Transporting heavy components with challenging dimensions or an off-center mass along an assembly line with traditional single-gantry systems creates bottlenecks due to long, empty return paths. Overhead cranes are often slower and less precise, while fixed conveyors lack the flexibility to adapt to variable production or different product models.
This powerful and compact solution is built on a compact module CKR-280 with dual belt drive which features two independently toothed-belt driven carriages on a single main X-axis. On each of these carriages, a vertical compact module acts as the Z-axis. This creates two independent lifting points on a shared track.
Controlled by the highly responsive automation platform ctrlX AUTOMATION, the system executes a "leap-frogging" motion. As one axis places a component at Station B, the second axis is already moving to pick up the next component at Station A.
Key Features & Benefits
Maximized Throughput by Eliminating Wasted Motion
A conventional single gantry spends almost 50% of its cycle time on an empty return trip. Our dual-carrier design eliminates this non-productive time entirely. By using a "leap-frogging" motion, one axis can place a component while the second moves to pick the next one. Even with controlled acceleration due to the heavy payload, the overall throughput is significantly higher because the system is always performing value-added work.Engineered for Heavy Loads & Precision
Handling heavy, off-center loads with two lift points demands exceptional structural rigidity. Our heavy-duty compact modules feature robust, integrated industry-proven Bosch Rexroth high-performance ball rail systems. This ensures the two carriers remain parallel and precise. Our LinSelect engineering software validates that the selected motors and modules are correctly sized to not only handle your load but also achieve the required service life, giving you confidence in the system's long-term reliability.Advanced Control for True Independent Motion
Positioning a heavy mass accurately without oscillation is a major challenge. The DriveX platform provides advanced motion profiling with jerk-limitation to create smooth acceleration and deceleration curves, actively suppressing vibration and minimizing settling times. This control unlocks the true flexibility of the independently driven carriages. Unlike systems with mechanically connected carriages that are locked into a fixed spacing, this design allows each axis to travel a different distance within the same cycle segment. This is ideal for optimizing motion around unequal station pitches or for handling asynchronous tasks a level of process flexibility impossible with fixed-spacing systems.Optimized Drive System via Common DC Bus
We optimize the entire drive system for cost and efficiency using a common DC bus architecture. This intelligent setup allows you to significantly downsize the main power supply unit. In a typical "pick-move-place" cycle, the vertical Z-axes are often stationary while the X-axis is traveling. The common DC bus requires only one power supply sized for this realistic peak load, not an oversized one for a theoretical maximum. This directly translates to lower hardware costs and less heat in your cabinet.
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Build your Application with Bosch Rexroth Products
Integrating reliable components is crucial for an optimal handling process. Rexroth’s components, including linear axes (compact modules), linear guides, screw drives, ctrlX controllers, work together seamlessly. This combination enhances precision, efficiency, and flexibility, ensuring every assembly line operates smoothly and effectively.