In the Audi e-tron GT, for example, you can find pillar trims that are manufactured with the smart AKE edge folding technology. We also supply assembly and testing lines for so-called module connectors and busbars as well as production lines for the battery management system of the new e-tron. In addition to the current-carrying components, intelligent modules for monitoring and managing the battery are included here.
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Close Look - the system technology in detail
The AKE “Verinno” press system for edge folding of pillar trims
High-quality workmanship is particularly important in the interior - the look and feel of the components are decisive for the driver's perception of quality. AKE supplies the “Verinno” edge folding system for processing the pillar trims from the vehicle interior of the Audi electric sports car.
With the press system and the associated quick-change tools, the pillar linings are folded over 100% without reworking. AKE offers the technology for processing fabric and Alcantara.
Assembly test cells for module connectors and busbars - one system for numerous component variants
The module connectors are responsible for interconnection of the individual battery modules, they are also used as an interface to the BMCe. Welding processes, automatic assembly processes of add-on or housing parts and screw assemblies are integrated into the production cells. HV tests ensure error-free processing. Pure end-of-line testing systems are also implemented on a regular basis. For the Audi e-tron, AKE technologies supplied several assembly testing cells for manufacturing and testing the integrated module connectors.
Variant-independent feeds with flex feeders or belt systems with camera recognition enable the integration of numerous component variants on just one production line. Intelligent, variant-independent grippers and handling systems are installed in the test cells, which independently adapt their gripping position to the respective component variant.
Assembly line for battery management systems - the brain of the electric vehicle
The battery management system (BMS) represents the interface between the HV battery pack and the vehicle. It monitors voltage, current, balance as well as temperature and transmits information on charge and cell status to the vehicle system.
AKE technologies offers a wide variety of concepts for the production of these components. Starting with workpiece carrier lines for the manual production of BMS, through partially automated production lines to fully automatic machines, there are numerous implementation options - the use of the respective concept depends on the quantity scenarios, production location and much more.
A manual production line was built for the new e-tron. The focus is on flexibility - both in terms of component variants and when taking into account ramp-up curves or call-off numbers of a product. The U-shape concept allows the deployment of workers to be adapted to the respective requirements. In addition, several variants can be integrated into the system thanks to the set-up cart principle. This smart concept offers clear advantages in terms of flexibility and costs.