Global industrial automation leader ABB has announced the deployment of its state-of-the-art robotic painting solutions at Audi’s newly built New Energy Vehicle (NEV) production plant in Changchun, China. This project marks a significant step in Audi’s strategy to advance intelligent manufacturing while achieving sustainability goals. As Audi’s first dedicated electric vehicle production base in China, the factory showcases the automaker’s commitment to high-quality, low-emission vehicle production.

The collaboration involves a comprehensive ABB painting robot system, including the IRB 5500 six-axis painting robots, ABB’s latest high-transfer-efficiency atomizer RB1000i-S, and the Digital Painting Suite analytics platform. This integrated solution enables full automation of the painting process—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, “Sustainability and efficiency are at the core of everything we do at ABB. By combining advanced robotics with digital analytics at Audi’s Changchun plant, we help automakers improve operational efficiency while reducing energy consumption and operational costs, contributing to sustainable manufacturing.”

The Changchun plant has installed 47 ABB robots, including over 30 IRB 5500 seven-axis painting robots. Most of these units are equipped with the RB1000i-S atomizer, which increases transfer efficiency by approximately 15% and reduces paint waste by roughly 50%. The reduced overspray not only lowers paint consumption but also significantly cuts CO₂ and volatile organic compound (VOC) emissions, while extending maintenance intervals and reducing manual labor requirements.

Zhao Huan, head of the Painting Project at Audi FAW Manufacturing, stated, “Since deploying ABB’s painting robots, the quality of our paint lines has improved dramatically. Production efficiency has increased, and costs have been reduced. The basecoat line is now 100% automated, and the robots handle tasks that were previously hazardous, creating a safer and healthier work environment for our staff.”

The plant also employs ABB IRB 5350 and 6700 series robots to manage automated hood, door, and trunk pre-treatment, as well as robot-assisted cleaning, achieving full process automation. ABB’s solution is highly space-efficient, reducing floor space by around 25% compared to traditional setups. The IRB 5500 robots support both floor-mounted and wall-mounted installation, expanding operational flexibility. Additionally, the “Stop-go” mode enables interior spray operations to be completed within the same station, optimizing space utilization further.

The Digital Painting Suite provides real-time monitoring, predictive maintenance, and lifecycle management, allowing operators to proactively address issues before failures occur. The intuitive interface improves system reliability and facilitates seamless production management.

This project aligns with Audi’s global environmental strategy, the “Mission: Zero” program, which emphasizes decarbonization, water management, resource efficiency, and biodiversity. ABB’s automated painting solutions support these goals while delivering operational and economic benefits.

The automation and digitalization of the painting line also ensure consistent quality. Unlike manual painting, which is subject to operator experience and environmental factors, ABB robots precisely control spray angle, speed, and paint volume, guaranteeing uniform coatings on every vehicle and enhancing overall product competitiveness.

Looking ahead, ABB plans to continue expanding its presence in China’s automotive market, offering energy-efficient, high-performance, and sustainable automation solutions. The collaboration with Audi demonstrates ABB’s technological leadership in high-end manufacturing and provides a model for green automotive production.

In summary, ABB’s robotic painting solutions have not only enhanced paint quality and production efficiency at Audi’s Changchun NEV plant but have also enabled the company to pursue sustainability goals, combining smart manufacturing with eco-conscious operations. As the global EV market continues to grow, automation and digital technologies are poised to become key drivers of industry transformation.