A battery tray measuring approx. 2.2 x 1.4 m is produced from 13 raw aluminium profiles. In addition to extruded profiles, the system can also process a product variant with die-cast components, enabling mixed joints between wrought aluminium alloys and cast aluminium.
The raw profiles are prepared in two loading areas, inserted into clamping fixtures by robot and moved into the welding area in shuttle operation. Three pairs of FSW spindles weld the profiles simultaneously from above and below. This allows twelve FSW seams to be completed in only four process steps, reducing takt time and minimizing weld distortion.