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The preparation of existing factories for the production of electric vehicles require a comprehensive modernization. The same thing happened with the Volkswagen plant in Zwickau (Germany). High efficiency is provided by technologies such as a new direct bolt-on system for securing the battery, a modified filling system for various antifreeze and a transport technology adapted to the geometry of the chassis of the electric vehicle platform.
For the flexible production of large vehicles, Dürr has
developed a new automatic window gluing solution for Volkswagen, which, for the first time, allows side windows to be installed using the Line Follower
process.
In terms of final assembly, the systemic shift towards
electric mobility implies huge structural changes. The refurbishment of the
Volkswagen workshop in Zwickau shows how far they have come. Since June 2020,
only electric vehicles have left this production line, and this number will
increase to 330,000 units per year in the future. Dürr has responded to the new
challenges in final assembly with the NEXT.assembly strategy for the final
assembly business. He gathers experience in all areas, from planning and
consulting to conveying, gluing, assembly, and filling systems, to final test
stations and the right digital solutions for final assembly. This allows
manufacturers to select individual components from a modular system or a global
solution optimized for their electrical attacks. The Volkswagen Zwickau example
shows how the Dürr product range is tailored to customer needs.
Window insertion: highly automated and flexible
The Modular Electrification Toolkit (MEB) Glazing Center has
undergone significant automation during the modernization of the plant. In the
future, everything will be fully automatic: feeding large windows of sequential
shipping containers and side windows of certain shipping containers through the
logistics module, applying glue and installing large windows in a loop. work
and side windows in stream mode. The automatic installation of side windows was
previously possible only in the "Stop-and-Go" mode. The Line Tracking
process, developed in close collaboration with Volkswagen, changes this situation
by forcing bodies to move across pallets while robots glue side windows. One of
the advantages is a significant cost reduction, since it is no longer necessary
to adapt the transport system to the duty cycle. In addition, the location can
be flexibly selected, since the side window gluing system can be integrated at
any point on the assembly line.
Filling technology: large in options, small in occupied area
To control the microclimate, the ID.3 uses a variety of
Zwickau antifreezes. One option for Volkswagen is to use R744 antifreeze for
the first time, as its thermodynamic properties allow it to be used for cooling
and heating purposes. The energy saved in this way increases the range of
electric vehicles. The change in production requires a new technological
approach also to the filling technology. The aim of the retrofit was to fill
the vehicles with R744 in the same cycle time as the antifreeze that was
previously used. This required upgrading the filling technology from the base
unit to adapters for the new generation of G4 Blue adapters. By modifying the
road consoles, it was possible to integrate new components for the R744.
Transport system: compatible and functional
The pilot plant in Zwickau has a 256 meter overhead conveyor
section. Previously, 22 C-hooks with scissor lifts were used to transport
vehicle bodies. They are incompatible with the chassis geometry of the MEB
platform, especially due to the high voltage battery. Therefore, Dürr has
replaced 22 pairs of C-hook arms with 4-arm hooks on the subframe of a scissor
lift for transporting vehicle bodies. Since this meant that the wheeled bodies
could no longer be transported on a hook, a suitable lifting platform was
included for the wheel mounting and handling operation.
At Zwickau, the individual components of the NEXT.assembly
modular system are combined into a final assembly system in which all processes
and technologies are optimally suited for the e-mobility era.