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Assembly & Test Systems for Propulsion Systems
KUKA Assembly & Test Corp. in Fenton and Saginaw, Michigan, USA, established in 1945 (B&K), supplies assembly and test systems globally. Employing 250 staff, and with the capacity to add 100 or more contingent workers as needed. We conceptualize, design, develop, process, manufacture, and deliver flexible assembly and test cells, equipment, and systems for the efficient manufacturing of Powertrain products like traditional axles, brakes, cylinder heads, engines, steering systems, transmission, and modern Drivetrain solutions like electrified axles, drive units, fuel cells, motors, power units, rotors, stators, transmission, as well as battery modules and packs.
The powertrain – The heart of your vehicle
The Drivetrain or 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 power unit to the drive axle in the vehicle.
The mobility sector is currently undergoing significant changes: the classic combustion engine will be augmented by electrification in the next few years. The future belongs to electromobility and diversified Drivetrain Technologies.
Currently, our streets feature three different drive types
The hybrid drive
As a combination of two different energy sources – a conventional gasoline engine and an electric motor, both drives are combined into one efficient system and can switch automatically while driving.
The classic internal combustion engine (gasoline or diesel engine)
A conventional powertrain consisting of an engine with flywheel, a clutch with gearbox, wheels and, depending on the version, various differentials, drive shafts and propshafts.
The electric vehicle
Features a greatly reduced, more efficient powertrain by eliminating parts such as the clutch and manual transmission. It includes a battery, an electric motor, power electronics and cooling systems or temperature management.
Passion is our drive
As one of the world’s leading suppliers of smart 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 over 81 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 that embraces innovation and delivers engineering excellence globally by combining mechanical engineering expertise with software and AI-defined infrastructure capabilities.
The automotive industry is undergoing a period of rapid transformation, driven by advancements in electric vehicle (EV) technology, artificial intelligence (AI), and digital connectivity amid shifting trade policies and evolving labor regulations. My team is ready to support our customers with state-of-the art smart assembly and test automation to drive our customer's success through cutting edge innovation and strategic collaboration.
Everything from a single source: We are driving smart automation forward
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:
Internal combustion engines, such as gasoline or diesel engines (from pre-assemblies to finished engines)
Electric drives (also with integrated EOL and/or test bay)
Electric drive units (EDU), such as rotors etc (pre-assemblies)
As well as drives using synthetic fuels and hydrogen
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Process expertise in engine and cylinder head assembly
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.
Our technology portfolio
We accompany you and your products from the development phase to production in order to turn perfectly coordinated automation solutions into reality.
Flexible hardware interface
Digital and analog, e.g. I/Os, CAN bus, Flexray, Profinet, etc.
Measuring technology
High-precision static and dynamic measuring systems
Joining technology
Force/travel monitored servohydraulic and pneumohydraulic joining systems
Conveyor system
Automatic component feeding systems for small load carriers (SLCs), bulk goods, etc.
Dispensing technology
Automatic systems for sealants and adhesives
Quality control
Camera systems, scanners, sensors (contact/optical) and databases
Handling
Pneumatic and electrical axis systems and multi-axis systems/robot systems
Screw technology
Single or multiple spindles and automatic screw feeding system
Transmission and axle assembly
We are well-versed in the assembly of transmissions and axles for cars and trucks.
Numerous automakersaround 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:
Manual and automatic gearboxes, continuously variable transmissions, dual clutch transmissions and differentials
Hybrid transmission (MHEV, PHEV)
Front and rear axles including automatic wheel alignment and camber setting
Wheel carriers
Brakes
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We can implement a customized assembly system for you too, with which you can manufacture your products more efficiently.
Assembly line for engine blocks
Linking systems
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 (AGCs/ AGVs/ AMRs)
Innovative robot-based linking solutions
Test systems for engines, transmissions and electric mobility
With our?test systems?and our specially developed?testing software, we ensure that your assembled unit functions perfectly. We design and implement the necessary?test?and?measuring equipment?in order to check your engines and transmissions with complex analyses.
We develop and manufacture?test systems?for a wide variety of fields:
Cold and hot tests
Leak tests
Functional monitoring of the oil system
Torque and noise measurement
Combined end-of-line test systems
End-of-line and/or test bay for electric drives
BOL and EOL test for batteries
BOL and EOL test for fuel cells
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These are just some of our solutions for determining the?optimum quality of?your assembled units and components.
Cold test system from KUKA Assembly & Test in Bremen
We are experiencing one of the biggest workplace transformations in history. AI and automation are reshaping everything from our workplace to manufacturing floors, and these changes are happening faster than most of us expected. Automation has been around for decades but the speed of technology advancement is driving a shift towards smart automation in the automotive industry. As an automation powerhouse with decades of real world experience, our team provides cutting edge innovation solutions based upon marked experience and best practices technologies to drive our customer's success.
State-of-the-art test bench solutions
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.
Innovative and sophisticated vehicle components require intelligent test systems and cutting-edge technology
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 ofpowertrain 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.
Driveline with adapted output shaft
Our technology portfolio
Automation software
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
Process control in assembly
Torque-to-turn, component leak test, test of the engine oil/water duct system (air), valve clearance measurement
Measuring technology
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
Analysis
All essential mathematical analysis methods, statistics, live monitoring and archiving in database-based systems
Product adaptations
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.
Benefit from our consulting and support services
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.
Expertise and experience
We bundle our synergies from our expertise in mechanical engineering and new?digital solutions?for efficient and intelligent automation in production
State-of-the-art technologies
We always keep our finger on the pulse and offer state-of-the-art automation technologies
Future-oriented and customized
Innovative as well as efficient systems and test systems for the mobility of the future:?from engineering to start-up and servicing, depending on requirements
Full flexibility
Tailored to your needs, we draw on a large network of suppliers while, at the same time, offering you in-house solutions and standard products
