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 KUKA friction stir welding (FSW) cell for maximum process efficiency

The KUKA standard cells KUKA cell4_FSW were specially developed for the growing electromobility market. Thanks to their modular concept, they offer outstanding economic efficiency as well as maximum versatility and configuration options.

KUKA friction stir welding cell: the modern solution with low investment costs

Efficiency
- Maximum process efficiency (up to 95%) thanks to two workstations in separate insertion 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 with 1 or 2 robots
- Arrangement of several clamping tools in the working area of the robot
- Simultaneous welding of several robots for larger components
- Simple customizing
Ready for Industry 4.0
- Interfaces based on OPC UA for easy data exchange
- KUKA Remote Service for quick help

Highly accurate, perfect weld seams thanks to precise path guidance

Ensuring a path accuracy up to 0.5 mm due to:

Use of special high-payload robots with high rigidity and long service life (KR FORTEC ultra)
laser-supported precise path calibration to compensate for path deviations caused by the different stiffness in the working area of the robot and the influences of different process forces
Almost no rework thanks to special tooling

Modular FSW robot cell for product variety and flexible adaptation of your production capacities

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 hybrid vehicles, power electronics housings or heat exchangers.

KUKA friction stir welding cell in two variants

FSW-Cell type	KUKA cell4_FSW midsize single	KUKA cell4_FSW large dual
Dimensions (L x W x H)	5.600 mm x 5.400 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
Process control	KUKA PCD 507 (optional)
Cell equipment	Siemens TIA Portal series 1500, KUKA.SafeOperation, 2 rolling gates with protection against stepping behind and light curtain, polycarbonate fence with 1 or 2 maintenance door(s) and guard locking
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
Cell operation	KUKA.HMI Advanced (23,4'' Display with IPC)	KUKA.HMI Advanced (23,4'' Display with IPC)

Option packages of KUKA cell4_FSW:

Process control PCD 507 with visualization on KUKA.HMI Advanced
Laser-based gestützte recognition of seam positions for automatic compensation of tolerances on the component
FSW tools
- Tooling kit „rotating shoulder“
- Tooling kit „stationary shoulder“
- Special tools on request
Product-specific clamping systems
Service for laser-supported path calibration

The KUKA cell4_FSW friction stir welding cells can be combined as required with accessories for maximum flexibility.

Maximum FSW process control with new web visualization

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

AI-based process monitoring for friction stir welding

Find out more about how you can reduce costs and increase process quality in e-mobility with the FSW robot cell

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

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Download brochure (PDF): further information and scope of delivery

KUKA_cell4_FSW_EN - pdf, 432,5 KB
KUKA_cell4_FSW_Application_Module_EN - pdf, 434,99 KB

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E-book: Welding aluminium? No problem!

Aluminium and aluminium alloys play an important role in e-mobility because of the ideal combination of lightness and strength. In welding and joining processes, aluminium has high demands on the processes used. With comprehensive process know-how and the right products, we make you fit for the technological transformation towards e-mobility. The example of the battery box shows how robots enable the production of aluminium components at the highest quality level;