HORSE, a global pioneer in low-emissions powertrain systems, is transforming its production process with the introduction of a highly digitalized, automated system called Matrix Flow, aimed at increasing productivity, quality, and sustainability. This innovative process is now operational at the Aveiro plant in Portugal, marking a significant shift from traditional conveyor belt systems to a more dynamic setup using Mobile Programmable Cobots (MPCs).
The Matrix Flow system utilizes autonomous platforms and workstations, specifically adapted for automotive powertrain production. This makes HORSE one of the initial adopters of such technology for constructing components like the Power Electronic Box (PEB), essential for managing electric motors in Hybrid and Plug-in Hybrid Electric Vehicles.
Antonio Vaz, Chief Process Engineering Officer at HORSE, emphasized the strategic importance of the new assembly line: “The Matrix Flow Assembly line in Aveiro signifies a major milestone for HORSE. It not only reinforces our leadership in powertrain technology but also enhances our production capabilities, allowing us to efficiently meet the growing demands for sustainable mobility.”
In collaboration with Prolynk, a project by OSE Group, the system’s MPCs deliver precise components and sub-assemblies directly to staff and robots throughout various production stages. The fleet is managed by a sophisticated controller hub that ensures seamless communication and adaptability among the cobots, enhancing flexibility and minimizing production delays.
The launch of PEB production at the Aveiro plant is imminent, with an initial annual target of 150,000 units, expected to increase to 200,000 by the end of 2024. By substituting traditional production lines with autonomous MPCs, HORSE has successfully reduced its factory floor space by 25% and overall building size by 30%, leading to a significant 50% cut in energy consumption. The digital identification of components has also eliminated the need for paper labels, contributing to more sustainable and precise manufacturing.
Matrix Flow positions HORSE at the forefront of the industry’s shift towards an electrified future. The flexibility of the system allows for rapid adjustments in production scales and the incorporation of new components or products. The Aveiro facility, designed to maintain a clean and safe environment for high-tech electric powertrain production, represents a state-of-the-art approach in manufacturing.
Investing in its workforce, HORSE provides training in the latest production technologies and techniques, including virtual reality tools, ensuring that employees are well-prepared for any operational changes.
As a company, HORSE continues to lead in the development and production of high-efficiency, low-emission powertrain solutions, with a strong global presence and a commitment to innovation and quality that drives its ongoing success.
