Automated Transfer System for Battery Pack Assembly provides a fully automated TS 2 conveyor solution for battery pack transport, featuring customized belt and timing-belt modifications. This system delivers improved precision and stability, high reliability, and optimized flow between workstations, essential for launching new battery pack assembly lines with reliable, low-maintenance intralogistics and a platform that can be standardized for future lines.
The efficient inter-station transfer of battery pack assemblies, which are the primary production stage, presents significant challenges. These products, transported on Rexroth WT2 640x640 workpiece carriers, are heavy (around 30 kg per carrier) and scratch-sensitive. Ensuring safe, stable transport of these heavy loads without surface damage is paramount, as is achieving repeatable positioning at several stations for dependable downstream processes. Production lines are often characterized by confined, multi-level layouts with limited floor space, adding complexity to integration.
Further critical process aspects include precise indexing between workstations, supported by a customized TS2 conveyor system with belt and timing-belt modules. The system must also facilitate fast commissioning and minimize software/electrical engineering effort, while offering a cost-effective solution with scalability for future expansions.
Technical Solution
To master these requirements, a tailor-made automation solution is typically designed, centered around a Rexroth TS 2 modular transfer system equipped with WT2 640x640 workpiece carriers.
The conveyance system is a customized combination of reinforced TS 2 belt conveyors for long runs and specialized timing-belt sections for precise indexing, providing improved precision and stability. Workpiece carriers are heavy-duty WT2 640x640 pallets, specifically matched to the product footprint and weight (approx. 30 kg). Customizations include belt and timing-belt adaptations to increase stability and reduce slip, along with guides and anti-scratch features to protect sensitive pack surfaces. Drive sizing is optimized for heavy payloads, and a sophisticated sensor concept ensures repeatable stop positions. Integration involves preparing mechanical and controls interfaces for the line integrator, with the layout engineered for a multi-level footprint and optimized station-to-station flow.
Key Features & Benefits
Robust Process Stability: Ensures reliable handling of 30 kg payloads with repeatable positioning across all stations, crucial for battery pack quality.
Optimal Product Protection: Customized belt/timing-belt adaptations, guides, and anti-scratch features prevent surface damage to sensitive battery packs.
Fast Implementation & Reduced Effort: Standardized, modular TS 2 approach with clear interfaces accelerates commissioning and minimizes software/electrical engineering.
Space-Efficient Layout: Tailored belt/timing-belt modifications and engineered layout fit confined, multi-level spaces without compromising throughput.
Scalability & Standardization Potential: The TS 2 base platform allows straightforward expansion and replication on future lines, enabling reuse in subsequent projects and lowering TCO.
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Explore TS2 System - Heavy-Load Handling
Explore TS2 System - Heavy-Load Handling
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.
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