KUKA welding technologies for e-mobility

The FSW cells (FSW stands for Friction Stir Welding) with various technologies and KUKA KR Fortec robots are integrated into production lines for electric vehicles, where they are used in several production steps: The robots in the cells weld battery trays together and connect cooling plates to the battery trays in a second production step.

FSW technology and complex clamping technology

KUKA is also responsible for the entire friction stir welding process. This is an important task, as battery trays play a crucial role in electric vehicles. They must be leak-proof and resilient, support the correct temperature of the batteries and help to prevent the battery from endangering the vehicle occupants in the event of an accident. A particular challenge in production is 3D welding, for which robot-based FSW technology is particularly suitable. This also requires complex clamping technology, for which KUKA was able to contribute its engineering expertise. A tool changer and a cleaning station for the FSW tools are also used for fully automatic operation.

In addition to the technical solution, the customer was impressed by KUKA's comprehensive expertise and many years of experience in the various areas, from process technology and engineering to good cooperation with the sales experts, according to the company.

Friction stir welding and FSW welding: Suitable methods for difficult-to-weld or dissimilar materials

In friction stir welding or FSW welding, a rotating, pin-like tool is guided between the contact surfaces of the component. The frictional heat causes the material to plasticize and the parts are joined together. Even difficult-to-weld or dissimilar materials such as aluminum can be welded to magnesium, copper or steel. This process consumes less energy and material and does not require shielding gas or flux cored wire as in conventional processes.

FSW welding is used in a wide variety of industries that have special requirements for weld seams, be it battery containers, side walls of high-speed trains or tank structures of rockets. In addition to the growth market of e-mobility, the technology is therefore also used in the aviation and electrical industries, for example.