By integrating actual displays and a digital gigafactory, Bosch Rexroth is highlighting specific process phases of advanced battery manufacturing at the Hannover Messe. Based on the goal of maximizing throughput, the intricate value streams can be illustrated by the example of round cell module assembly: from the virtual warehouse, cell preparation, module and pack assembly to transport and end-of-line testing.
The manufacture of batteries is regarded as a vital technology for the energy transition. Producers can only satisfy the increasing demand in the future by swiftly enhancing their battery production capabilities. To accomplish this, production needs to be more efficient, more economical, and more sustainable. At the Hannover Messe, Bosch Rexroth will showcase authentic material flow solutions throughout the complete value stream to demonstrate how intricate value streams and material movements can be achieved with optimal dynamics.
A solution for managing and moving cells integrates the VarioFlow chain conveyor system with a spiral conveyor. The spherical cells are initially transported by the autonomous mobile robot (AMR) ACTIVE Shuttle and subsequently positioned on the conveyor by a cobot from Kassow Robots. The spiral conveyor enables the distribution of different tasks, like sorting, across multiple levels up to a height of 3.5 meters, thereby establishing significant buffers and storage spaces above the transport paths of the actual production.
The linear high-speed motion system ctrlX FLOWHS can achieve speeds of up to 5 m/s, allowing for individual movement and control for real-time testing of single round cells or for insulation application, among other uses. The system relies on the ctrlX CORE control unit and thus takes advantage of the openness and security of the ctrlX AUTOMATION automation system.
Bosch Rexroth provides additional solutions for module and pack assembly – comprising transportation, insertion, gluing of cells, and fastening of the cover. At the trade fair, Bosch Rexroth demonstrates a solution where two linear robots automatically place and screw on the lid. Due to the exceptional accuracy of the Rexroth linear axes, positioning eliminates the need for extra measuring systems like image processing, resulting in quicker and more cost-effective assembly.
The TS 7 plus robust transfer system allows for the secure and highly dynamic movement of battery packs weighing more than three tons on workpiece carriers across the complete battery pack assembly line. Due to its modular construction and minimal maintenance needs, the roller conveyor can be installed rapidly and can also be easily modified later for product changes or updated production workflows.
Together with a cobot from Kassow Robots, manual assembly workstations and a battery discharge solution, the TS 7 transfer system is also part of a battery recycling solution at the trade fair: In Deutsche Messe AG’s “Battery Use Case” exhibitor project (hall 6, booth D62), companies will be jointly showcasing their solution portfolio for the production and recycling of vehicle batteries.
“With our mix of solution examples and virtual gigafactory, we will be demonstrating at our booth how battery production can be achieved faster and more economically with innovative solutions,” comments Dr. Andreas Letsch, Head of Center of Competence Battery at Bosch Rexroth. “We support machine and system manufacturers along the entire value stream with the broadest product and solution portfolio on the market, including clean room designs, a future-proof automation platform and transport solutions that can be combined as required from a single source.”
Bosch Rexroth at the Hannover Messe: Hall 6, Booth D26