New robots for electromobility

The assembly of five million high-voltage connectors annually for electric and hybrid vehicles places high demands on automation. At Eberhard AG, one of the six installed TX2-60L robots from Stäubli is responsible for inserting a connector housing into the workpiece carrier. (Copyright: Stäubli Tec-Systems GmbH Robotics)

Voltjet assembly system, Nordfels, Austria: A SCARA TS2-60 in ESD version receives the round cells and inserts them in an upright position into a customer-specific battery pack. (Copyright: Stäubli Tec-Systems GmbH Robotics)

The production of nickel-containing cells must take place under extremely dry room conditions - relative humidity 0.5%, dew point -45°C. These extreme conditions place special demands on automation. Only Stäubli robots are certified for use in such demanding environments. (Copyright: Stäubli Tec-Systems GmbH Robotics)

The SCARA robots from Stäubli in ESD design (ESD = Electrostatic Discharge) are perfectly suited for precise assembly of battery packs. (Copyright: Stäubli Tec-Systems GmbH Robotics)

From June 18 to 20, 2024, a trade fair will take place in Stuttgart that couldn't be more fitting for the era of change in the automotive industry. It is the Electric & Hybrid Vehicle Tech Expo Europe. Here, e-mobility is the focus, and Stäubli emphasizes its expertise in this future market at booth A10 in Hall 10.

The phase-out of combustion engines and the accompanying transformation of the automotive industry have significant impacts on production technology as well as robotics. New processes, new markets, new requirements, and new suppliers are shaping the scene.

Stäubli already possesses extensive expertise and references for the new applications and can serve the automotive industry as a competent partner. Stäubli Robotics will showcase its dynamic four- and six-axis robots at the trade fair, which, due to their special feature profiles – cleanroom compatibility, acid resistance, resistance to moisture or extreme dryness – are perfectly suited for all possible applications related to electromobility.

With an innovative demo cell, Stäubli Robotics demonstrates the performance of its ultra-fast TS2 series of SCARA robots in stacking electrodes in battery manufacturing. Today, leading manufacturers worldwide already rely on the precise four-axis robots of the TS2 series, which are characterized by high dynamics and the shortest cycle times. These robots have also proven their worth in downstream processes as well as in assembly and inspection for some time now.

Four- and Six-Axis Robots for All Applications

Even in battery module manufacturing, where the highest demands are placed on both precision and cleanroom compatibility of robots, thousands of Stäubli robots are in use, impressing with their hygienic design.

Completely different properties are required when filling battery cells with electrolyte. This must be done at very low humidity levels of less than one percent – a requirement that disqualifies many standard robots. In contrast, all four- and six-axis robots from Stäubli are qualified and certified for these hyper-dry environments.

When it comes to assembling electronic components such as electronic units in the battery pack, controllers, AC/DC converters, and the like, an ESD-safe environment plays a crucial role. For this reason, all Stäubli kinematics are available in ESD versions. These machines also excel in reliably preventing any uncontrolled electrostatic discharge.

The wide range of special configurations available for all Stäubli robots allows the manufacturer to offer an optimal solution for almost every application in the field of e-mobility. This will be demonstrated at the trade fair in Stuttgart.