As the global electric vehicle (EV) industry rapidly expands, industrial automation and smart manufacturing are becoming key drivers for improving production efficiency and ensuring product quality. ABB, a leading industrial automation company, has recently deployed its advanced robotic painting solutions at Audi’s Changchun New Energy Vehicle (NEV) factory in China, marking a major step toward fully automated and intelligent EV production. This collaboration highlights ABB’s technical expertise in automotive painting and provides a replicable model for high-efficiency manufacturing.

Audi’s Changchun factory is the company’s first dedicated EV production facility in China. The plant’s painting workshop features 47 ABB robots, including IRB 5500, IRB 5350, and IRB 6700 series, integrated with ABB’s latest high-transfer-efficiency atomizer RB1000i-S and the Digital Painting Suite analytics platform. This comprehensive system enables full automation of the painting process, covering everything from cleaning and basecoat application to clearcoat spraying and surface inspection. Han Chen, ABB Group Senior Vice President and President of Robotics in China, commented, “Combining intelligent robots with digital platforms allows us to deliver complete automated painting solutions that enhance production efficiency while minimizing energy consumption and operational costs.”

Precision Spraying Enhances Product Quality

At the core of the painting workflow, IRB 5500 seven-axis robots work in tandem with the RB1000i-S atomizer to achieve high-precision coatings. The atomizer improves transfer efficiency by approximately 15% while reducing paint waste by nearly 50%. This ensures efficient use of materials, cost reduction, and reduced volatile organic compound (VOC) emissions—an environmentally sustainable approach.

Zhao Huan, head of the Painting Project at Audi FAW Manufacturing, explained, “ABB’s automated painting system enables precise coating application, significantly improving production line efficiency. Tasks that previously required multiple operators are now fully automated, reaching 100% line automation while maintaining consistent quality standards. At the same time, workers are protected from hazardous exposure, improving overall safety.”

The IRB 5350 and 6700 series robots perform automated pre-treatment operations for hoods, doors, and trunks, as well as robotic cleaning tasks, ensuring seamless workflow integration. Robots precisely control spray paths, angles, and paint volumes, achieving high-quality finishes and consistency across all vehicles.

Space Optimization and Flexible Deployment

To accommodate the compact factory layout, ABB’s system employs a “Stop-go” operation mode, allowing interior spray processes to be completed within a single station. This design reduces floor space usage by approximately 25% compared to conventional setups. The IRB 5500 robots can be floor-mounted or wall-mounted, offering greater flexibility and coverage. The compact and efficient layout not only increases production capacity but also allows for future scalability.

Digital Enablement and Predictive Maintenance

The Digital Painting Suite serves as the digital backbone of the system. The platform provides real-time monitoring, data collection, and predictive maintenance, enabling operators to address potential issues before they lead to downtime. This data-driven approach reduces maintenance costs, extends equipment life, and improves production reliability.

The platform also monitors critical parameters such as coating thickness, orange peel, and color consistency. By analyzing these metrics, management can adjust production parameters in real time, optimizing workflow and maximizing efficiency across the entire line.

Driving Green Manufacturing

Although this article emphasizes technology and efficiency, ABB’s solution also supports environmentally sustainable manufacturing. High-transfer-efficiency atomizers, precise spraying, and automated operations reduce material waste and VOC emissions. Coupled with digital monitoring and predictive maintenance, energy consumption and resource use are optimized. These measures support Audi’s “Mission: Zero” initiative, promoting decarbonization and sustainable production practices.

Summary

ABB’s robotic painting solutions at Audi’s Changchun NEV factory demonstrate the company’s strong capabilities in smart manufacturing and automotive automation. By deploying IRB 5500, 5350, and 6700 series robots equipped with the RB1000i-S atomizer and integrated with the Digital Painting Suite, the factory achieves full-process automation, space optimization, enhanced production efficiency, and environmentally friendly operations.

This project not only streamlines Audi’s EV production workflow but also provides a replicable model for the automotive industry, illustrating how automation, digitalization, and sustainability can be combined effectively. As the EV market continues to grow globally, ABB’s technology will remain a critical enabler of safe, high-efficiency, and environmentally responsible production.