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

When designing assembly systems for module connectors for electric vehicles, the issue of safety is of particular importance. Various HV and LV tests are integrated into our systems. Pure end-of-line testing systems for module connectors are also regularly implemented.

General information

• Different machine designs existing of different robot cells
• Component-independent feeding of the individual parts with flex feeders and belt systems with cameras to detect the position of the components
• Design as a test system or in combination with various manual and automatic processing steps
• Automatic change of robot grippers
• Integration of manual workstations (e.g. housing assembly)

Processes

Mechanical machining processes

• Welding of busbars
• Assembly of additional parts such as sockets and screws
• Assembly of housings
• Application of component labels

Testing processes

• Optical measurement of mounting brackets
• Optical testing of mold fillings and geometric characteristics
• Visual testing of the screwing surfaces to ensure that they are free of overmolding and damage
• Presence and variant testing of injected inserts
• Testing of screw lengths
• Testing of housing latches
• Component-specific HV insulation and breakdown tests
• Flexible component-independent HV insulation tests

Scope of documentation

• Batch numbers of the individual parts
• Mounting forces and paths in assembly processes
• Welding parameters
• Camera images and results
• Test results from the HV tests
• General information of the component such as the individual part number, production time, product variants, and much more.

Our World of Automation | Learn more about our values and about the passion for our automation solutions in the team AKE!

Learn also more about our further production lines in the field of e-mobility: