Martorell, Spain – September 2026 – SEAT S.A., a leading European electric vehicle (EV) manufacturer, has announced a 22% increase in battery assembly line efficiency and 75% fewer wiring-related delays after deploying the ABB SCYC55830 58063282A terminal board at its Martorell production plant. The upgrade, completed in Q3 2026, solved critical connectivity issues in the plant’s EV battery module assembly line—where legacy terminal boards struggled with high-density wiring, corrosion, and compatibility gaps, costing SEAT €290,000 annually in lost output.
The Challenge: High-Density Wiring and Corrosion in EV Production
Prior to adopting the ABB SCYC55830 58063282A, SEAT’s Martorell plant faced three core hurdles in battery assembly:
- High-Density Wiring Complexity: EV battery modules require 4x more sensor/actuator connections than traditional vehicles. Legacy terminal boards had limited terminal density, forcing messy “daisy-chain” wiring that increased short-circuit risks.
- Corrosion & Humidity Damage: Battery assembly areas have higher humidity (40–60% RH); unprotected legacy terminals corroded after 18 months, causing signal loss and module failures.
- Maintenance Downtime: Replacing corroded terminals required shutting down the entire battery line (8-hour downtime per replacement), as legacy boards lacked hot-swappable functionality.
- Compatibility Gaps: Legacy boards didn’t integrate seamlessly with SEAT’s ABB 800xA DCS, requiring custom adapters that increased wiring complexity.
“EV battery production is all about dense, reliable connections—our old terminal boards couldn’t keep up,” said Laura Gómez, SEAT’s Plant Operations Director. “We needed a terminal board that could handle high-density wiring, resist humidity, and integrate with our existing control system.”
ABB SCYC55830 58063282A: The EV-Focused Terminal Board Solution
After testing competitors from Harting and Molex, SEAT selected the ABB SCYC55830 58063282A for its high terminal density, corrosion resistance, and ABB DCS compatibility:
- High-Density Terminal Layout: 32 terminals in 18mm width (2x denser than legacy boards) eliminates daisy-chaining; supports up to 64 sensor/actuator connections per control cabinet.
- Corrosion-Resistant Materials: Tin-plated copper terminals and IP65-rated housing (when used with protective cover) withstand 40–90% RH and chemical cleaning agents, extending service life to 10+ years.
- Hot-Swappable Design: Allows terminal board replacement in 15 minutes without line shutdowns, reducing maintenance downtime by 90%.
- Plug-and-Play DCS Integration: Pre-configured for ABB 800xA DCS; no custom adapters needed—simplifies installation and reduces wiring errors.
- Temperature Tolerance: Operates in -40°C to +85°C, ideal for battery assembly areas with temperature fluctuations from charging processes.
Results: Efficiency Rises, Costs Fall
Six months post-deployment, SEAT’s Martorell plant achieved impressive results:
| Metric |
Before ABB SCYC55830 58063282A |
After ABB SCYC55830 58063282A |
Improvement |
| Assembly Line Efficiency |
72% |
90% |
22% Increase |
| Wiring-Related Delays |
10–12/Month |
2–3/Month |
75% Reduction |
| Terminal Corrosion Failures |
4/Year |
0 |
100% Elimination |
| Maintenance Downtime |
32 Hrs/Year |
3.5 Hrs/Year |
89% Reduction |
| Annual Cost Savings |
— |
€235,000 |
Direct ROI |
“The SCYC55830 58063282A has been a game-changer for our EV production,” Gómez said. “We can now handle the dense wiring of battery modules without short-circuit risks, and maintenance no longer derails entire shifts. It’s a critical component for scaling our EV output.”
Carlos Ruiz, ABB’s Automotive Industry Solutions Lead, highlighted the terminal board’s EV-specific design: “EV manufacturers face unique connectivity challenges—high density, humidity, and tight space constraints. The SCYC55830 58063282A is engineered to solve these, helping automakers boost efficiency and reliability.”
SEAT plans to deploy the ABB SCYC55830 58063282A across its new EV plant in Valencia, Spain, and expand to its Hungarian facility by 2028, targeting a 20% group-wide increase in battery production efficiency.
