Case Study: EV Battery Pack Housing Coating Line
Summary
A robotic powder coating line for a manufacturer of EV battery pack housings in Thailand that supplies Asian and European EV brands, coating housings up to 1,800 × 1,500 × 400 mm at 1,000–1,200 sets per day. Four ABB spray robots with 2-axis manipulators apply insulating epoxy powder at 80–120 μm with insulation resistance above 1,000 MΩ and a 180 °C continuous temperature rating, and four handling robots load and unload. First-pass film rate is 99.8% with full MES traceability per part. Figures as reported after commissioning in 2024.
Project Background
The client manufactures EV battery pack housings (PACK shells) for major Asian and European EV brands. Their new factory in Thailand needed an automatic coating line with 300,000 sets/year capacity.
The Challenge
Battery pack housings are large (max 1.8×1.5×0.4 m), complex in shape (multi-cavity), with special requirements on coating insulation and heat resistance (180 °C for battery thermal management).
MUSI's Solution
MUSI deployed a robotic coating solution: 4 ABB IRB52 spray robots for upper/lower surfaces + 2-axis manipulator for 360° rotation — ensuring no missed spots at edges. Coating uses insulating epoxy powder rated to 180 °C.
Equipment Configuration
| Robots | 8 ABB units (4 spray + 4 load/unload) |
|---|---|
| Workpiece | Battery pack housing, max 1,800×1,500×400 mm |
| Film thickness | 80-120 μm |
| Insulation resistance | ≥1,000 MΩ |
| Temperature rating | 180 °C continuous + 300 °C short-term |
| Daily capacity | 1,000-1,200 sets |
| Film pass rate | 99.8% |
| MES integration | Full data traceability |
Equipment used on this line
- Automatic spray coating lines — overhead chain, floor belt and robotic flexible lines
- Powder coating systems — electrostatic booths, vertical lines, quick colour change and powder recovery
Implementation
100-day implementation. Full MES integration: every part's spray parameters (robot path, film thickness, curing temperature) automatically logged for OEM quality traceability.
Results
After commissioning, the client secured volume orders from Thai EV joint ventures and Chinese EV brands' Thailand factories. Capacity ramped to 90% within 6 months, annual revenue exceeded $50 M USD. MUSI's solution was rated 'beyond expectations' by the client's technical team.
Client Feedback
"The EV industry demands speed and quality together. Delivering a fully robotic line in 100 days kept our project schedule on track perfectly."
— Project Manager, Client Side
Selection logic: why this configuration
Powder was chosen over liquid paint because an insulating epoxy powder reaches 80–120 μm in one coat with the dielectric strength the pack specification calls for, and no VOC treatment is needed in the new plant. Robots with 2-axis manipulators were preferred to reciprocators because housings have deep cavities and edges that must be covered without thin spots. MES logging was included from the start because OEM audits ask for per-part cure records.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| Spray robots | 4 × ABB with 2-axis manipulators | 360° rotation for cavity coverage |
| Handling robots | 4 × ABB load/unload | |
| Powder booth | Automatic, cyclone recovery | Insulating epoxy powder |
| Pretreatment | Spray tunnel for aluminium housings | |
| Curing oven | Gas convection oven | Cure profile logged per part |
| MES | Per-part recording of path, film and cure |
Key components
Key components are available from international brands, configurable per customer specification, so that spare parts can be sourced locally over the life of the line. Brand names below are the usual options for this type of equipment; the brands actually fitted are fixed in the contract specification.
| Component | Brands available on request |
|---|---|
| Painting robots | ABB IRB 5500, FANUC P-350iA, Yaskawa MOTOMAN MPX series, KUKA, Kawasaki |
| Automatic powder guns and powder feed | International tier-one powder spray gun brands |
| Oven and dryer gas burners | Riello RS series, Weishaupt monarch WM-G, Baltur TBG, Honeywell Maxon OVENPAK, Eclipse |
| PLC and HMI | Siemens SIMATIC S7-1500, Mitsubishi Electric MELSEC iQ-R, Schneider Electric Modicon, OMRON NX, Rockwell Automation Allen-Bradley |
| Variable-frequency drives | ABB ACS580, Siemens SINAMICS G120, Danfoss VLT, Schneider Electric Altivar, Yaskawa, Mitsubishi Electric |
| Pretreatment pumps and chemistry | Grundfos CR, KSB Etanorm, Xylem; Henkel BONDERITE, Chemetall Gardobond, PPG Zircobond, Nippon Paint |
| Dust collector filter cartridges | Donaldson Ultra-Web, Parker BHA, Camfil, MANN+HUMMEL |
| Sensors and temperature controllers | SICK, Pepperl+Fuchs, OMRON E5CC, Honeywell UDC, Yokogawa UT, ifm, KEYENCE |
Not included in the scope of supply
- Civil works, foundations and pits
- Building services up to the battery limit: power supply, gas, compressed air, water and drainage
- Local permits, emission approvals and third-party inspections
- Paint or powder supply, unless stated in the contract
Services included with every line: engineering design, manufacturing, shipping documentation, installation supervision, commissioning, operator training, warranty and spare parts.
Typical programme
The durations below are typical for equipment of this class and are given for planning; they are not the recorded schedule of this project. A complete line usually runs 90–180 days from contract to acceptance, a single unit 30–60 days.
| Stage | Typical duration | What happens |
|---|---|---|
| Site survey and workpiece review | 5–10 days | Remote review of drawings and photos, or an engineer visit |
| Layout and detail design | 15–30 days | Layout drawing, utilities list and specification sign-off |
| Manufacturing | 45–90 days | Booths, ovens, conveyor, pretreatment and controls built and pre-assembled at the works |
| Shipping | 20–45 days | Sea freight; equipment shipped in sections for on-site assembly |
| Installation | 15–40 days | MUSI supervision with the client's installation crew or MUSI crew |
| Commissioning, training and acceptance | 7–15 days | Trial runs on the client's parts, operator training, acceptance record |
Results: before and after
Figures are those published on this page; measurement party, sample size, test date and method are not on record here and are left blank rather than estimated.
| Metric | Before | After | Change | Measured by | Single / average | Samples | Test date | Method / instrument |
|---|---|---|---|---|---|---|---|---|
| First-pass film rate | — | 99.8% | — | |||||
| Capacity ramp | — | 90% within 6 months | — |
Applicability and limits
The film, insulation and rate figures apply to aluminium pack housings coated with insulating epoxy powder on a robotic line. Housings above 1,800 × 1,500 mm, steel housings, or plants that need two-colour output would change the booth and oven sizing, and the insulation value depends on the powder grade specified by the pack maker.
Results shown in this case study reflect the stated operating conditions and should not be interpreted as guaranteed performance under different feed, production, environmental, or site conditions.
After-sales and spare parts
Warranty on a MUSI coating line runs from acceptance: 12 months on the complete line excluding consumables, 36 months on critical components such as motors, drives and the PLC, and 60 months on structural parts such as steel structure, ducting and oven bodies. Failures within warranty, excluding misuse, are repaired free of charge.
Support starts remotely: the service line is staffed around the clock, a preliminary diagnosis with recommendations is given within 2 hours, and where a site visit is needed an engineer reaches any major city within 72 hours. A spare-parts inventory is held at the Changzhou headquarters with same-day shipping, and customers can keep a dedicated parts stock at MUSI for emergencies. Details are on the after-sales service page.
FAQ
Powder or liquid for EV battery pack housings? Powder for most steel and aluminium housings: one coat gives 80–120 μm with the insulation the pack needs and no VOC plant. Liquid is used when a thin decorative topcoat or a specific colour system is mandated.
What insulation resistance does the coating give? Above 1,000 MΩ on this line with insulating epoxy powder at 80–120 μm; the figure is measured on production parts as part of the MES record.
How fast is a robotic pack housing line? 1,000–1,200 sets per day on this line with four spray robots and four handling robots, ramped to 90% of capacity within six months.
Why robots rather than reciprocators? Housings have cavities, edges and mounting bosses that a straight reciprocator pass leaves thin; robots with 2-axis manipulators rotate the part and follow the geometry.
What data does the MES keep? Robot path, film thickness and curing temperature for every housing, so the client can answer an OEM traceability request part by part.
Next step: a configuration proposal for a similar line
If your parts, volumes or plant conditions are close to this project, MUSI can return a line configuration and layout proposal. To prepare it we need four things:
- Photos and dimensions of the workpieces, with weight and material
- Required output (pieces per hour or per day, and shifts)
- Number of colours and how often colour changes are needed
- Available floor space and ceiling height, with the utilities on site
Message us on WhatsApp with these details, or use the quotation form.
Provided by Lin Cong, Technical Director, MUSI Technology · Published 2026-05-02 · Updated 2026-09-30 · Last technical review: 2026-09-30
QQuestions buyers ask before ordering
quotation · price · lead time · installation · warranty
What information do you need to prepare a quotation?
Send part drawings or photos, the largest part size and weight, the material, the required output per shift, the paint or powder type and number of colours, and the available floor space, ceiling height and power or gas supply. MUSI engineers reply within 24 hours; a recommended configuration and quotation follow once your part data is complete.
How much does this equipment cost?
Budget depends on part size, throughput and the level of automation. Indicative ex-works ranges are published in our complete coating line cost guide; a configured quotation is prepared from your part data. Published indicative ex-works ranges: a complete powder coating line is roughly USD 75,000–230,000 semi-automatic, USD 200,000–600,000 for a standard automatic line and USD 600,000–2,000,000 for a high-throughput automated plant.
What is the lead time?
Standard configurations ship in 30–60 days from contract signing and down payment; custom configurations take longer. The delivery date is fixed in the contract.
Do you install and train operators overseas?
Yes. MUSI engineers carry out on-site installation and commissioning and give 3–5 days of operator and maintenance training. MUSI has delivered 800+ coating lines to customers in 36 countries.
What warranty and after-sales support are included?
12 months full-machine warranty, 36 months on critical components and up to 60 months on structural parts. International customers get 24-hour phone response and 72-hour on-site arrival; spare parts ship from the Changzhou headquarters.
Can the environmental equipment be supplied with the line?
Yes. VOC treatment (RTO, RCO, activated carbon, zeolite rotor), dust collection and paint wastewater treatment are supplied with the coating line under one contract; MUSI has equipped 50+ coating facilities whose projects all passed local environmental compliance reviews.
Get a Similar Solution
If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.