Electromobility

For the production of battery compartments, we supply efficient solutions using a unique technology: friction stir welding. It combines precision with cost-effectiveness and meets the highest standards in terms of leak-tightness and safety. Friction stir welding can particularly be used for high-quality joining processes with various aluminum alloys and other non-ferrous metals. Here, a rotating tool uses friction heat between the clamped parts to be joined in order to create a very robust joint.

From single-part production to the complete assembly of modules, KUKA offers the right 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 advantages of the fuel cell as an energy supplier for electric drives are obvious: a long range and short refueling times similar to those of combustion engines. This is why they play a major role in making passenger and freight transport more climate-friendly. In our research and development, we focus intensively on systems engineering for fuel cell assembly. Our production systems are individually adapted to the given requirements. The goal here is for the fuel cell to already be designed in the engineering phase in such a way that assembly and testing can be simplified and accelerated in order to reduce production costs. From the initial idea through to simulation and the project phase and on to series production, KUKA’s many years of experience mean that our customers can be sure that everything has been thought of.

Cell 2 Body technology, also called Cell 2 Pack technology, integrates the battery cell with the vehicle body, chassis, electric drive, heat management, and various high and low-voltage control modules – and can thus significantly increase the range.

With the Digital Factory, we are pursuing the goal of creating a flexible and adaptable system that optimizes itself during production operation on the basis of the process values collected. The core element of this approach in the Digital Factory is the digitalization of the entire value chain right from the beginning.
The starting point of the project is the creation of a virtual system model before the real production facility is set up at the customer’s site. In this initial step, we achieve fully networked production. For this purpose, we make use of the digital twin as a virtual 3D image of the system. This tool enables us to collect all available data and to visualize them simply and intuitively. This allows cycle times to be analyzed and the causes of malfunctions identified in advance in order to ensure a risk-minimized and thus smooth start of production later on.

Every product starts with a small individual part. With the standardized cells from KUKA, these can be produced efficiently. As electromobility has gained increasing importance, we have developed our own cell solution.

The manufacture of electric motors is an established technology. It nonetheless poses particular challenges for manufacturers. For 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.

Electric vehicles contain a large number of, in many cases, new electronic components, which can be manufactured by robots. Robots are used in areas such as assembly (e.g. installation of high-voltage cables), the sensitive connection of flexible cables (e.g. automatic insertion of high-voltage battery module connectors as well as for headlights), adhesive bonding processes (e.g. for inverters), component inspection (e.g. for high-voltage components such as inverters), as well as in conventional screw-fastening and handling processes. Here, the ESD certification of KUKA robots plays a major role in ensuring that the often sensitive components are not destroyed. Even processes with critical cycle times can be carried out by the very fast KR SCARA and AGILUS-2. As an expert in electronics manufacturing, KUKA supplies the necessary equipment and know-how for innovative automation solutions for the electronic components of electric vehicles.

One challenging assembly task in automotive production is the “marriage” of the powertrain to the vehicle body. This also applies to electric vehicles in which the electric motors are already integrated into the axle modules. A particular challenge is the bolting of the heavy batteries into the underbody. The positioning of these components can be performed using conventional lift tables on slides, or with robots or automated guided vehicle systems (AGVS). Depending on customer requirements, KUKA offers the appropriate solutions with partially or fully automatic assembly fixtures.

KUKA delivers expert solutions for the production of car bodies in all conceivable variants. From the smallest hang-on part to the complete body-in-white, from fully-automated to semi-automated production. Learn more about body-in-white construction from KUKA:

Since 2010, KUKA has been developing automated assembly systems for the production of components in electrified powertrains and integrating them successfully at customers’ plants. KUKA delivers assembly lines for electric motors, rotors, hybrid transmissions, axles and integrated axle systems – with the corresponding test systems in each case. The trend in electromobility is towards ever more integrated and compact e-modules. KUKA is supporting this rapid development with innovative automation. We are the specialists for the planning, design, manufacture and commissioning of automation equipment, individual assembly lines and complex assembly systems. Electromobility components such as electric motors, front and rear axles and transmissions for hybrid vehicles are assembled for the electric powertrain. KUKA testing technology and KUKA high-tech test systems ensure that your assembled unit functions perfectly. Additionally, the assembly lines and the corresponding machinery are planned and designed on a modular basis. This enables scalable design and, in the case of growing demand, a cost-effective increase in the number of units produced.

The production of a battery resembles a ‘battle of materials’. To ensure that everything is always in the right place at the right time, we develop the right logistics solution together with the customer. We have the experts on hand to offer our customers a comprehensive package for all their needs. From automated guided vehicle systems (AGVS) and component feeding systems to warehouse logistics, we offer the entire portfolio.

Feasibility studies, simulation and method planning are central components of the engineering process and require the highest level of expertise during planning. We develop efficient manufacturing strategies and support our customers in their optimal implementation. In doing so, we draw on our in-depth expert knowledge. The result is process-reliable and cost-optimized manufacturing concepts – perfectly tailored to the needs of our customers.

In the battery module, the individual cells are connected to each other. We offer our customers flexible and reliable system technology as well as professional project management for module assembly. 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. From pre-assembly to insulation and bracing, and from the assembly of electrical contacts, boards, sensors and end plate to the inspection station. The level of automation and the variability are tailored to the individual customer.

Modern electric vehicles place special requirements on the vehicle design which also heavily influence the body architecture: The large battery is usually bolted into the underbody and the battery compartment thus becomes a structural component. The use of high-voltage technology increases the safety requirements, particularly for crash tests. As an expert in body production, KUKA provides the know-how required for innovative automation solutions for mass production and meets your specific vehicle body requirements for every kind of body architecture.

Automotive manufacturers are also faced with the challenge of producing ever greater numbers of electric vehicle models alongside their portfolio of conventional vehicle models with internal combustion engines. Increasing type variety, more frequent changes of model and strongly fluctuating batch sizes require maximum flexibility and versatility. KUKA SmartProduction unites precisely these factors and enables our customers to produce different assemblies for internal combustion and electric models cost-effectively in a single system. The production cells in KUKA SmartProduction are supplied with components and tools independently of their location. This takes customized production to a new dimension. The battery is also a very critical component. As a result, the obligation for inspection reports and documentation is even more important here than for other products.

The battery systems in electric vehicles are central and highly complex modules. Pack assembly involves putting together several modules and other electronic elements (such as cables and control devices) that can then be inserted into an electric vehicle. 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. Battery producers and vehicle manufacturers can produce the battery packs quickly and efficiently with our scalable and easily expandable assembly lines. Inspection systems for reliably ensuring zero-defect production are an important part of pack assembly. Here, we tap into our Group’s expertise for testing and inspection rigs.

KUKA provides professional project management. In this way, we successfully guide our customers from the idea to the product. We ensure that project schedules are transparent and guarantee the highest level of quality. Highly qualified and committed employees from the KUKA project management team are there to provide assistance throughout the project planning and implementation stages. We collaborate with you in an interdisciplinary and intercultural manner using state-of-the-art communication and project management tools. Benefit from our many years of experience of working on projects in Germany and abroad.

Because everything should be perfect: we are the right partner for prototype construction – from design to the finished component. For prototype and small series assembly, KUKA offers scalable and individually tailored solutions. Here, we cooperate closely with our customers and are able to implement change requests promptly and adapt planning.

In the field of e-mobility in particular, our customers benefit from our many years of experience in numerous process technologies such as:

• Aluminum welding

• Arc welding

• Laser welding

• Laser hybrid welding

• Milling

• Contract manufacturing with friction welding

• Friction stir welding

• Rotational friction welding

• Magnetarc welding

Take advantage of our comprehensive range of services around the globe: from commissioning and repairs to maintenance, servicing and system expansion. Our Service naturally also offers training courses for system operators at our KUKA College or on site as well as hotline support and spare parts management.

We offer our customers test systems for batteries and fuel cells as well as for the complete powertrain. In order to ensure that the energy storage systems meet the high quality standards and stringent safety requirements, KUKA systematically subjects them to various inspections in different process steps during production. These extensive function tests require corresponding know-how and experience in measuring and inspection technology. Strict safety requirements and maximum quality standards must be met, especially for high-performance batteries in electromobility. Each individual battery component is repeatedly subjected to the closest scrutiny during production, culminating in end-of-line testing of the battery. In addition to leak testing, the battery systems undergo extensive electrical tests relating to communication with the electric vehicle and signal processing. Additionally, the electrical properties of the battery are tested, necessitating the corresponding high-capacity charging and discharging equipment. Furthermore, KUKA also takes into consideration reworking strategies to be adopted in the event of faults.

Whether conventional or hybrid – with our assembly lines, all engine types can be included. In each individual engine assembly line, the engines are produced in an individually tailored manner from hundreds of individual parts according to customer requirements. Throughout the process, state-of-the-art production technologies and coordinated logistics concepts complement KUKA’s engineering expertise.

The battery cell is the basic component for subsequent module and pack production. In principle, there are three different cell formats used in electromobility: prismatic, cylindrical and pouch. The production of these battery cells takes place under special ambient conditions. This means that, on the one hand, the production area must be very clean and particle-free (cleanroom), and, on the other hand, the air must be free of humidity (dry room). Our robots, which are used for battery production, meet these requirements and can be used there.

One variable when it comes to sustainability is the source of energy. The more renewable energy is used in the production process and in the energy supply of the electric vehicles, the more sustainable the electric cars are. There is also continuous further development in storage technologies, regardless of the production processes – for example, for storing surplus energy using hydrogen. The efficient use of resources with the aim of achieving a circular economy thus bridges the gap between economic and ecological sustainability.

Sustainability, however, goes far beyond that. How sustainable is manufacturing overall? How energy efficient are the products used? How carbon-neutral is the system? KUKA offers the right solutions and concepts here to make production facilities fit for the future.

Electromobility is at the forefront of climate protection and offers the opportunity to reduce dependence on petroleum-based fuels. Although battery production does consume a lot of energy, the carbon footprint of electric vehicles is better than that of conventional combustion engine vehicles. The benefits of an electric car for the climate continue to grow the more often it is charged using green electricity. With further advances in development – particularly more efficient manufacturing processes, higher energy density and improved cell chemistry – there is also further potential to improve the battery’s carbon footprint in the coming years.

Whether for second-life batteries (i.e. the further use of a decommissioned electric car battery; for example, for electricity storage in private households) or the recovery of the valuable raw materials, concepts for recycling must be developed as early as the planning phase of a new production system. The disposal of vehicle batteries and industrial batteries by incineration or landfill is prohibited, so it must be ensured that all returned used batteries are treated and recycled using state-of-the-art technology.

In addition to the recycling of rechargeable or non-rechargeable lithium-ion batteries, the production of these batteries also plays a crucial role. Currently, the production of batteries for electric cars still requires scarce raw materials (graphite, lithium) as well as a high energy consumption. In the medium term, however, research will open up even more sustainable alternatives here as well.

From the manufacturer’s point of view, the total cost of ownership must also be taken into account when building the system. Which differentiated costs and services for a machine or system are to be considered? Will, for example, the robot also be available for future conversions? The construction of energy storage systems in particular is undergoing rapid change. Which system components can continue to be used in a system rebuild? The “second life” plays a major role here. With a TCO analysis as part of the project, KUKA can help ensure that future expenses can already be identified and estimated during the planning phase.