At the Hannover Messe, Bosch Rexroth is using a combination of real exhibits and a virtual Gigafactory to show selected process steps in high-performance battery production. Under the premise of maximizing throughput, the complex value streams can be experienced using the example of the assembly of a round cell module from the virtual warehouse, cell preparation, module and pack assembly, to transport and end-of-line testing.
Scaling capacities in battery production
Battery production is considered a key technology for the energy transition. In the future, manufacturers will only be able to meet the high demand by rapidly scaling capacities in battery production. To do this, production must become more efficient, cost-effective and sustainable. At the trade fair, Bosch Rexroth will be demonstrating how complex value streams and material movements can be realized with maximum dynamics using real material flow solutions along the entire value stream.
Combined chain conveyor system with spiral conveyor for cell handling and transport
A combination of the Varioflow chain conveyor system with a spiral conveyor is used to handle and transport cells. The round cells are first delivered by the autonomous mobile robot Active Shuttle. A Kassow Robots cobot then places them on the belt. The spiral conveyor makes it possible to distribute various tasks, such as sorting, across several levels up to a height of 3.5 meters. This makes it possible to implement important buffers and storage systems above the transport routes of the actual production.
With transport speeds of up to five meters per second, the linear high-speed motion system “ctrlX FLOWHS” can be individually moved and controlled for on-the-fly testing of individual round cells or for applying insulation, among other things. The system is based on the “ctrlX CORE” control system and thus benefits from the openness and security of the “ctrlX AUTOMATION” platform.
Faster module and pack assembly in battery production
For module and pack assembly, Bosch Rexroth offers further solutions that include transport, insertion, gluing of the cells and screwing on of the cover. In one solution shown at the trade fair, Bosch Rexroth demonstrates how two linear robots place the cover and automatically screw it on. Due to the high precision of the Rexroth linear axes, the positioning can be done without additional measuring systems such as image processing, making assembly faster and more economical.
Dynamic transport from one kilogram to over three tons
The heavy-duty transfer system “TS 7 plus” enables the safe and highly dynamic transport of battery packs weighing up to three tons on workpiece carriers along the entire battery pack assembly process. Thanks to its modular design and low maintenance requirements, the roller conveyor can be quickly installed and can also be quickly adapted in the future for product modifications or new or revised manufacturing processes.
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 the “Battery Use Case” exhibitor project of Deutsche Messe, companies are jointly presenting their solution portfolio for the production and recycling of vehicle batteries.
Scalable automation portfolio for the entire value chain
“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.” You will find Bosch Rexroth at the Hannover Messe in hall 6, booth D26.
