在电机和电池生产中，性能并非由单个组件决定，而是取决于整体的生产架构。 因此，电动动力总成制造需要稳定运行的系统，能够随着产量增长和产品型号的增加而灵活扩展。

为支持制造商向完整系统架构过渡，Festo 提供模块化的自动化解决方案和工程专业知识，帮助制造商设计高效、可扩展的电动动力总成制造生产系统。

与 Festo 专家探讨您的生产架构，评估适合您的解决方案，降低集成复杂性。

因此，自动化从基于元件件的方法转变为结构化的生产系统。

在面向电池生产和电机装配中的自动化中，工艺流程必须实现高度可重复。 必须能够精密协调类似连接、定位和紧固任务，以及高压元件的集成等流程，才能可靠实现电动汽车生产线的自动化。

自动化解决方案支持：

• 精确定位敏感元件
• 可重复的接合和装配过程
• 集成测试和下线系统，包括自动化装配电池包
• 可扩展的生产线架构，以适应不断增长的产量

目标是为可扩展的电动动力总成制造提供稳定、标准化的生产过程。

Battery cells, rotors, and power electronics are extremely sensitive to deviations in motion, force, or dynamics. Accurate positioning and controlled motion profiles are therefore key quality factors in the automation of electric powertrains and EV production lines.

Electric axis systems, intelligent drives, and combined automation concepts offer high positioning accuracy while allowing flexible adaptation to product variants. This results in production systems that combine dynamic performance and precision without adding complexity to e-mobility manufacturing systems.

The following assembly steps demonstrate that each process requires individually designed handling and tooling solutions to achieve cost- and performance-optimised production:

Six-axis robots are frequently used in electric vehicle manufacturing automation. They provide maximum freedom of movement, regardless of whether all degrees of freedom are required in the process.

A comparison with Cartesian gantry systems shows clear differences:
Because only the axes that are needed for the process are integrated, battery pack assembly automation lines can have a footprint that is up to 20% smaller and require around 50% fewer drives.

The reduced number of axes lowers complexity, energy consumption, and integration effort.
By combining electric and pneumatic automation a clearly structured hybrid motion architecture can be created that sustainably improves stability, efficiency, and line performance.

Having transparent production data is essential for cost-efficient electric powertrain manufacturing. Process parameters must be continuously gathered, analysed, and documented to reliably evaluate quality, traceability, and OEE.

Modular control platforms provide the technical basis to achieve this. They enable:

• End-to-end data acquisition along the production line
• Integration into MES and IoT infrastructures
• Real-time condition monitoring

Digital solutions and AI-supported analytics – for example with Festo AX – further continuous optimisation of performance and system availability in e-mobility manufacturing systems.

Processing high-voltage components requires consistently integrated safety architectures. Functional safety is not an add-on but should be seen as an integral part of system design from the very beginning.

Standards-compliant safety concepts reliably protect people and machines without restricting productivity. At the same time, system availability remains high, as safety functions are structurally embedded in the overall architecture.

The following example of a safety concept for battery module assembly illustrates how these requirements can be implemented in practice. Depending on the specific risk assessment and application, additional safety measures may be required and can be adapted to other production stations.