200+ ESTUN Robots Power Fully Independent Automotive Parts Welding Line

Abstract: As a global highland for the new energy vehicle industry, China's new energy vehicle production in 2025 reached 16.626 million units, accounting for approximately 74.5% of global new energy vehicle production. At the same time, China's automotive equipment manufacturing industry, with its independent technology, globally leading efficiency, and customization capabilities, has become a weather vane for global automotive equipment manufacturing.

ESTUN has joined hands with a well-known domestic intelligent vehicle brand to jointly build an intelligent manufacturing factory for automotive parts with a core process automation level of 90%. The super-large production line with more than 200 sets of ESTUN robots completed installation and commissioning within 60 days and successfully entered trial production. This is not only a major breakthrough for ESTUN industrial robots in achieving large-scale, full-process application in the high-end automotive manufacturing field, but also, with its excellent and stable performance, sets a new industry benchmark in new energy vehicle manufacturing, demonstrating the solid pace of "China's Intelligent Manufacturing" moving toward high-end and independent innovation.

In the newly commissioned intelligent factory for automotive parts, robot application scenarios are numerous and the processes are complex, including mixed processes such as spot welding, gluing, SPR, FDS, stud welding, handling, and arc welding. More than 200 ESTUN robots are deployed across the entire line, with loads ranging from 6 kg to 500 kg, meeting the production demand for parts for an annual capacity of 300,000 vehicles.

Spot Welding Application

SPOT WELDING APPLICATION

ESTUN's heavy-load series industrial robots used in the spot welding process have obtained a 120,000-hour MTBF (Mean Time Between Failures) certification, reaching the industry's top level in terms of stability, reliability, and durability. At the same time, the robot has a repeat positioning accuracy of ±0.06 mm, and with the deep integration of high-speed servo welding guns and the robot control system, it significantly improves the work cycle and production efficiency. Its dedicated spot welding process software package integrates rich process data and a convenient human-machine interface, shortening commissioning time from days to hours, and enabling minute-level changeover, greatly simplifying the commissioning process and achieving rapid deployment.

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Spot Welding Application

SPR & FDS Application

SPR & FDS APPLICATION

With excellent structural rigidity and precise motion control capabilities, ESTUN robots successfully adapt to the process requirements of SPR (Self-Pierce Riveting) and FDS (Flow Drill Screw), and can withstand a recoil force of 4000 N, ensuring efficient, reliable, and high-quality connections when joining various types of lightweight materials such as aluminum, fully meeting the stringent requirements of lightweight body manufacturing.

SPR (Self-Pierce Riveting)

FDS (Flow Drill Screw)

Arc Welding, Handling, and Dispensing

ARC WELDING, HANDLING, AND DISPENSING

ESTUN's dedicated arc welding robots ensure stable and reliable welding quality in narrow spaces with extremely high trajectory accuracy and vibration suppression capabilities; ESTUN handling robots, relying on excellent load capacity (3-1200 kg), outstanding motion performance, and rich peripheral interfaces, complete the transfer and assembly of large sheet metal parts and assemblies at high speed and with high precision; in the dispensing process, ESTUN robots complete uniform, break-free dispensing tasks with ±0.1 mm trajectory accuracy. The three major processes work together to jointly support the efficient and high-quality output of the production line.

Arc Welding, Handling, and Dispensing Applications

As the domestic automation brand with the most complete range of robot categories, ESTUN not only provides industrial robots that meet various automotive welding line process scenarios, but also provides customers with professional and customizable product solutions based on ESTUN's independent core technology system. Through the AI digital platform (E-Noesis), it provides full-lifecycle operation and maintenance services, helping customers build digital factories and achieve stable and efficient factory operation.

The completion of the fully independent automotive parts welding line marks that in the automotive parts welding field with stringent technical requirements, ESTUN fully possesses the development capability from core equipment to fully independent intelligent solutions, powerfully validating the extreme performance and engineering resilience of domestic high-end equipment.