The end of the combustion engine?

How automotive manufacturers are successfully responding to the growth in e-mobility

For years, the automotive industry has been experiencing a boom in e-mobility and a real paradigm shift. Away from the combustion engine and towards electric drives. In June 2023, more new electric cars were registered in the EU than diesel vehicles. While manufacturers are no longer investing in the development of new combustion engines, the production of electric vehicles (EV) is growing rapidly. Some conventional manufacturers have even announced their intention to abandon the combustion engine altogether in the near future. This development is confronting automotive manufacturers and suppliers with new challenges, which they are meeting with intelligent and flexible automation solutions from Zimmer Group.

Market challenges: small quantities, lack of experience

The rapid change in the industry is confronting manufacturers and suppliers with a number of challenges. Manufacturers of electric vehicles (EVs) are currently looking for innovative and automated solutions to make their manufacturing processes and production units simple, reliable and productive. One of the biggest challenges in battery production is the relatively small, but increasing, production batch sizes. Automation solutions and production systems must therefore be designed to be flexible, to enable rapid scalability from prototype to series production. A great deal of investment in new developments has therefore been needed, particularly in the area of battery production.

At the same time, developers and engineers are often under great time pressure. It is not uncommon for product development and automation development to take place in parallel. Some projects also require basic development, since new technologies require new approaches. This requires a high degree of flexibility in the design of an automation solution and in the way of thinking of the engineers involved.

For the automation experts at Zimmer Group, customers and their requirements vary greatly. They range from machine and plant manufacturers to robot system integrators and original equipment manufacturers. That is why every Zimmer Group customer receives intensive support from the initial enquiry and concept phase to implementation and beyond. THE KNOW-HOW FACTORY has established itself as an important development partner for well-known automotive manufacturers thanks to its expertise and in-house production depth.

Automation specialist Zimmer Group: developments in the market have been noticeable for several years

The shift towards electric drives was already clearly noticeable for Zimmer Group in 2014. As an automation specialist, the self-confessed KNOW-HOW FACTORY has developed a broad portfolio in the development and production of handling technology and system solutions for the automotive industry over many years. Cylinder heads, engine blocks, crankshafts – the Zimmer Group supports the entire powertrain value chain with everything from individual components to complete systems.

To actively support the technological shift from the combustion engine to electric mobility, the company is drawing on its more than 30 years of experience with end-of-arm tooling (EOAT) for the assembly of drive trains and the loading of machining lines in the automotive industry. This has allowed Zimmer Group to quickly develop and implement several modular solutions for EV vehicle construction.

In doing so, the company relies on close cooperation with the customer. Zimmer Group is considered a valued research and development partner of automobile manufacturers and offers solutions for the operation of production lines, handling systems and tools for the manufacture of battery cells, battery packs and battery modules. The entire value chain of battery production, from cell production to assembly and handling of the housing, can be mapped with automation solutions. In addition, Zimmer Group offers specific solutions for rotors, stators, contact rings, gear wheels and various other parts along the value chain.

Special handling, industry standards and customized systems from a single source

Individual components, special handling, industry standards and individual requirements – with its broad portfolio, Zimmer Group can fulfill almost any customer request in the field of e-mobility. In doing so, it draws not only on the knowledge and technologies acquired over decades as a solution provider in the field of mobility. The Zimmer Group's existing close cooperation with the automotive industry has also provided rapid access to developments in e-mobility and the resulting new technologies.

Close communication and trusting collaboration between automobile manufacturers, plant manufacturers and gripper manufacturers are crucial for the successful implementation of customized solutions. The collaboration does not end with delivery of the finished system: The global positioning of the Zimmer Group, with 125 sales offices worldwide and a strong partner network, enables the KNOW-HOW FACTORY to offer comprehensive customer service on site and to advance automation in companies internationally.

In order to meet individual customer requirements and to be able to react quickly, Zimmer Group has developed a high level of vertical integration. In the field of system technology alone, the group has its own machine park with around 10 machining centers. A further 300 machines are available in other departments of the company, which can be accessed at peak times. Added to this is the expertise in special processes such as 3D printing, plastics processing and metal injection molding (MIM), which can also be implemented in the Zimmer Group.

In addition to the expertise in-house, the group has a strong partner network that enables fast and effective machining, sheet metal processing and welding technology. This allows Zimmer Group to offer a broad spectrum of services and to fully meet the requirements of its customers.

Prepared for the future

Just a few years ago, 90 percent of Zimmer Group Systemtechnik's customers were in the automotive industry. Thanks to decades of close cooperation with automobile manufacturers, the end of the combustion engine was foreseeable for Zimmer Group at an early stage. Now, standardization of the automation solutions is in demand. This is already in place for the production of combustion engines due to many years of experience. And the e-mobility portfolio is also growing: Since 2014, Zimmer Group has built up a pool of scalable system solutions. System solutions are developed and delivered faster and at a lower cost. The KNOW-HOW FACTORY, with its in-house developments, high level of vertical integration and strong network of automotive and partner companies, is committed to advancing the automation of processes in e-mobility.