Fully Automated Line Enhances Electric Vehicle Component Production

HAHN Automation Group develops fullautomatic solution for busbar assembly

The HAHN Automation Group delivered a fully automated solution for a global automotive manufacturer’s production of high-voltage battery plug boards featuring integrated busbars. These components are critical to electric vehicle (EV) battery systems, demanding both precision and scalability. 

Designed for precision, scalability, and space efficiency, the system highlights HAHN’s expertise in complex automotive automation and reinforces its role as a trusted partner in the EV sector.

#Automotive #Electronics #Production #Busbars

 

  • End-to-End Automation
  • Scalability
  • Space Efficiency

 

Challenge

The customer, a global automotive manufacturer, faced challenges in producing high-voltage battery plug boards—key components in electric vehicles. A major issue was the precise insertion of busbars into the mold, as misalignment or deformation during overmolding threatened product integrity and required rework.
 

The customer also needed a fully automated solution that could handle these sensitive processes within tight spatial constraints on the facility’s second floor. The system had to support two product variants and meet strict testing standards, including electrical and sealing checks, while delivering speed, precision, and scalability.

 

Developing a Solution

To address these challenges, the HAHN Automation Group developed a fully automated production line tailored to the client’s needs. It featured a precise feeding system for busbars and bushings to ensure consistent alignment during overmolding. A two-cavity interface with a 650-ton IMM enabled dual-part production with a 50-second cycle time. 

To prevent distortion, molded parts passed through a straightening station and cooling buffer. Gaskets were assembled using highprecision systems, followed by integrated testing for high-voltage performance, component positioning, and leak integrity. A packaging module then loaded finished parts into trays and onto Euro pallets. The compact system met performance targets and offered flexibility for future scaling.

 

Process Overview

  1. Feeding and handling of busbars and bushings; in/out transfer to IMM
  2. Straightening and cooling after overmolding
  3. Gasket mounting and quality testing (HV, position, leak)
  4. Tray packaging and palletizing

Cycle time: 50 seconds for two parts

Results

The automation solution from HAHN Automation Group significantly improved efficiency and quality in highvoltage battery plug board production. With a 50-second cycle time for two parts, the system delivers 144 parts per hour. Integrated testing and precise handling ensure consistent quality with minimal manual effort.