EV battery tray welding cell — aluminum 5083, 0.2 mm flatness
Robot MIG cell for aluminum EV battery trays with vision-guided seam start and a post-weld dimensional gate.
- Client
- Confidential — EV Drivetrain
- Location
- Kentucky, USA
- Capabilities
- Robotics Integration · Process Engineering
The challenge
Customer was launching a new EV battery tray in aluminum 5083 with flatness requirement of 0.2 mm and a 120-second cycle. Manual MIG could not consistently hit dimensional spec on the thin walls.
What we built
Fronius CMT pulse welding on a Yaskawa MA2010 arm. Vision-guided seam start with a Photoneo 3D camera compensates for stamping variation. Welded tray transfers to a Zeiss handheld arm CMM gate before unload.
Key equipment
- Yaskawa MA2010
- Fronius TPS 500i CMT
- Photoneo MotionCam-3D
- Zeiss Atos Q reference
From the floor
Illustrative image — representative of project scope; customer-identifying details have been removed.
Results
Cell holds 0.2 mm flatness across 50-tray verification batches at 118 s average cycle. Program is in serial production.
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