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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
5.600 mm x 4.600 mm x 3.500 mm
6.750 mm x 5.400 mm x 3.500 mm
Welding zone
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
28,2 m2
42,8 m2
Weight
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)
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.
Read what is important for aluminum welding in electromobility.