With the rapid development of the global new energy vehicle industry

the demand for power batteries has grown exponentially

and traditional production methods can no longer meet the requirements for large-scale

high-precision

and high-efficiency assembly. This paper focuses on the design and application of industrial robots in electric vehicle (EV) battery assembly

aiming to address industry bottlenecks in production capacity and quality control.First

the paper identifies the seven core processes in EV battery assembly and systematically analyzes the characteristics and application scenarios of five types of industrial robots—welding

material handling

assembly

sealing

and inspection—laying the foundation for subsequent design optimization. In terms of robot design

innovations are made from two key dimensions: end effectors and robot body parameters.End Effectors: A "servo motor + curved flexible gripper" optimizes flexible clamping

while integrated pressure

temperature

and vision sensors enable closed-loop control. Additionally

a micro-fastening spindle and glue-dispensing inspection probe are innovatively integrated to achieve "grasping-positioning-fastening-inspection" in one operation.Robot Body Parameters: Optimization focuses on motion accuracy

load capacity

dynamic response

and structural reliability. For instance

high-precision harmonic reducers and 17-bit absolute encoders improve repeatability to ±0.02 mm

modular joint designs adapt to varying load scenarios

and high-power-density motors with carbon fiber-reinforced arms enhance dynamic performance.To validate the design

two case studies are presented:(1) The X2 parallel robot achieves high-speed battery packing at 80–120 cycles per minute with a positioning accuracy of ±0.5 mm

improving efficiency by over 50% compared to manual labor

thanks to its large workspace-to-volume ratio

high dynamic performance

and specialized end effector.(2) In a KUKA robot system integration case

eight robots across three workstations perform tasks such as battery shell welding and deburring

achieving trajectory accuracy below 0.5 mm

a 95% utilization rate

and cost savings from reduced system redundancy.The paper also highlights current challenges

including insufficient flexible production capability

inconsistent precision stability

high costs

and safety risks. Accordingly

four optimization directions are proposed: enhancing flexibility

improving precision stability

reducing costs

and strengthening safety measures.The research ultimately delivers a robot design that balances precision

efficiency

and cost

effectively alleviating supply chain bottlenecks in power battery production and supporting the expansion of the new energy vehicle industry. Looking ahead

deeper integration with digital twin and AI technologies

along with the development of specialized and lightweight equipment

is expected to further advance the intelligence and cost-effectiveness of industrial robots in EV battery assembly.