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.