E-mobility

Assembly systems for module connectors and busbars

Assembly plant consisting of welding and testing cells for the production of module connectors

When designing assembly lines for module connectors for electric vehicles, safety of paramount importance.
Our systems integrate various high-voltage (HV) and low-voltage (LV) tests . We also regularly implement end-of-line testing systems

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Generally

Various system configurations consisting of different robot cells
Component-independent feeding of individual parts on flex feeders and belt systems with cameras for position detection of the components
Design as a pure testing facility or testing stations in combination with various manual and automatic processing processes
Automatic exchange of robot grippers
Integration of manual workstations (e.g., housing assembly)

Processes

Mechanical machining processes

Welding of busbars
Assembly of attachments such as bushings and screws
Assembly of enclosures
Applying component labels

Testing processes

Optical measurement of screw-on tabs
Optical inspection of mold fillings and geometric features
Visual inspection of mounting surfaces to ensure they are free of overmolding and damage
Presence and variant testing of injected inserts
Checking screw lengths
Testing of locking mechanisms
Component-specific high-voltage insulation and flashover tests
Flexible component-independent high-voltage insulation testing

Documentation scope

Batch numbers of the individual parts
Joining forces and paths in assembly processes
Welding parameters
Camera evaluations
Test results from the HV tests
General information about the component, such as part number, production time, product variants, etc.

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