EV Manufacturing
Drive Unit and Inverter Assembly Lines



Inverter Assembly Line Features:
- (20) Fastening Robots
- (2) Robotic Inspection Stations
- (4) Robotic Soldering Stations w/ AOI Inspection
- (1) Material Handling Gantry
- (2) End of Line Testing Material Handling Robots
- (2) Rejection Spurs
- (42) Automatic and Manual Work Stations
- Each conveyor is individually motorized and contains RFID readers and lift & locate systems for pallet positioning
- Each Pallet contains RFID tags and bushings for accurate locating
- ESD rated conveyor, pallets, and process
Drive Unit Assembly Line Features:
- 115 Total Stations
- 3 Robots
- 2 Assists
- 101 Total Conveyor Stations
- Each conveyor is individually motorized and contains RFID readers
- Lift & Locate systems for pallet positioning in auto stations
- Each pallet contains RFID tags and bushings for accurate locating
- 50% of buffer stations are populated with pallets for optimal buffering
- Station Quantities:
- M01 Gear Assembly: 14 Stations & 1 Assist
- M02 Gear Assembly Line: 12 Stations & 1 Assist
- Shield Assembly: 34 Stations
- Shield Marriage: 3 Stations & 1 Robot
- Assembly Conveyor: 29 Stations
- End of Line Cell: 20 Stations & 2 Robots


EV Battery Marriage and Auto Secure

Features:
- rpGatta's custom designed electric vehicle battery installation system is capable of semi-automatically lifting and fastening the heaviest modern batteries:
- System automatically conveys battery on a pallet into in lifting fixture and centers the battery
- An operator places bolts into the electric torque tools
- The heavy duty electric motor driven lift raises the battery to the under side of the vehicle and locates the battery and fasteners automatically
- Torque specifications are verified and sent to quality database on plant network
- Our decades of automated fastening experience yields robust and highly reliable fastening systems
- PLC Controls, HMI, and Safety Programmable Laser Scanners ensure maximum safety and equipment uptime
HEV Battery Assist

Features:
- Overhead rail system with carriage to track along with the vehicle
- Assist device mounted off of a vertical torque tube manipulates the high voltage battery pack from the rack to install onto the vehicle
End of Line Test Systems




Gearbox Assembly Line Presses

Features:
- The conveyor transfers pallets from station to station
- Manual stations in between press stations where operators can load parts
- Each of the (8) custom servo presses installs a different part




Pinion Press


Features:
- Utilizes 2 FEC servo presses to press fit each pinion gear on two A-Shield motor shafts
- Full press reaction force is contained within the equipment by attaching to the A-Shield motor shaft tapped hole with custom spindle
- +/- 2mm of X-Y float designed into press tooling to account for pallet and part variance
- Equipment bottoms out on top surface of motor shaft to set datum for accurate press distance data

Floating Press Tooling

Features:
- Press tooling designed to retain intermediate and output outer races onto pilot
- +/- 2mm of X-Y float designed into press tooling to account for pallet and part variance
- Intermediate press tooling bottoms out on press surface and compresses to avoid interference
- Sensors added to ensure TRB’s are fully seated on press tooling
- Guarding added around front sensors to prevent operator interference
- Compressive tooling piloted by an oil embedded (self-lubricating) flanged bronze bushing and hardened shaft
- At full press the compressive tooling pilot will retract allowing tooling to not interfere when pressing the bearing into the C’Bore
- Once the ram starts to retract a spring will force the pilot back to its starting position
- The parts are offset so pilot will compress and bottom out on pressing ram before over compressing the spring



