Intelligent product transport revolutionizes battery production

When it comes to large-scale battery cell production, fast and precise processes are essential. Even the smallest time or energy savings in individual process steps can add up to significantly increased output, lower costs, and reduced carbon emissions. One of the key levers for improving efficiency in battery production is product transport, and Beckhoff is setting new standards here with its intelligent XTS linear transport system and high-performance PC-based control technology.

Conventional product transport vs. XTS

In conventional linear transport systems, the material flow is often interrupted by return paths involving empty runs. This is where Beckhoff’s XTS system takes a different approach, featuring a continuous, closed-loop track to maintain uninterrupted material flow and improve the overall efficiency of the production line. Each mover on the active XTS track is individually controlled and capable of braking, accelerating, positioning, and exerting constant force at any point – both at rest and in motion. This ensures the transported products are handled gently and securely, enables easy switching between formats, and significantly reduces buffering requirements.

Modular system for flexible product transport

A key strength of the XTS is its modular design. The system length can be precisely scaled using variable modules, allowing for customized and expandable configurations. Straight motor modules are available in various lengths, while curved modules come in a range of bend radii. There are also modules with an extended range of functions, such as contactless power and data transmission to the movers (No Cable Technology – NCT), as well as modules with a reduced range of functions for sections without processing stations (EcoLine motor modules). This full compatibility across module types allows the transport path to be optimally adapted to specific battery production processes and makes the most efficient use of available space.

Optimal synchronization

With PC-based control technology from Beckhoff and the EtherCAT Industrial Ethernet communication system, movers and other processes can be controlled in parallel and synchronized with high precision. This contributes to improved process quality and potential material savings. It also eliminates the need for stops during steps such as loading and unloading, helping to reduce downtime. Even movers operating on two separate systems can be linked via software, enabling greater load capacity or tighter product spacing.

High transport speeds and product throughput

With transport speeds reaching up to 4 meters per second and accelerations of up to 10 g, XTS delivers high throughput. The speed can be adjusted as required to meet the specific requirements of each production step.

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