Automated Assembly Line for EV Coolant Circulation Pump

The customer required a fully automated assembly line for a coolant circulation pump used in EV battery cooling systems. The specification combined a demanding 8.5-second cycle time with high quality requirements, full process transparency, and integration with higher-level digital systems.

One of the key challenges was the handling of electronics, including PCB depalletizing, programming, and testing under strict ESD requirements. At the same time, the process had to ensure stable cooperation of eight robots across seven stations, with short and precisely coordinated process sequences.

Another important requirement was the full integration of the line with SCADA and iTAC, ensuring traceability, process visibility, and quality-related data consistency across the system.

We designed and implemented a fully automated production solution consisting of 6 automatic stations and 1 semi-automatic station, tailored to the assembly and testing requirements of the EV coolant circulation pump.

The line combined advanced robotics for assembly, handling, and depalletizing with integrated solutions for PCB programming and testing, including IPTE integration. The process architecture was designed to maintain stable cycle performance while ensuring safe and repeatable handling of electronic components.

The solution also included a full package of functional and process-related operations, such as:

• leakage testing,
• flow testing,
• vibration testing,
• press-fit processes,
• bonding,
• welding.

To support quality assurance and process compliance, the line was equipped with dedicated SPC / NIO / rework modes and full traceability.

The implemented solution was designed to validate not only throughput, but also process stability and quality performance under demanding production conditions.

Key technical aspects of the line included:

• stable cooperation of 8 robots across the process,
• execution of short process sequences within an 8.5-second cycle time,
• safe handling and testing of PCB electronics under strict ESD conditions,
• integration with SCADA and iTAC for process transparency and digital control,
• full functional verification through leakage, flow, and vibration tests,
• dedicated quality-supporting modes for SPC, NIO, and rework,
• complete traceability for process monitoring and compliance.

The line achieved the required performance targets while maintaining high process stability and quality.

Key outcomes included:

• achievement of 95% OEE,
• stable operation at the required 8.5-second cycle time,
• fulfillment of the specified quality requirements,
• high repeatability of automated assembly and testing,
• full quality control through integrated leakage, flow, and vibration testing,
• complete ESD safety for PCB electronics,
• high process transparency supported by SCADA / iTAC integration and traceability.

This project demonstrated the value of combining robotics, electronics handling, testing, and digital integration within one coordinated production concept.

For the customer, this meant:

• a stable and repeatable assembly process for a demanding e-mobility product,
• high equipment effectiveness without compromising cycle time,
• improved process visibility and quality control,
• safer handling of sensitive electronic components,
• readiness for serial production with strong compliance and traceability requirements.

This project showed that in e-mobility manufacturing, success depends on more than automation alone.

What matters is the ability to connect robotics, electronics handling, functional testing, and digital process integration into one stable and repeatable production system. By combining these elements within a single line architecture, Nextomation delivered a solution that met demanding cycle time, quality, and transparency requirements without compromise.