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