EV Battery Pack Housing Coating Line
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 |
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
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.