Case study: Efficient and reliable bonding of battery covers for electric vehicles

The company Teijin Automotive Technologies Czech s.r.o. is part of a global leader in innovative materials and technologies for the automotive industry. By combining the most modern design with traditional craftsmanship, it creates components that ensure the safety and environmental friendliness of vehicles. When producing battery covers for electric vehicles, they faced the challenge of finding a reliable bonding technology that would meet high demands for quality and efficiency.

The challenge

The company had used industrial gluing in the past. However, the original technology could not ensure reliable adhesive application on complex three-dimensional parts. CTO Lukáš Mildorf explains: "We needed a solution that would allow us to maintain the high standards of our products. The previous supplier was unable to meet our expectations, particularly in terms of service availability."

Cooperation with JHV – SOLUTIONS s.r.o.

JHV was selected as the backbone supplier of the new modern production line. JHV specialises in the design and manufacture of automated production lines for industrial applications. It has extensive experience in technology integration and provides innovative solutions tailored to clients' needs.

Petr Jakube, JHV project manager, adds: "Our goal is to provide reliable and efficient production systems that help our clients increase their competitiveness. In the project for Teijin Automotive Technologies Czech s.r.o., we focused on selecting advanced bonding technology that would meet their demanding requirements for quality and flexibility."

Involvement of Kaletech

JHV identified the need for advanced bonding technology and recommended Kaletech, which specialises in this area. Tomáš Langer, project manager at Kaletech, recalls: "We were approached with the challenge of supplying bonding technology for a new, highly automated production line. We knew that thanks to our experience and Robatech technology, we could offer a solution that would exceed expectations."

Design and implementation of the solution

Kaletech proposed the use of Swiss Robatech MultiMelt technology with gear pumps and spray multi-module heads with Aero modules. Two bonding workstations were installed on the production line:

• First workstation: Hot melt PUR adhesive is applied to the inner side of the aluminium pressing. In the past, this application was carried out with 5 nozzles. As part of the optimisation, Kaletech proposed a solution with 6 nozzles, which shortened the total application time, carried out by a KUKA industrial robot. Thanks to individual control of the modules, the robot can precisely apply adhesive to the required areas of the part, while the heads automatically skip areas where application is undesirable with high precision.

Petr Jakube adds: "The ability to switch off individual modules in real time allowed us to achieve high application accuracy even on complex three-dimensional surfaces. The previous supplier could not provide this level of flexibility."

• Second workstation: Application of a spray adhesive to bond boards that increase the resistance of the battery cover to burn-through. Again, the Aero head with individually controlled nozzles was used, ensuring consistent and accurate adhesive application even when the part parameters change.

The adhesive supply for both workstations is provided by one large drum unloader, which melts it and feeds it via heated hoses into the Robatech MultiMelt units.

Tomáš Langer further describes the significance of this technology: "Thanks to the technology's capabilities and appropriate pressure setting, we were able to solve the requirement for the line to be universal for two product sizes. As part of standardisation, we managed to find a solution with a single type of nozzle, which significantly simplifies maintenance of the production station."

Testing and optimisation

So that Teijin Automotive Technologies Czech s.r.o. could optimise production parameters and materials even before live deployment, Kaletech provided the MultiMelt device with the Aero head through its Rental programme. Maintenance manager Miloš Hrabák appreciated this approach: "The ability to produce prototype parts before installing the line allowed us to fine-tune all the details and ensure a smooth production start. The quality of service and support from Kaletech was and is excellent."

Results and benefits

The implementation of the new technology brought a number of benefits for Teijin Automotive Technologies Czech s.r.o.:

• Guaranteed production quality: Precise adhesive application without overlaps or gaps improved the quality of the final products.
• Efficiency: Fast application of larger amounts of adhesive without the need to change nozzle types made it possible to achieve the same production times on both products.
• Reliability: Thanks to thorough training, tailor-made maintenance manuals in Czech and a schedule of regular maintenance of key components, Robatech technology works perfectly. The technology has been working flawlessly for almost a year, with no unexpected outages.
• Reliable service: If needed, immediate expert help from a professional technician is always available at Kaletech.

Lukáš Mildorf summarises: "Cooperation with JHV and Kaletech allowed us to achieve a high level of quality and efficiency. We are satisfied not only with the technology, but also with the support and service, which is key in our field."

Continuing the cooperation

Satisfaction with the results led Teijin Automotive Technologies Czech s.r.o. to decide to use the services of JHV and Kaletech also for the construction of a third, even more complex line. Tomáš Langer of Kaletech adds: "It is a great pleasure for us to continue the cooperation. Together we can bring innovative solutions that deliver the highest possible value and quality to end customers."