KUKA Picus 2

Prismatic, pouch or cylindrical: irrespective of the battery cell form, KUKA develops process-reliable and dependable battery module assembly lines for high-voltage energy storage systems for subsequent installation in battery packs. From pre-assembly to insulation and bracing, and from the assembly of electrical contacts, boards, sensors and end plate to the inspection station.

The manufacture of electric motors is an established technology. Nonetheless it produces some major challenges for manufacturers. For the use in vehicles, a high level of automation of the production systems is required. Moreover, the associated production processes are subjected to the most stringent quality requirements. KUKA develops and implements turnkey, modular assembly lines for electric motors: from design and planning to final implementation and integration in your production environment – scalable from small to large-series production. In order to ascertain the optimal quality of your assembled motors and powertrains, KUKA also designs and implements all required inspection and measuring systems.

For the sealing of electronic modules, for example, KUKA develops flexible automation solutions that apply endless extruded plastic sealing profiles directly onto the desired components. Depending on the customer’s specific sealing task, KUKA provides the most appropriate robot-guided extrusion process to ensure greater flexibility, shorter cycle times and thus more cost-effective production.

The chassis of electric vehicles with independent front and rear axles is increasingly being developed as a fully integrated electric axle drive system. This is delivered directly to the production line and installed as a complete module. This reduces weight, installation space and production costs.

The assembly process for battery packs begins with the provision and preparation of the housing components such as the tray and frame. The cooling systems are then assembled and thermal compound or gap filler applied. The individual battery modules are inserted into the pack housing and fastened. This is followed by the electrical and thermal integration, cover installation and quality and safety testing of the battery pack.