Automated guided vehicles from DS are already in use in numerous installations at car manufacturers. In the area of flexible assembly systems, these are mostly track-guided systems. (Image: DS Automotion)

Conventional assembly lines with their fixed conveyor systems lack the necessary flexibility to react dynamically to the changing requirements of battery assembly. Here, it is particularly important to assemble even the smallest batch sizes economically. Automated guided vehicles from DS are already in use in numerous installations at car manufacturers. In the area of flexible assembly systems, these are mostly track-guided systems. Users see the fact that the Navios Trackguide control system is based on PLC technology as an advantage. As this is a de facto standard in the German automotive industry, its production and maintenance engineers are very familiar with this technology. The AGVs for battery assembly can therefore be seamlessly integrated into the overall automation processes.

The vehicles navigate along magnetic tapes or induction loops which, in addition to navigation, also serve to permanently recharge the batteries in the vehicles to avoid charging breaks. The superficially laid guideways and the ability to intervene in the control software also keep the AGV flexible, as they allow changes to be made to both the layout and the driving behavior at short notice.

Drive command via WLAN

There are companies that strive to implement a holistic approach in the sense of Industry 4.0 and therefore integrate the battery assembly systems into their general intralogistics. In such cases, preference is given to freely navigating systems for reasons of compatibility. Their Navios Freeguide control system calculates path sections, which it transmits to the vehicles, usually via WLAN, as quasi driving commands for the automatic execution of the desired tasks. These do not require any guidelines, as they aim at reference points - magnets embedded in the floor or laser reflectors on walls and shelves - to check that the route specified by the master computer is being followed. It continuously checks that the route targets are being met. The guidance control software is hierarchically positioned one level above the individual machine control systems. It communicates at eye level with MES and ERP systems, from whose information it derives the optimum movements.

The AGVs communicate with the safety-related control systems of the cells so as not to trigger a safety violation when passing through gates and light grids. (Image: DS Automotion)

The automated guided vehicles from DS also communicate directly with other parts of the production plant. This allows them to enter the robot cells through the light curtains without triggering a safety violation and bringing them to a halt. This ensures maximum production efficiency and optimum protection for employees.

The very sparsely dimensioned aisles between the individual assembly cells require particularly maneuverable AGVs. "As a special feature, the AGVs in the production facilities for car traction batteries have to enter the cells in reverse, and often enough in a tight curve," says Kurt Ammerstorfer. "Thanks to our decades of experience with similar problems, especially in the automotive environment, we can guarantee the perfect functioning of this maneuver under all conceivable operating situations, even with track-guided systems." as