Automated Assembly Line for Battery Modules offers a robust, scalable carrier-based transfer solution designed for large-volume battery manufacturing. It reliably handles stacking and arraying of cells, then accurately assembles and moves heavy modules across multiple stations. This system ensures high positional accuracy, sustains quality at medium line speeds, and manages long layouts effectively.
Building large-volume battery module assembly lines presents significant challenges. A primary concern is the heavy-load transport of large, heavy modules (over 5 kg per carrier) on oversized carriers without any loss of positional accuracy. Achieving high-precision station alignment is critical for repeatable positioning during sensitive stacking, arraying, and joining operations. Such lines also face the complexities of evolving specifications and supply logistics, requiring solutions that can manage frequent version changes and component consolidation while meeting delivery milestones.
The operational environment for these lines is typically standard industrial production at room temperature, with long conveyor layouts exceeding 30 meters and multiple stations requiring high-precision positioning. Maintaining long layout stability is crucial, demanding sophisticated flow control to coordinate accumulation and movement at medium speeds without bottlenecks.
Technical Solution
To master these requirements, a tailor-made automation solution can be designed, centered around a Bosch Rexroth TS-class transfer system equipped with WT 2/H heavy-duty workpiece carriers.
The transfer platform utilizes WT 2/H heavy-duty workpiece carriers in two formats (1,200 × 640 mm and 1,040 × 640 mm) to cover various module sizes, ensuring a fit-for-purpose solution for heavy loads. Precision at stations is achieved through specialized stopper and positioning units, which deliver high-precision alignment crucial for stacking, arraying, and assembly processes, with mechanical interfaces tailored to specific station requirements. Flow control is managed by medium-speed conveyor sections featuring controlled accumulation, which maintains stable spacing and mitigates pressure on carriers. The long-layout design is optimized to minimize recirculation.
Key Features & Benefits
High Assembly Quality: Repeatable, high-precision positioning at stations significantly improves process capability and module quality.
Robust Heavy-Load Conveyance: WT 2/H carriers ensure stable transport of large, heavy modules, reducing mechanical risk and minimizing downtime.
Scalable Architecture: Support for dual carrier sizes and modular transfer sections enables future station additions or format adjustments, enhancing long-term flexibility.
Balanced OPEX at Medium Speeds: Controlled accumulation and reliable hardware contribute to lower operational risk and reduced maintenance effort, optimizing operating expenses.
Schedule Assurance Under Change: Flexible sourcing and local finalization capabilities help keep project delivery on track, even with specification changes.
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Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including transfer systems, drive technology, an automation platform, and structural and safety components. Please note that you can also purchase these components individually from us. The links to the respective product pages are listed here.
Bosch Rexroth Transfer Systems: Ensure smooth and flexible material transport and handling of all weights.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.
Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.