Modular heavy-duty handling for battery production

In battery production and special machine construction, companies rely on standardized, modular linear technology to precisely and efficiently automate the handling of large and heavy workpieces.

Activity and operational challenges
As a global provider, Robert Bosch Manufacturing Solutions GmbH (BMG) develops production equipment and automation solutions. In the manufacture of battery packs, handling large workpieces requires precise heavy-duty handling with high dynamics and short cycle times. The central operational challenge was that traditional special machine construction reached its limits in this area, as complex gantry systems had to be designed from scratch for each project, consuming valuable development time.

Improvement objectives
The primary objective was to develop a reusable system architecture for the industrialization of large multi-axis systems. The company aimed to be able to offer, design, and implement such systems more agilely in the future. In addition, the time-to-market was to be significantly reduced, and the solution space expanded beyond the classic automation station.

Selected technical solution
As a solution, BMG developed a standardized toolkit in cooperation with its sister company Bosch Rexroth. For an initial gantry portal for handling 250-kilogram tools for battery assembly, BSHP series precision ball rail systems (size 25) were installed for the horizontal X and Y axes. Each linear guide operates with three runner blocks, with the Y-axis having higher load ratings to safely move the Z-axis and its payload. The system is driven by ML3 linear motors from Bosch Rexroth. For the vertical Z-axis, the heavy-duty version of the CKK compact module series (size 280) is used as a complete solution.

Implementation and support
The implementation took place as a joint pilot project, in which Bosch Rexroth contributed the modular linear technology solutions as well as comprehensive engineering support. Through close technological collaboration, a highly flexible reference architecture was created, specifically designed for process requirements with long travel distances and large payloads.

Quantifiable results
Thanks to standardization, BMG now has a validated blueprint that eliminates the need for constant redesign and significantly shortens the time-to-market in project execution. Based on this reference architecture, the toolkit can be effortlessly scaled to much higher payload ranges of up to 2,000 kilograms. As a result, demanding applications such as the high-performance assembly of battery modules, the automated loading of machine tools, or furniture production can be implemented much more easily and quickly.

Edited by Maria Brueva, Induportals editor – adapted by AI.

www.boschrexroth.com