EV PTC Heater Assembly Automation with Hyundai Robotics Collaborative & Industrial Robots

Industry > AutomotiveApplication > AssemblySector > Manufacturing

#EVPTCHeater#AssemblyAutomation#HyundaiRobotics#CollaborativeRobot#IndustrialRobot#HighVoltageProcess#DefectReduction#24_7Production

Process Overview

This solution is an assembly automation system that automates hazardous EV PTC heater assembly using Hyundai Robotics collaborative robots (YL012) and industrial robots (HH7, HH020).

This project was implemented to safely automate hazardous high-voltage/high-current operations and enable 24/7 production of automotive PTC heaters.

By unmanning high-voltage/high-current processes, the solution increased productivity through 24-hour operation and reduced the defect rate.

Components

Robot	Hyundai Robotics Collaborative Robot YL012 (x4) 6-axis articulated robot Payload: 12 kg Working radius: 1,305 mm Weight: 43 kg Repeatability: ±0.1 mm Equipped with a 6-axis torque sensor Hyundai Robotics HH7 (x1) 6-axis articulated robot Payload: 7 kg Working radius: 932 mm Weight: 42 kg Repeatability: ±0.03 mm Hyundai Robotics HH020 (x1) 6-axis articulated robot Payload: 20 kg Working radius: 1,742 mm Weight: 225 kg Repeatability: ±0.06 mm
Peripherals	Robot base Pallet jig infeed/outfeed conveyor Product transfer conveyor Silicone dispensing unit Silicone curing system (separate equipment)

Robot

Hyundai Robotics Collaborative Robot YL012 (x4)
- 6-axis articulated robot
- Payload: 12 kg
- Working radius: 1,305 mm
- Weight: 43 kg
- Repeatability: ±0.1 mm
- Equipped with a 6-axis torque sensor
Hyundai Robotics HH7 (x1)
- 6-axis articulated robot
- Payload: 7 kg
- Working radius: 932 mm
- Weight: 42 kg
- Repeatability: ±0.03 mm
Hyundai Robotics HH020 (x1)
- 6-axis articulated robot
- Payload: 20 kg
- Working radius: 1,742 mm
- Weight: 225 kg
- Repeatability: ±0.06 mm

Peripherals

Robot base
Pallet jig infeed/outfeed conveyor
Product transfer conveyor
Silicone dispensing unit
Silicone curing system (separate equipment)

Workflow

STEP 1.	(1st robot) Bar material loading
STEP 2.	(1st robot) Transfer of loaded pallet jig
STEP 3.	(2nd robot) Load flexible material onto the bar
STEP 4.	(2nd robot) Transfer to infeed jig
STEP 5.	(3rd robot) Transfer bar & flexible material to silicone dispensing process
STEP 6.	(4th robot) Perform silicone dispensing on the material
STEP 7.	(5th robot) Assemble and inspect components after loading into curing equipment
STEP 8.	(6th robot) Discharge inspected products

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Features

Precise operation and maximized space utilization using compact collaborative robots
Ensures safety and improves space efficiency by using collaborative robots in areas where operators and robots share the workspace
Enables precision force/torque-controlled operations with a built-in 6-axis torque sensor
Improved productivity and quality through continuous operation
Enables 24/7 operation through unmanned core processes
Prevents misloads/mix-ups and reduces defect rate

Results

ROI Period	2 years
Key Benefits	Higher productivity through continuous operation Reduced process defect rate
Client Feedback	High-voltage/high-current operations caused frequent injuries to operators, but automation eliminated hazardous tasks and improved productivity.

EV PTC Heater Assembly Automation with Hyundai Robotics Collaborative & Industrial Robots

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Application Field: Industry > Automotive, Application > Assembly, Sector > Manufacturing

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