Car production of the future
The automotive industry is undergoing a paradigm shift towards sustainable mobility due to the increasing electrification of vehicle powertrains. Flexible production lines and multi-model production systems enable parallel production of combustion engine, hybrid and electric vehicles. Automation and digitalization are key drivers of innovation and efficiency. High cost pressures, complex manufacturing requirements and the use of AI in autonomous, connected production pose challenges for manufacturers, as do increasing cybersecurity requirements.
B&R offers future-proof solutions with modular automation. Plug & Produce enables fast and flexible system configuration through standardized interfaces such as OPC UA. Networked machines and sensors ensure real-time monitoring and control through IoT integration. Software-based approaches ensure that production remains scalable and flexible. B&R controllers guarantee the highest level of IT security, and OPC UA FX provides protection at the field level with integrated encryption – a decisive advantage in digitally networked production.
Energy storage
Energy storage – whether in the form of batteries or hydrogen – is essential for electric transport. B&R has proven expertise in battery production, where precise cell handling and short cycle times are essential. The same is true for fuel cells. Precision and speed are particularly important in the production of bipolar plates. Automated quality control ensures the highest level of safety and durability.
Electric motor
Manufacturing precision is a key factor in determining the performance, efficiency and service life of electric motors. With precise drive technology and minimal cycle times, B&R is setting new standards in bending, winding and assembly processes. Adaptive machine concepts reduce setup times and downtime while maximizing productivity.
Inspection & testing systems
Test and validation systems play a central role in ensuring the quality of today's vehicle components. They provide seamless, real-time data acquisition for analysis and optimization. By seamlessly integrating them into the production line and using advanced simulation and test technologies, B&R accelerates time-to-market and ensures the highest product quality.
Modular, precise and digital – The future of automotive manufacturing
Industrial PCs and panels
The PCs and displays systems used to guide workers in automotive manufacturing need to be rugged, reliable and ergonomic, yet intuitive and fast to use. They must be easy to integrate into existing systems and meet safety and energy efficiency requirements. B&R PCs and panels are the ideal choice for automotive manufacturing, where flexibility, durability and high performance are critical.
Transport system for component assembly
B&R offers customized solutions for the production of batteries, fuel cells and power electronics. We increase productivity with flexible product movements, higher speeds and up to 50% shorter throughput times. Real-time synchronization with external devices ensures the highest precision and quality. With minimal changeover times, modular adaptability and ergonomic design, our systems offer maximum flexibility and ease of use. Our mechatronic systems are low-maintenance, quiet and guarantee maximum availability, even in 24/7 operation.
Open communication
OPC UA is an open, vendor-independent communication protocol that enables secure, cross-platform data transfer between disparate systems. The OPC UA FX extension enables real-time communication and deterministic control for time-critical processes such as robotics and assembly automation. The scalable architecture makes it easy to expand and integrate new devices. With plug-and-play integration and centralized management, OPC UA streamlines the commissioning, maintenance and operation of your systems.
Machine-Centric Robotics
Robots are an indispensable part of automotive manufacturing, providing high precision, flexibility and productivity. Machine-Centric Robotics integrates robotics and machine control in a unified architecture to achieve complete synchronization of all automation components. This results in increased productivity, especially for small parts and short cycle times, while reducing overall costs by eliminating redundant hardware components.
Energy and resource efficiency
B&R offers regenerative drives and energy monitoring solutions to reduce energy consumption and optimize the use of resources throughout the production chain. Based on the ISO 50001 standard, B&R helps companies implement globally recognized energy efficiency standards. Energy measurement and monitoring at the machine and production level, the use of regenerative drive systems and the replacement of pneumatic components can significantly reduce energy consumption.
Edge controller
B&R enables the comprehensive collection of process data and transforms it into valuable information for precise analysis and adjustment of machine performance in real time. The result is improved resource utilization, higher plant efficiency and lower operating costs. AI-powered analytics and continuous data collection can detect machine anomalies early and prevent unplanned downtime. Seamless integration with open standards such as OPC UA and TSN and scalable edge computing solutions provide flexibility for existing and new equipment while optimizing maintenance strategies.
References & Success Stories
Smart connections for less CO2 – Efficient joining technology
EJOT has developed an innovative technology for the precise joining of lightweight materials in car body construction: EJOWELD. It enables the fast and precise joining of aluminum, carbon fiber reinforced composites and high strength steels. Thanks to highly dynamic control technology and flexible automation, the system guarantees the highest quality and promotes the environmentally friendly use of lightweight materials in automotive production.
Ahead of the curve – Hairpins for electric motors
With the BM-HP 3000 servo-controlled production system, Bihler is revolutionizing the production of hairpins for electric motors. Thanks to innovative automation technology and fast variant changeover, the machine produces up to 120 hairpins per minute. The use of B&R technology enables high cycle rates, flexibility and efficiency – ideal for the mass production of components for electric mobility.
Workpiece transfer system creates innovation – Piston assembly with SuperTrak
Harrandt, a manufacturer of special-purpose machines, is revolutionizing piston assembly with a new workpiece transport system based on B&R's SuperTrak transport system. The new assembly line makes it possible to process 65 different types of pistons with changeover times of only 20 to 30 minutes. This flexibility and small footprint allow manufacturers to benefit from the higher production speeds and easy system expansion.
Additional contact options for B&R: Local value provider
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Take advantage of our global network for end customers.
In addition to more than 200 B&R subsidiaries in over 70 countries around the world, we have a global network of value providers. B&R value providers work seamlessly with B&R to bring our products and services to your location. They combine in-depth knowledge of B&R technology with a deep understanding of your local market.