Automated Assembly System for BMCe Components

A highly automated assembly system has been developed for the production of modern BMCe systems (Battery Management Controller extended), enabling efficient and precise assembly of positive boxes, negative boxes, and control units. The system combines intelligent feeding technology, automated material logistics, and high process reliability for e-mobility applications.

A key feature is the specially developed load-handling attachments, which enable safe and ergonomic handling of large material supply containers. This optimizes material flow and significantly reduces manual effort.

U-shaped layouts are used to ensure space-saving and efficient material supply. Fully loaded material pallets are fed directly into the system, unloaded automatically by robots, and then discharged as empty pallets. This concept reduces the space required for logistics and storage, minimizes staffing requirements, and enables extended periods of autonomous production.

The integrated screw feeding system automatically supplies the required screws, ensuring reliable, controlled, and traceable assembly.

With this custom-built special-purpose machine, we provide our customer with a high-performance, future-proof solution for the production of BMCe components.

  • Number of Assembled Components:PlusBox cover (2 variants), PlusBox carrier plate (2 variants), MinusBox cover (2 variants), MinusBox carrier plate (2 variants), AUX fuse (3 variants), Pyrofuse fuse (2 variants), Shunt sensor (2 variants), Relay (2 variants), Control unit, PlusBox GapPad, MinusBox GapPad,
PlusBox insulation film, Minusbox insulation film
  • Variant Diversity/Complexity:The boxes can be built in all variants requested by the customer. 
  • Workpiece Transport:Workpiece with workpiece carrier on a recirculating pallet conveyor
  • Cycle Time:39 sec.
  • Number of Processes:Screw fastening of shunts, Pyrofuse  and AUX fuses, Press-fitting the relays, Joining the covers to the carrier plates, Screw fastening of the relays, Applying insulation film, Inspecting insulation film using a camera with dome lighting, Pressing down the insulation film, Positioning and rolling down the GapPad, Laser marking the DMC code.
  • Required Staffing:2 employees, 1 machine operator
  • Inspected Parameters (Characteristics):4 automatic scanners, 3 cameras
  • Control Technology and Data Transmission:7 PLCs, 6 robots, 1 host computer, 1 camera PC, 2 load cells

Technical Specifications:

  • Transport pallet: 1000 × 1200 mm
  • Designed for this project for a fully loaded pallet weighing approx. 400 kg and an empty pallet weighing approx. 100 kg
  • 6 chain conveyors for infeed/outfeed
  • 2 chain conveyors for transverse transport
  • 4 pressure units at the transfer points
  • 2 light curtains with muting function at the infeed/outfeed
  • 1 lifting unit with a screw jack
  • Modular chain conveyor design, with each conveyor mounted on its own height-adjustable frame for levelling
  • Can be adapted for industrial trucks
  • Changeover time for 1 pallet: approx. 55 s