What Changes When the Vehicle Gets Bigger?
An SUV is a full size larger. Battery pack: 80 to 120kWh. The slat conveyor widens to 2600mm, pallet capacity increases to 4 tons. The trim section gains sunroof and roof rail stations. The chassis section’s battery lift handles 1.5 tons with 800mm stroke.
High-torque spindles range from 200 to 800Nm — SUV chassis bolts see much higher loads than sedan equivalents. A high-capacity vacuum filler handles the larger coolant volume.
Large SUVs create a blind-spot problem for assembly workers in the final section. Side step and power liftgate stations are equipped with surround-view cameras. Operators see their surroundings on a display, reducing installation errors and scratches.
The pallet is reinforced to prevent large-body deformation during transport. The battery marriage section uses dual synchronized lifts. If deviation between the two lifts exceeds 1mm, the system stops.
Cycle time: 60 to 90 seconds, comparable to a sedan line. Building a dedicated SUV line only makes sense if single-model monthly sales exceed 10,000 units. Otherwise, using flexible pallets for mixed production on a sedan line is more economical.
Technical Specifications
Applicable Models: BEV SUVs and MPVs with 80–120kWh battery packs; full-size vehicles requiring wider conveyors and higher capacity tooling; suitable for single-model monthly sales exceeding 10,000 units for dedicated line justification.
Line Layout: Extended slat conveyor (2,600mm width, 4-ton capacity); trim section with additional sunroof and roof rail stations; chassis section with dual synchronized battery lifts (800mm stroke, 1.5-ton capacity); final assembly with surround-view cameras for blind-spot stations.
Core Equipment: Dual synchronized battery lifts (±1mm deviation tolerance — automatic stop at >1mm deviation); high-torque servo spindles (200–800Nm range); high-capacity vacuum coolant filler; surround-view camera system at side step and power liftgate stations for blind-spot elimination; reinforced pallets preventing large-body deformation during transport.
Key Technical Features: Dual synchronized lifts ensure battery pack alignment within 1mm — deviation beyond 1mm triggers automatic stop. Large body creates blind spots for final section operators — surround-view cameras at side step and power liftgate stations reduce installation errors and scratches. Reinforced pallet prevents large-body deformation during transport. Battery marriage section uses independent lift control with real-time synchronization monitoring.
Production Metrics: Cycle time 60–90 seconds per unit (comparable to sedan line); dual lift sync tolerance ±1mm; spindle torque range 200–800Nm; dedicated SUV line only economical when single-model monthly sales exceed 10,000 units; mixed production on flexible pallets recommended below this threshold.
