This solution provides a multi-level, intelligent conveyor system that overcomes extreme space constraints and demanding cleanroom conditions. It automates material flow, significantly boosting efficiency, quality, and process reliability while reducing errors and labor costs.
In the high-precision world of optics manufacturing, every millimeter and second counts. Manual logistics between individual production steps can become a significant bottleneck. This often involves the labor-intensive and error-prone transportation of sensitive items, such as eyeglass lenses in trays, between numerous processing machines. The fundamental goal of automation in these scenarios is to increase efficiency, enhance process reliability, and drastically reduce the manual error rate.
Integrating advanced material flow systems presents several inherent challenges. The biggest hurdles include the need to incorporate extensive conveyor lines into existing, fully equipped production halls, which requires innovative solutions to utilize minimal available footprints effectively (a "brownfield" approach). The system must also intelligently connect numerous machines, ensuring precise distribution and collection of items.
Furthermore, demanding environmental conditions, such as semi-cleanroom environments (e.g., Class 10,000), impose strict requirements on the abrasion resistance and material properties of components to prevent contamination. Lastly, to avoid production interruptions, the implementation often needs to be incremental, allowing for flexible integration into ongoing operations.
Technical Solution
To master these complex requirements, Bosch Rexroth designed a tailor-made automation solution centered around the versatile VarioFlow plus chain conveyor system (VF90).
The technical solution is intelligent and space-saving: A three-level main conveyor line runs like a backbone through the production hall. This design makes optimal use of the vertical dimension, enabling an impressive total length of 300 to 400 meters to be realized within a minimal footprint. Individual conveyor lines branch off from these three main levels to the respective processing machines. Specialized stopper units ensure repeatable pre-positioning of the trays before the machine takes over for final placement. An intelligent control system manages the complex routing, ensuring every tray is at the right place at the right time—from the central loading/unloading station to the machine and back. Thanks to its ability to create custom curve radii and track layouts, the VarioFlow plus system can be integrated even into the tightest areas of the hall—a decisive advantage over competitor solutions that fail to meet this challenge.
Key Features & Benefits
Massive Productivity Increase: Automating transport processes significantly reduces required personnel, leading to substantial cost savings and rapid return on investment.
Significant Quality Improvement: Automated and gentle handling of trays eliminates damage risks, directly reducing the scrap rate of valuable lenses.
Maximum Space Efficiency: Long conveyor lines are integrated into existing plants with outstanding compactness and flexibility, making optimal use of minimal footprint.
Centralized Process Control: A single loading and unloading point simplifies the entire logistics chain, improves product traceability, and creates a more organized and safer production flow.
Adaptable & Flexible Integration: Phased implementation allows for integration into ongoing operations without interruption, facilitating smooth transitions.
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including conveyor technologies, automation platform, and structural elements. Please note that you can also purchase these components individually from us to build your specific application. The links to the respective product pages are listed here.
Bosch Rexroth VarioFlow Belt Systems: Enable smooth and reliable transport of workpiece carriers up to 20 kg.
The Bosch Rexroth Aluminum Profiles and EcoSafe Protective Fence Components: Are flexible and ensure compliance and safety.
The ctrlX AUTOMATION Platform from Bosch Rexroth: Manages all processes and tasks and is a flexible gateway to other systems.