The automated material flow system is designed to efficiently manage the transport of pressure-sensitive optics and lenses within a confined production environment. It solves the challenge of high-volume material distribution while ensuring product integrity, reducing lead times, and enabling localized production. This solution offers a robust, scalable prototype for delicate item handling.
In the rapidly evolving global market, manufacturers are increasingly seeking agile, localized production capabilities to meet demand and shorten lead times. This application exemplifies how efficient, scalable logistics can be implemented for sensitive products. It addresses the critical need to integrate a high-throughput, multi-level tray conveying system into a confined production footprint without disrupting ongoing operations.
The system reliably distributes and collects 2,200 trays per hour across multiple grinding machines. Simultaneously, it consistently ensures delicate optics remain perfectly protected from damage. This innovative approach, combining modular design with meticulous engineering, transforms complex logistical puzzles into seamlessly integrated, high-performance manufacturing realities, setting a new benchmark for automated optical production. It manages evolving specifications and prototype validation while maintaining commercial competitiveness, ultimately supporting a "produce-near-market" initiative. The system ensures reliable routing and consistent infeed alignment to each machine, safeguarding the pressure-sensitive items during accumulation, transfers, and machine handoffs.
Technical Solution
This material flow solution for pressure-sensitive products is powered by a central PLC/HMI architecture that integrates distribution logic, accumulation control, and interlocks to machine interfaces. The line speed is precisely tuned to achieve a throughput of 2,200 trays per hour while maintaining gentle handling at approximately 50 m/min.
A modular tray-conveyor backbone forms a multi-level network of standardized conveyor modules interconnecting loading stations, processing cells, QA, and packaging. Diverters and merges efficiently balance the material flow to machines, while return lanes collect trays post-process. The workpiece carrier concept utilizes a standard 220 x 260 x 70 mm tray, enabling stable conveyance and repeatable positioning. Stopper units and sensors ensure consistent infeed alignment to each machine, crucial for delicate product handling.
The design emphasizes space-constrained integration, allowing a high-throughput system to fit into confined, multi-level areas without disrupting ongoing operations. The execution model involved internal teams leading mechanical engineering and project layout, with a local partner providing electronics and fulfillment, ensuring seamless installation staged to minimize disruption and validate the prototype on-site.
Key Features & Benefits
High Throughput: Achieves an impressive 2,200 trays per hour at ~50 m/min through a modular, multi-level conveyor backbone, enabling significant production scalability and efficiency.
Gentle Handling: Ensures consistent product quality and minimizes damage to pressure-sensitive optics by utilizing standardized trays with precise positioning and controlled transfers.
Space Efficiency: Integrates seamlessly into confined existing production areas with its custom routing and multi-level design, optimizing facility utilization without major civil work.
Reliable Automation: Features a centralized PLC/HMI architecture that precisely controls distribution, accumulation, and machine synchronization for stable and predictable operations.
Market Agility: Facilitates rapid market response and reduced lead times through a prototype-proven design that supports localized production and agile manufacturing strategies.
Build your Application with Bosch Rexroth Products
The solution shown here is based on a system that integrates various Bosch Rexroth components, including advanced software, drive technology, 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.