Following a major order last year for 23 friction welding cells with integrated robots for the electric vehicle production of a major automotive manufacturer in the US, Kuka has now received a follow-up order for 12 additional cells for a production expansion.
The delivered cells will be installed and commissioned in stages by August 2025. The FSW cells (FSW stands for friction stir welding) with Kuka KR Fortec robots and clamping devices tailored to the welding process will be integrated into production lines for electric vehicles, where they will be used in several manufacturing steps:
The robots in the cells weld battery cases together and, in a second production stage, connect cooling water jackets to the battery cases. Kuka is also responsible for the entire friction stir welding process, including assembly, commissioning, training, and final acceptance at the customer’s site.
Flexible Production on a New Level
Kuka technologies are being utilized in a comprehensively retooled production plant. This new, flexible plant enables the manufacturing of combustion engines, hybrids, and electric vehicles on the same production lines. This adaptability is essential in today’s ever-changing automotive market where consumer preferences shift rapidly.
The technological challenges inherent in this setup are substantial. For instance, one of the critical processes is joining battery trays made from two cast half-shells using advanced 3D welding techniques. Kuka’s FSW robots are particularly effective in executing these complex joints, showcasing the technology’s flexibility and precision.
Moreover, the reconfiguration of the production landscape has been designed with a strong focus on employee welfare and environmental sustainability. The goal here is to create a working environment that is not only safe and comfortable but also conducive to maximizing quality, efficiency, and value for customers.
FSW: Higher Quality, More Efficient, and More Sustainable Welding
Friction stir welding (FSW) is a revolutionary technique that utilizes a rotating pin-like tool to weld materials by generating heat through friction. This heat plasticizes the materials, allowing them to fuse together seamlessly. This process is especially beneficial when working with challenging materials, such as joining aluminum to magnesium, copper, or steel.
Notably, FSW is recognized for being more energy-efficient and for reducing material waste compared to traditional welding methods. Its applications span across sectors that demand high-quality weld seams, such as electric vehicle battery cases, sidewalls of high-speed trains, and even the structures of rockets.
As the market for e-mobility expands, so does the application of FSW in industries like aviation and electronics, where precision is paramount. The increasing versatility of this technology is drawing attention from several sectors eager for reliable and efficient welding solutions.
The Special Requirements for FSW Robotics
Robots utilized for friction stir welding encounter unique challenges due to the complex nature of the process, which often involves significant forces. Kuka has adeptly addressed these challenges by offering a specialized machine tooling (MT) variant within its KR Fortec product family. This variant boasts a more powerful motor and features pregears designed to enhance rigidity, making it perfectly suited for FSW applications.
Kuka is continuously expanding its portfolio to meet the demands of modern manufacturing. Two new MT variants from the KR Fortec ultra robot family are set to define new benchmarks in performance and reliability. These advanced models come with a double swing arm and adapted robot parameters that ensure maximum path accuracy while achieving a 20% increase in process force.
With a reach of up to 3,400 mm, these new models will significantly expand the effective working range for customers involved in friction stir welding, allowing for enhanced versatility in production setups.
Innovative Solutions for the Future
The integration of new FSW robots into Kuka’s comprehensive FSW solution portfolio highlights the company’s commitment to innovation. This portfolio includes the new FSW application module, modularly scalable production cells known as the cell4_FSW type, and turnkey solutions customized to meet specific customer requirements.
These advancements signify a crucial step toward a more efficient and sustainable manufacturing landscape, ensuring that companies can respond effectively to the needs of a changing industry. As Kuka continues to roll out these innovative technologies, the automotive sector can look forward to enhanced production capabilities that promise efficiency, reliability, and superior quality.