Mercedes-Benz Trucks Mannheim plant to start production of eActros 600 components

Mannheim will produce the eActros 600’s ‘front box’ module, which is located in the space previously use to mount the combustion engine. This unit, made up of more than 1,000 individual parts, contains several control units, high-voltage components and an electric air compressor, but does not have a specific drive function. The company notes that the assembly of the unit uses a ‘layered structure, in which the individual components are built up from bottom to top this allows high number of components to be located in a very confined space.

The company carried out extensive renovation work in a building that is more than 100 years old to create the front box production line. This included coating the 5,500 sq.m floor renewing hall ventilation and lighting and rebuilding the supporting structure. The production line with a logistics zone was installed and the company notes this offers a high degree of flexibility for different quantities, product variants and subsequent generations.

The front box assembly line consists of four consecutive production sections. Each of these sections contains various assembly stations where the individual levels of the front box are completed one after the other. After each completed level, the front box passes through a quality gate, where the correct execution of the assembly process is verified before the next level is built. Once all quality gates have been successfully passed and the assembly quality has been confirmed in the so-called “End of Line Inspection” (EOL inspection), the front box is prepared for shipment to the Mercedes-Benz plant in Wörth.

Andreas Moch, Plant Manager at the Mercedes-Benz Mannheim plant says: “The front box is an assembly-intensive unit for battery-powered vehicles. After a successful prototype phase, we are now pleased to be able to move into series production. Both the frame preparation and the installation of all individual components and the testing of these units are performed by the Mercedes-Benz Mannheim plant.”

Moch continues: “Our Mercedes-Benz Mannheim plant is the competence centre for battery technology and high-voltage systems at Daimler Truck. With the start of production of the front box, we are already reaching the second milestone this year, after we opened our Battery Technology Centre in the summer.”

The front box assembly line consists of four consecutive production sections. Each of these sections contains various assembly stations, with the corresponding material zones and pre-assembly stations located to the side. Here, the individual levels of the front box are completed one after the other. After each completed level, the front box passes through a so-called quality gate, where the correct execution of the assembly process is verified before the next level is built. Once all quality gates have been successfully passed and the assembly quality has been confirmed in the so-called “End of Line Inspection” (EOL inspection), the front box is prepared for shipment to the Mercedes-Benz plant in Wörth.

The production team currently consists of 25 employees, but this number could increase to 170 in the future. The employees at the Mannheim site have been trained in a new high-voltage training centre since October of this year. It offers a practical learning environment in which participants can gain comprehensive knowledge of the latest high-voltage and battery technologies. Teaching methods used for this include virtual reality glasses and augmented reality technology.

The plants in Gaggenau and Kassel, which are part of the production and technology network for electric drive components and battery systems at Daimler Truck, will also supply key components for the eActros 600. Gaggenau will manufacture transmission components such as shafts and gears as well as housing parts. These will be delivered to the plant in Kassel, where the axle and transmission components will be fully assembled.