Dürr Equips Volvo Cars’ First Electric Vehicle Facility

Dürr is delivering turnkey final assembly systems to equip Volvo Cars’ first dedicated all-electric vehicle plant in Košice, Slovakia, which is scheduled to begin production in 2027 with an annual capacity of up to 250,000 cars. The project integrates automated conveyor, fluid filling, and end-of-line testing equipment to support the vehicle manufacturer's expansion into fully electric production.

Integrated Turnkey Assembly Architecture
Implementation is executed under Dürr’s NEXT.assembly concept, a modular framework consolidating planning, consulting services, conveyor transport, filling systems, and testing technology into a coordinated installation. The arrangement provides single-source coordination to maintain planning reliability throughout final vehicle assembly stages.

Adaptive Fluid Filling Systems
Fluid dispensing technology at the Košice facility builds on installations operated at other manufacturing locations, such as the five-console filling line at Volvo Cars' Torslanda facility in Sweden. The Slovakian installation incorporates handling systems configured for future manufacturing requirements, including capabilities to meter low-conductivity coolants for electric drivetrains and next-generation air conditioning refrigerants aligned with upcoming European regulations.

End-of-Line Optical Testing and Wheel Alignment
Chassis alignment and geometric measurement will be managed by the x-wheel test stand, utilizing the non-contact x-3Dsurface sensor to execute area-based dimensional measurements across variable tire and body geometries. Data from the vehicle driving axis calculated during wheel alignment dictates the calibration parameters for the forward illumination systems.

To address multi-LED headlamp architectures, Dürr is installing the x-light measuring and setting system. This camera-based setup inspects low-beam, high-beam, and fog-lamp configurations, performing semi-automated adjustments to meet ECE and SAE photometric standards.




Conveyor Logistics and Plant Transport
Material movement between assembly workstations will be handled by more than three kilometers of conveying infrastructure. The transport layout combines electric monorail systems, skillet lifting platforms, and modular chain conveyor lines engineered to transfer car bodies and door subassemblies through sequential stations.

Additional Context
This section details technical specifications not included in the original news release.

End-of-line chassis measurement stands in modern automotive manufacturing utilize optical 3D area sensors rather than rim-clamped mechanical targets, enabling wheel toe and camber angle evaluations with repeatability tolerances typically within ±1 to ±2 arcminutes without vehicle contact. Camera-based optical gantry systems assessing automotive matrix LED lighting calculate horizontal cut-off gradients and luminous intensity distributions via integrated digital projection sensors, achieving angular measurement resolutions below 0.01 degrees across varying ride heights. In electric vehicle fluid servicing, low-conductivity thermal management fluids require closed-loop vacuum evacuation and pressure filling processes to eliminate trapped air pockets in high-voltage battery enclosures, frequently operating under evacuation vacuums down to 1 to 5 mbar absolute prior to fluid introduction to prevent dielectric breakdown or localized hot spots.

Edited by Romila DSilva, Induportals Editor, with AI assistance.