Dorner’s 2200 Precision Move Pallet System conveyors are designed to provide accurate positioning and routing of parts for assembly, robotic and inspection applications. Recently, Dorner completed an assembly automation system utilizing a series of 2200 Heavy Load Precision Move Pallet conveyors for a customer that needed to transport 80 lb battery cells glued inside painted steel module housing. This particular application is unique because of the heavy load nature of the battery, and the need for electrostatic dissipative timing belts due to the battery being conveyed without pallets.
The system begins with the battery being infed from a laser welder directly onto a 2200 Series Heavy Load Precision Move Pallet Conveyor. It is then transferred 90 degrees using a Lift & Transfer module. When the lift is in the middle position it stops the battery on the conveyor, the lift then moves to the up position and transfers the battery onto the transverse conveyor.
The battery then travels to an enclosure unit equipped with a Lift & Rotate module. Lift & Rotate modules operate by pneumatically lifting from the center of the conveyor and rotating to the desired orientation. These modules can support up to 200 lbs and include break-away magnetic coupled rotation plates for product safety in case of malfunction. The enclosure unit is a safety precaution for workers from high speed units, and also includes safety interlock switches on all access points.
Once the battery leaves the enclosure it reaches two pneumatic Stop & Lift modules that serve as operator assembly stations. All of the Stop & Lift units on this system are complete with cushioned pallet stops that are pneumatically activated with spring return. Once the battery has completed the first two operator assembly stations it then reaches a second Lift & Transfer module where it is transferred 90 degrees left or right to a testing station.
Finally, once the battery has completed the testing station it returns back to the Lift & Transfer module which then lowers to to allow the battery to pass over the unit. Additionally, an E-stop can be seen. This system is equipped with E-stop/release push button stations that work in conjunction with the lifts. After the battery has moved through the final two operator assembly lift and stop units a crane removes the battery from the line and onto the next phase or production.
With the help of this new system the customer has increased their production to 20 batteries/hour. The system has also increased worker safety by utilizing a belt that is used as a protectant when conveying conductive materials that can produce electrostatic charges. If you would like to learn more about assembly and industrial automation we have many great resources available, or if you’re ready to increase your production contact us today.