motor includes 10 main procedures, which involve insulation paper forming and insertion, wire cup insertion into the stator core, wire end cutting, stator dipping and electrical performance testing.
The manner of linking the individual assembly systems can be as varied as your product.
We develop a wide variety of linking systems for:
Conventional, driven transport systems including workpiece carriers
Rail-guided transport systems including intelligent and self-propelled workpiece carriers: these have an ergonomic design and enable a working position that can be individually adapted to the employees
Intelligent automated guided vehicle systems (AGVS)
Innovative robot-based linking solutions
Current changes relating to the acute shortage of skilled workers as well as continuous further development of the electrified powertrain are forcing a rethink in the automotive industry. A high level of automation will be part of the solution. As an automation specialist with decades of experience, we create innovative solutions that combine market-specific know-how with unique technology and development expertise.
Mobility is being reexamined and requires a rethink?and reorientation of both the automotive industry?and its suppliers. The technological changes resulting from electrification will thus also affect the mechanical and systems engineering sector, which is an important supplier to the automotive industry. The impact on the dominant manufacturing processes for conventional drives is immense.
Inspection and test systems for the development and manufacture of electrical components in the powertrain are vital in vehicle development. They are an important element for ensuring vehicle quality and safety. Particularly when it comes to the required leaps in efficiency that are expected of cars and commercial vehicles, every engine and every drive has to be tested and inspected in detail. We already offer the key technologies for virtually every task.
Our portfolio of powertrain test benches is continuously adapted to changing market requirements and also keeps pace with the growing demand for e-mobility solutions for electric and hybrid drives. This means that your components can be tested and verified on our test benches at very early phases of projects.
A system alone does not ensure success; comprehensive understanding of the customer’s product is equally important. No matter what size your vehicle is, from motorcycles or passenger cars to trucks and rail vehicles, we always offer you the appropriately adapted test system.
Proprietary, universal software, easy drag-and-drop test sequence modeling, modular and scalable. Leakage test as well as NVH testing 100% integrated, flexible, configurable bus system communication (CAN, LIN, Flexray), residual bus simulation for all testing/inspection applications
Torque-to-turn, component leak test, test of the engine oil/water duct system (air), valve clearance measurement
Proprietary, highly integrated signal conditioning, freely configurable, deterministic and real-time capable control hardware (PWM, control loop, SENT), FPGA-based, compact as well as extremely fast. NVH system analysis, leak testing, He (helium) as well as KUKA’s own forming gas leak testers and individual battery test systems
All essential mathematical analysis methods, statistics, live monitoring and archiving in database-based systems
Pneumatic, servo-driven, standardized “floating” or self-clamping, crankshaft drive systems with gripper or screw couplings, tool changers, manual sealing adapters and automatic sealing concepts, flexible floating adaptation and clamping concepts
We install our test systems where our customers are: around the globe. From planning, implementation and support to the installation of individual test benches or the modernization of existing systems – we offer all solutions from a single source. Our test systems ensure more efficient and sustainable production with the highest quality and safety standards.
We have an open ear for our?customers ’ requirements and offer?excellent service worldwide thanks to our global network and the use of state-of-the-art communication tools. Here, we value speed, reliability and professionalism as crucial characteristics for efficient production processes – throughout the?entire life cycle?of your?automation solution.?
Rely on our experienced and well-coordinated team. When it comes to powertrain tasks, we combine enthusiasm and passion with knowledge and expertise.
