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KUKA cell4_FSW: Modular friction stir welding cell for e-mobility

The FSW robot cell offers a highly automated solution for friction stir welding in electric vehicle production. It has a modular design, is scalable for different production scopes and is fully Industry 4.0-compatible.


Flexible friction stir welding cell for maximum process utilization

The KUKA cell4_FSW friction stir welding cells were specially developed for the growing electromobility market and, thanks to their modular concept, offer maximum versatility and configuration options in addition to outstanding economic efficiency.

Low costs, high quality - the advantages of the FSW robot cell

  • Economic efficiency

      • Maximum process utilization (up to 95%) thanks to two workstations in separate loading areas
      • Cycle time-neutral loading and unloading
      • High degree of standardization
  • Maximum versatility

    • Use for 2D & 3D welding tasks thanks to 6-axis robot
    • For various tasks in the field of e-mobility
  • Modular and flexible

      • Scalable solution
      • Arrangement of several clamping tools in the robot work area
      • Parallel welding of several robots on large components
      • Individually configurable
  • Ready for Industry 4.0

    • Interfaces based on OPC UA for easy data exchange
    • KUKA Remote Service for quick help
KUKA robotics solutions for the environmentally friendly welding process: Robot cell for friction stir welding, contract manufacturing, KUKA product portfolio for e-mobility.

FSW cells for e-vehicle production at a glance

The modular cell concept is based on the KUKA FSW application module with one or two robots (single-sided and double-sided welding) and is suitable, for example, for battery housings of electric and hybrid vehicles, power electronics housings or heat exchangers.

FSW-Cell type KUKA cell4_FSW midsize single KUKA cell4_FSW large dual
Dimensions
(L x W x H)
5.600 mm x 4.600 mm x 3.500 mm 6.750 mm x 5.400 mm x 3.500 mm
Welding zone
(L x W x H)
1.250 mm x 880 mm x 280 mm (2 pieces) 2.000 mm x 1.180 mm x 280 mm (2 pieces)
Installation area
(incl. cabinets)
28,2 m2 42,8 m2
Weight
(without clamping system and manipulator)
ca. 5.000 kg ca. 8.000 kg
Cell equipment

Siemens TIA Portal series 1500, KUKA.SafeOperation, 2 roller shutters with rear step protection and light curtain, polycarbonate fence with 1 or 2 maintenance door(s) and guard locking device(s)

FSW application module 1 x  FSW application module  2 x FSW application module 
Robot type KR 300 R2800-2 MT (KR FORTEC ultra) 2 x KR 300 R2800-2 MT (KR FORTEC ultra)
Robot controller KR C5 for KSS KR C5 for KSS
Cell operation KUKA.HMI Advanced (23,4'' Display with IPC) KUKA.HMI Advanced (23,4'' Display with IPC)

Your production, your choice: The FSW cell with scalable options

  • PCD 507 & HMI Advanced

    100% process control, pin breakage detection and documentation with display on the HMI Advanced

  • Seam position detection

    Laser-assisted detection of seam positions for automatic compensation of tolerances on the component

  • Clamping systems

    For holding the component on the worktable (product-specific)

  • Tooling kit “Rotating shoulder” (pin & shoulder)

    Standard tool with adjustable welding pin length for different component thicknesses

  • Tooling kit “Stationary shoulder” (pin & shoulder)

    Tool with stationary shoulder and rotating pin (lower heat input, less burr formation)

  • Automatic cleaning station for tool SSFSW

    Cleaning station for FSW tools - removes aluminum from the tools

  • Automatic tool changer SSFSW

    Increased productivity thanks to fully automatic change of the FSW tool with standing shoulder

  • Automatic tool changer CFSW

    Increased productivity thanks to fully automatic changer for classic FSW tools Automatic changeover by robot

High-precision, perfect weld seams thanks to optimum system coordination

Path accuracies of up to 0.5 mm can be achieved by:

  • the use of special heavy-duty robots with high rigidity and a long service life, which guarantee high repeat accuracy (KR FORTEC ultra)
  • precise path calibration to compensate for path deviations caused by the varying rigidity in the robot's working area and the effects of different process forces
  • special tooling for seam surfaces that require virtually no reworking.

Maximum control in the FSW process - for the future of e-mobility

The unique KUKA PCD 507 (Process Control and Documentation) system controls and documents all relevant process parameters during welding and has been transferred to the new intuitive KUKA.Web HMI. It thus guarantees:

  • 100% reproducibility
  • 100% quality monitoring in real time
  • 100% process reliability (minimization of rejects)
  • 100% documentation of the welding process
Process monitoring for all FSW path processes: Data export, process diagnosis and electronic archiving of all process data

Smart financing for your FSW technology

We support you in the planning phase and offer flexible financing models

E-Book: Welding aluminum - solutions for e-mobility

From FSW to laser: a comparison of welding technologies

Aluminum is light, stable - and demanding in terms of welding technology. Reliable joining technologies are needed in e-mobility, for example for battery boxes. The e-book provides an overview of modern welding processes such as MIG, TIG, laser and FSW (friction stir welding) - including practical examples and tips on automated production. KUKA shows you how to bring the right technology into your production efficiently.

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Read what is important for aluminum welding in electromobility.

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