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  6. Key applications for the electric powertrain

Solutions for battery and electric motor assembly

Automated production of the electric powertrain

The reliability of an electric car or commercial vehicle depends heavily on the safety of the individual components. As the operation of such a system requires a high degree of component safety and reliability, the individual processes are usually fully automated. In addition to classic handling technologies, joining methods such as gluing and screwing are also used. This places very different requirements on the choice of drive components and gantry systems. We work with you to develop efficient and cost-effective solutions, taking into account the individual requirements for the application in question.

Automation solutions for battery modules and battery packs

Battery module: core module assembly

Whereas the conventional assembly process for combustion engines is all about high-precision assembly of mechanical components, the production of battery modules involves assembling very expensive and hazardous electrochemical components. We offer perfectly matched solutions, particularly in the area of handling technology, for example for sturdy, reliable and precise gripping of battery cells.

Suitable products for core module assembly

Battery module – core module assembly

Battery pack: inserting the modules

Applying thermal paste

The battery cell as an electrochemical component should, if possible, always be able to operate in an ideal temperature range, regardless of wind and weather influences. This requires the installation of a so-called thermal management system in high-voltage systems. For efficient thermal transfer, paste-like thermal conductors are frequently used that must be supplied and dispensed with great accuracy. Our components play an important role here.

Suitable products for applying thermal paste

Inserting the modules

As the modules are inserted into the thermal paste, the narrow tolerances normally require an extremely precise gripper system with position correction.

Suitable products for inserting the modules

Pressing in the modules

By pressing in the module, its contact surface with the thermal conductor is maximised. It also guarantees that the battery pack is geometrically correctly positioned so that it can then be screwed in and sealed.

Suitable products for pressing in the modules

Screwing in the modules

Since the pack is part of the vehicle, it also needs to meet all crash test requirements and, as a last step, must be attached to the car underbody. This is supported by dynamic positioning of the screwdriving systems.

Suitable products for screwing in modules

Battery pack: leak testing

Like all components used in passenger cars and lorries, battery packs are also exposed to the weather. That is why classic IP67 tests often have to be carried out in addition to leak tests for the vehicle’s cooling systems.

Suitable products for leak testing

Battery pack: dismantling

The end of a battery's life cycle is reached after approx. 15,000 charging processes. To recover valuable minerals, the first step is to safely and efficiently dismantle the battery into modules, cells and other components. Our automated application has an impressively high level of flexibility and precision.

Find out more about the automated dismantling of battery packs here.

Electric motor: automation solutions for rotor and stator assembly

At first glance, electric motors seem to be mainly produced using established technologies. The actual challenges for production plants are about having to maintain consistently high quality and precision in high-volume production. After all, the parts, which are often cylindrical, must be repeatedly aligned, turned and joined as they pass through the production chain. Thanks to our wide range of linear axis systems, swivel units and grippers, Festo always has the right solution.