The production of the electric drive is realized according to the concept of modular assembly. These are manufacturing systems, robots as well as torqueing, joining and measuring stations on fixed positions, i.e. not coupled to a linear conveyor. The drives are produced modularly in “manufacturing isles”. Despite of a pre-defined assembly sequence, the modular arrangement allows branched paths and more scope in the production process. The component transport to the workstations is realized by driverless transport vehicles (FTF), controlled by an intelligent IT system. The asynchronous motors produced are used in the front and the rear axle of the Audi e-tron. The modular assembly concept emphasizes the claim „Vorsprung durch Technik“ (advantage through technology).
As the classic engine assembly system, the E-engine assembly system is a customized special purpose system for the automated assembly. Application range is the complete assembly of the E-axle, starting with the stator in the housing and up to the final assembly of the flanged shafts. The complete assembly is realized in monitored and documented quality, with usual component weights of up to 250 kg. Higher weights are possible, specific for the application.
Customized assembly system for E-engine assembly
– Base rack in welded construction
– (Typical) component weights: max. 250 kg or specific for the application
– Integration of manual workplaces possible
– Customer-specific interface for connection to a master computer, data filing
The E-engine block is placed into a part-dedicated support on a component carrier and fed to the process stations by a driverless transport vehicle (FTF) or a linking system. Depending on the respective case, several process stations are combined in a cell on a common machine rack. A flexible design of the systems for changing products or product variants is possible. For handling of parts to be joined, also robots can be used. Important joining processes are screwing operations by single or multiple torqueing units with force-path monitoring and documentation or insertion. The assembly steps may include the application of sealants or the dosing of lubricants etc. Possible test steps are e.g. presence and assembly controls, integrated leak tests, flow tests for oil or cooling water circuit as well as electro-mechanical function tests. Manual assembly places which are designed foolproof can be integrated in the assembly system and these are monitored e.g. by identification systems and automated assembly controls.
The assembly systems for E-engines are developed and supplied as customized turnkey solution by KIENER. The systems are realized as far as possible with modular components from our own manufacture in the requested automation degree. A flexible design for changing products or product variants is possible. Typically, the systems are based on a component carrier transfer system with free circulation and are mounted on solid, welded base racks.