Connecting
conveyor systems

The task

Conveying
Staple
Separate

Battery modules in load carriers are to be automatically unloaded from a truck, repacked from a stack of 7 to a stack of 4 and fed to a warehouse repacked and fed into a warehouse. Production should retrieve the battery modules, assemble them into a vehicle battery and transport them back to the warehouse in stacks of 4. Here, stacks of 7 should be packed again and automatically fed to the truck. In addition, the empties and basic pallets must be handled.

The solution

An automatic truck unloading system brings the stacks of 7 on a base pallet to a frame store. There the stacked into stacks of 4 and the base pallets are stacked 5 high. The finished stacks are moved to the warehouse and reported to the higher-level control system. When battery modules are called off from production, they are taken from the warehouse and moved to the module handlers via the conveyor system. There the load carriers are there, the load carriers are fed individually to the handling units, which recognise the module position by camera and transfer them to the production conveyor line. Empty load carriers are loaded with a finished battery, which is fed from production, brought together in stacks of 4 and transported to the warehouse. As required, stacks of 4 batteries are removed from storage, restacked into stacks of 7 and automatically loaded into the truck.

Facts & figures

Takt time modules 3,5 s
Takt time batterie 33 s
Load capacity 2,5 / 5 tons

Alztec team:
12 design & engineering staff
50 assembly & commissioning staff
25 electrical & control engineering staff

Main components:
380 metres chain conveyors
21 rotary tables
10 distribution cars
13 staple-/Latchmodules
3 framestorages
4 modulehandlings
300 sqm platform with stairs and railings
1 system control including visualization