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KUKA robot manufactures automotive electronics

Automated manufacturing of automative electronics

The rapidly progressing development of electronics in vehicles places increasing demands on them. With our diverse product portfolio, ESD-protected robots and in-depth expertise, we are your expert for automation. Top quality and good cost-effectiveness are guaranteed.


Automotive electronics production of the future

Perfect synergy between innovation and cost-effectiveness thanks to our specialized robotics portfolio and expert know-how

The automotive and electronics industries have more points of contact from one year to the next, with automotive electronics being the most automated sector in the electronics industry. KUKA has years of expertise in both sectors as well as the correspondingly certified robotics and software. To ensure that the high demands on the vehicle electronics components are met, such as temperature resistance, long service life and extreme robustness against vibrations and shocks, automated production is indispensable. We offer customers complete system solutions, from the concept and implementation through to maintenance.

Bundled expertise from two worlds: electronics and automotive industry

  • Global expertise

    • Many years of experience in the automotive industry, e-mobility, electronics industry and battery production
    • Global network of certified partners for expert knowledge
    • Turnkey solutions successfully implemented globally
    • Specialist expertise in many processes, including joining techniques
    Realized customer projects
  • Full service support

    • Highly qualified service technicians and programmers in your area
    • Customer-specific service throughout the product life cycle
    • Global infrastructure and local hubs for fast supply of spare parts
    • Robot training courses for every target group
    my.KUKA digital customer portal
  • Smart solutions

    • Standardized controller and programming language for various kinematic systems
    • Software motion modes for special tasks
    • Quality control of electronic components with camera systems 
    • Automation for demanding processes such as coil winding and handling of non-rigid parts
    Examples of projects
  • Extensive robot portfolio

    • Diverse kinematic systems: cobots, 6 axis robots, SCARA robots
    • ESD protection for all KUKA industrial robots
    • Cleanroom robots for particle-controlled environments
    • Certified robots for dry rooms
    • Reach and payload adaptation in the field
    Automotive electronics robotics

Technological progress for the manufacture of modern vehicles: solutions and products from KUKA

In the interactive graphic, discover the successful use of our robots and cobots in vehicle electronics in order to maximize manufacturing capacities and make production more efficient and reliable. We rely not only on high-quality machines, but also on environmentally friendly and sustainable automation solutions:

Automotive electronics Components in the vehicle
  • Thermal management system

    Extreme temperatures have a negative impact on e-mobile batteries, cause rapid discharge and shorten service life. Efficient thermal management is of decisive importance for protection. Precise production of the systems prevents failures.

    Industrial robot applications
    • Adhesive bonding
    • Plasma and cleaning process
    • Pick & place
  • Display and infotainment

    On-board electronics systems improve functional safety for humans and comfort when traveling. Manufacturers have to respond quickly to changing trends. Robots are indispensable in the manufacture of these components, as they can be retaught in a very short time and ensure the long-term success of the manufacturers.

    Industrial robot applications
    • Assembly
    • Plasma and cleaning process
    • Adhesive bonding
    • Pick & place
  • Electric motor

    The use of robots in production offers flexibility in the continuous development of electric motors. ESD-protected robots enable reliable and flexible production. With the KUKA RoboTeam software, multiple machines are used and coordinated efficiently in assembly.

    Industrial robot applications
    • Screw fastening
    • Adhesive bonding
    • Assembly
    • Marking / needle embossing
    • Handling
    • End-of-line inspection
  • Inverters

    The inverter converts direct current into alternating current for the vehicle motor and can also convert AC to DC to charge the battery. Robots manufacture the complex inverters with very short cycle times and perform quality inspection using vision systems.

    Industrial robot applications
    • Adhesive bonding
    • Plasma and cleaning process
    • Pick & place
    • End-of-line tests

    → Learn more in our case study

  • Headlights and rear lights

    Vehicle lighting must be energy-efficient and durable. Robots have been supporting production for many years and ensure that every headlight and every rear light is produced absolutely waterproof and clean. And at high speed, with precisely calculable production costs.

    Industrial robot applications
    • Adhesive bonding
    • Plasma and cleaning process
    • Screw fastening
    • Painting/coating
    • Handling of non-rigid parts
    • Insertion of connectors
    • Pick & place
    • Abrasion test
  • Supercomputers and other control units

    In vehicle technology, high performance computers (HPCs) in electric cars enable fast Internet, regular safety updates and innovative driving functions. Reliable robots that work with great precision are used to manufacture these highly complex electronic devices.

    Industrial robot applications
    • Assembly
    • Pick & place
    • Handling of non-rigid parts
    • Insertion of connectors
    • ICT test
  • On-board charger

    Since on-board chargers are becoming ever more compact and with improved interference suppression options, many companies are increasingly relying on the use of robots. These enable fast adaptation to new requirements and make it easier for people to master tasks featuring small parts.

    Industrial robot applications
    • Adhesive bonding
    • Plasma and cleaning process
    • Pick & place
  • Battery management system (BMS)

    The BMS is essential for electric cars, as it controls, monitors and detects the charge of the drive battery. It also provides thermal management and balancing of the battery cells. Robots ensure quality in BMS production.

    Industrial robot processes
    • Quality inspection
    • Assembly
    • Screw fastening
    • Adhesive bonding
    • Pick & place
  • DC/DC converters

    EVs and HEVs have two separate DC networks connected by the DC/DC converter. Our automation technology keeps things flowing in the production of DC/DC converters.

    Industrial robot processes
    • Adhesive bonding
    • Plasma and cleaning process
    • Pick & place
  • Lithium-ion battery cell

    Battery cells are the basic building block of battery systems in electric cars. Robots support the production of pouch cells by transporting and assembling them, thereby ensuring the quality of the individual battery cells.

    Industrial robot processes
    • Pick & place
    • Stacking
    • Packaging

     

    → Further information about battery cell manufacturing

    → Further information in our case study on battery pack assembly

Do you want to automate your automotive electronics production?

We will be happy to support and advise your company in the search for the right robotic component, optimized processes and the best technology for your specific automotive applications

Certified robotics for automotive electronics

Our products are modular and adaptable solutions for the entire vehicle electronics value chain. They are also suitable for handling sensitive electronic components and have particularly low maintenance requirements. Precision, repeatability and the highest safety standards are also an integral part of our product portfolio to ensure a safe working environment for humans.

 


White Paper: Opportunities through automation 

How the production of electronic components for the automotive industry is taking off

  • Preview 1
  • Preview 2
  • Preview 3

Discover how industrial robots and cobots are driving electromobility.

Download the white paper

Successful use of industrial robots in automotive electronics at OEMs and suppliers in practice

Pre-assembly of HV cables for electric cars

 Handling of non-rigid parts of high-voltage batteries 

Assembly and end-of-line testing of supercomputers

Assembly line for car headlights assembly

Wide range of application software: short start-up, high process reliability

KUKA.AppTech: Programming of KUKA robots in the application environment

KUKA.RobotSensorInterface: Interface for communication between the industrial robot and its sensor system

KUKA.Sim: Smart offline programming of robot applications in real time for maximum planning reliability and minimal costs

KUKA.PLC mxAutomation: Universal PLCopen-certified PLC interface

KUKA.SafeOperation: Safety-oriented monitoring of robot workspaces

KUKA.ForceTorqueControl: Programming of process forces and torques for a robot motion

KUKA.GripperSpotTech: Control of tools and grippers in the work environment

KUKA.VisionTech: 2D object recognition, code and OCR recognition as well as quality control

KUKA.RoboTeam: Cooperation of up to 4 machines in a team as well as synchronization of external axis kinematic systems such as workpiece positioners or robot linear axes

KUKA iiQoT: Industrial IoT platform for digitalized vehicle electronics production