Advancing E-mobility: Focus on automation

We provide efficient solutions for battery housing production through friction-stir welding. This technology combines precision with economic efficiency and achieves the highest standards in terms of leak-tightness and safety. Ideal for high-quality joining processes with aluminum alloys and other non-ferrous metals.

The battery cell is the basic component for module and pack production. There are three cell formats in electromobility: prismatic, cylindrical and pouch. Production is carried out in cleanroom and dry room conditions. Our robots for battery production meet these requirements and are therefore ideally suited.

From single-part production to the complete assembly of modules, KUKA provides the suitable line. This ensures that the individual assembly steps are carried out professionally and economically at the same time. Where possible, we use standardized products to make production systems efficient and cost-effective for our customers.

The fuel cell enables a long range and short refueling times, ideal for climate-friendly transportation for passengers and freight. We develop custom production systems for fuel cell assembly that are designed for quick and easy assembly and testing already in the engineering phase, reducing production costs. From the initial concept through to series production: With KUKA’s experience, everything is taken care of.

The Cell 2 Body or Cell 2 Pack technology integrates the battery cell directly into the vehicle body with chassis, electric drive, heat management and high/low-voltage control modules. This can significantly increase the range.

At our digital factory, we create flexible systems that optimize themselves. We digitize the entire value creation chain from the outset with a virtual system model prior to the set-up at the customer’s plant. The digital twin enables the early analysis of cycle times and cause of malfunctions, leading to a smooth production start.

Every product starts with one small component. With the standardized cells from KUKA, these can be produced efficiently. As electromobility has increasingly gained in significance, we have developed our own cell solution for friction-stir welding.

The manufacture of electric motors requires a high level of automation and the highest quality standards. To achieve this, KUKA develops turnkey, modular assembly systems from planning to integration, scalable from small to large-scale series. For quality assurance, we also design and implement all necessary testing and measuring equipment.

Numerous new electronic components which can be manufactured by KUKA robots are installed in electric vehicles. These robots are used to assemble high-voltage cables and connect flexible cables, and for adhesive bonding processes, component inspection, and traditional screw-fastening and handling processes. The ESD certification for KUKA robots protects sensitive components. Cycle time-critical processes are solved with the fast KR SCARA and KR AGILUS. KUKA provides the necessary equipment and expertise for innovative automation solutions.

The final assembly in automotive production, especially the “marriage”, is demanding. This also applies to electric vehicles in which electric motors are integrated in the axle modules. Particularly challenging is screwing heavy batteries into the underbody. They can be positioned with lift tables, industrial robots or autonomous mobile robots (AMR). KUKA provides suitable solutions with semi-automatic or fully automatic assembly fixtures, depending on the customer requirements.

KUKA provides solutions for every car body, from the smallest flap to the complete body shell. Our fully and semi-automatic production processes set new standards, which large brands and small manufacturers trust alike. The best joining technologies ensure the highest quality. Our modular systems are flexible and customizable, enabling tailor-made production.

Since 2010, KUKA has been developing automated assembly systems for the electrified powertrain. We supply assembly lines for electric motors, rotors, hybrid gear units, axles and integrated axle systems. With innovative automation, we support the development of integrated and compact e-modules. As a specialist for the planning, design, manufacture and start-up of automation equipment, we assemble electric motors, front and rear axles and gear units for hybrid vehicles. Our testing technology ensures the functionality. The modularly planned and designed assembly systems enable scalable and economic production.

To ensure that everything is always in the right place at the right time, we develop the suitable logistics solution together with the customer. KUKA experts provide an all-round carefree package, which covers the entire portfolio from autonomous mobile robots (AMRs) to component feeding systems and warehouse logistics.

Our expertise in feasibility examinations, simulation and method planning enables cost-optimized and efficient manufacturing strategies as well as process-reliable manufacturing concepts, perfectly tailored to the needs of our customers.

The cells are connected in the battery module. We provide flexible and reliable system technology as well as professional project management for module assemblies. Irrespective of the cell shape, KUKA develops process-reliable assembly lines for high-voltage energy storage systems, from the pre-assembly to the inspection station. The degree of automation is adapted to the individual customer requirements.

Modern electric vehicles require special body architectures and high safety standards, especially for crash tests. KUKA provides innovative automation solutions for mass production and meets individual requirements. KUKA SmartProduction enables flexible production of combustion engine and electric models on a single system and ensures comprehensive customization and flexibility.

The battery systems are main assemblies in electric vehicles. Modules and electronic elements are assembled in the pack assembly. The process includes the preparation of housing parts, assembly of cooling systems, insertion of battery modules, electrical and thermal integration, cover assembly and quality and safety tests. Our scalable assembly lines enable efficient production with zero-error testing systems.

KUKA provides professional project management and accompanies customers, from the initial idea to the finished product. We organize project sequences transparently and ensure maximum quality. Highly qualified and dedicated employees are available for planning and implementation. We collaborate with you in an interdisciplinary and intercultural manner with state-of-the-art communication and project management tools. You can benefit from our many years of experience at home and abroad.

We are the suitable partner for prototype construction – from the design to the finished component. For the assembly of prototypes and small series, KUKA provides scalable, individually coordinated solutions. We cooperate closely with our customers and implement change requests in a timely manner.

You can benefit from our many years of experience in various applications, especially in the field of e-mobility!

• Aluminum welding
• Arc welding 
• Friction-stir welding
• Rotational friction welding
• Laser welding
• Laser hybrid welding
• Milling
• Contract manufacturing with friction welding
• Magnet arc welding
• Other applications

From the initial idea to the upgrade, we accompany you worldwide throughout the entire life cycle of your automation. You can benefit from our high-quality consultation and support services:

• Training courses
• 24/7 hotline
• On-site service
• Spare parts supply within 24 hours
• Modernization of robots, systems and plants
• Machine overhauls
• Used machines
• Customized solutions to maximize your system availability
  
  

We provide test systems for batteries, fuel cells and the powertrain. KUKA inspects energy storage systems during production to ensure high quality and safety standards. The high-performance batteries undergo rigorous testing, including leak and electrical tests. Each battery component is tested several times and then subjected to an end-of-line test. KUKA also incorporates any reworking in the event of a fault.

Whether conventional or hybrid: Our assembly lines can integrate all motor types. Hundreds of components are used to create motors, according to individual customer requirements. State-of-the-art production technologies and coordinated logistics concepts complement each other with KUKA’s engineering expertise.