KUKA cell4_FSW: Modular friction stir welding cell for e-mobility

The FSW robot cell offers a highly automated solution for friction stir welding in electric vehicle production. It has a modular design, is scalable for different production scopes and is fully Industry 4.0-compatible.

Flexible friction stir welding cell for maximum process utilization

The KUKA cell4_FSW friction stir welding cells were specially developed for the growing electromobility market and, thanks to their modular concept, offer maximum versatility and configuration options in addition to outstanding economic efficiency.

Low costs, high quality - the advantages of the FSW robot cell

Economic efficiency
Maximum versatility
- Use for 2D & 3D welding tasks thanks to 6-axis robot
- For various tasks in the field of e-mobility
Modular and flexible
Ready for Industry 4.0
- Interfaces based on OPC UA for easy data exchange
- KUKA Remote Service for quick help

FSW cells for e-vehicle production at a glance

The modular cell concept is based on the KUKA FSW application module with one or two robots (single-sided and double-sided welding) and is suitable, for example, for battery housings of electric and hybrid vehicles, power electronics housings or heat exchangers.

FSW-Cell type	KUKA cell4_FSW midsize single	KUKA cell4_FSW large dual
Dimensions (L x W x H)	5.600 mm x 4.600 mm x 3.500 mm	6.750 mm x 5.400 mm x 3.500 mm
Welding zone (L x W x H)	1.250 mm x 880 mm x 280 mm (2 pieces)	2.000 mm x 1.180 mm x 280 mm (2 pieces)
Installation area (incl. cabinets)	28,2 m²	42,8 m²
Weight (without clamping system and manipulator)	ca. 5.000 kg	ca. 8.000 kg
Cell equipment	Siemens TIA Portal series 1500, KUKA.SafeOperation, 2 roller shutters with rear step protection and light curtain, polycarbonate fence with 1 or 2 maintenance door(s) and guard locking device(s)
FSW application module	1 x FSW application module	2 x FSW application module
Robot type	KR 300 R2800-2 MT (KR FORTEC ultra)	2 x KR 300 R2800-2 MT (KR FORTEC ultra)
Robot controller	KR C5 for KSS	KR C5 for KSS
Cell operation	KUKA.HMI Advanced (23,4'' Display with IPC)	KUKA.HMI Advanced (23,4'' Display with IPC)

Find and request the right FSW solution

Technical data & seminars on friction stir welding

Your production, your choice: The FSW cell with scalable options

PCD 507 & HMI Advanced

100% process control, pin breakage detection and documentation with display on the HMI Advanced
Seam position detection

Laser-assisted detection of seam positions for automatic compensation of tolerances on the component
Clamping systems

For holding the component on the worktable (product-specific)
Tooling kit “Rotating shoulder” (pin & shoulder)

Standard tool with adjustable welding pin length for different component thicknesses
Tooling kit “Stationary shoulder” (pin & shoulder)

Tool with stationary shoulder and rotating pin (lower heat input, less burr formation)
Automatic cleaning station for tool SSFSW

Cleaning station for FSW tools - removes aluminum from the tools
Automatic tool changer SSFSW

Increased productivity thanks to fully automatic change of the FSW tool with standing shoulder
Automatic tool changer CFSW

Increased productivity thanks to fully automatic changer for classic FSW tools Automatic changeover by robot

High-precision, perfect weld seams thanks to optimum system coordination

Path accuracies of up to 0.5 mm can be achieved by:

the use of special heavy-duty robots with high rigidity and a long service life, which guarantee high repeat accuracy (KR FORTEC ultra)
precise path calibration to compensate for path deviations caused by the varying rigidity in the robot's working area and the effects of different process forces
special tooling for seam surfaces that require virtually no reworking.

Maximum control in the FSW process - for the future of e-mobility

The unique KUKA PCD 507 (Process Control and Documentation) system controls and documents all relevant process parameters during welding and has been transferred to the new intuitive KUKA.Web HMI. It thus guarantees:

100% reproducibility
100% quality monitoring in real time
100% process reliability (minimization of rejects)
100% documentation of the welding process

Process monitoring for all FSW path processes: Data export, process diagnosis and electronic archiving of all process data

Smart financing for your FSW technology

We support you in the planning phase and offer flexible financing models

Download brochure (PDF): further information and scope of delivery

KUKA_cell4_FSW_EN - pdf, 432,5 KB
KUKA_cell4_FSW_Application_Module_EN - pdf, 434,99 KB

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E-Book: Welding aluminum - solutions for e-mobility

From FSW to laser: a comparison of welding technologies

Aluminum is light, stable - and demanding in terms of welding technology. Reliable joining technologies are needed in e-mobility, for example for battery boxes. The e-book provides an overview of modern welding processes such as MIG, TIG, laser and FSW (friction stir welding) - including practical examples and tips on automated production. KUKA shows you how to bring the right technology into your production efficiently.