How can batch size 1 be effortlessly integrated into the selective inline soldering process?

Batch sizes of 1 or small quantities pose challenges for every process because the established series production process has to be interrupted in a time-consuming manner. New ideas and concepts are therefore necessary. This also applies to the selective soldering of electronic assemblies. This challenge can be met with new line production concepts based on the XPlanar from Beckhoff.
The new line production concept offers maximum flexibility and is characterised by dynamics and sustainability. The units transport assemblies seemingly chaotically from one process cell to the next, adapting paths and speeds to achieve the highest possible level of efficiency. Because a wide variety of assemblies can be produced simultaneously in one production line, the transport systems are the solution to the challenges of today's and tomorrow's production.

The XPlanar mover enables each product to be transported separately and independently through individual process stations and cells and positioned with maximum precision. This means that batch size 1 or even small quantities can be produced simultaneously on one line within large-scale production without any problems. XPlanar technology can completely take over the axis and robot handling systems required in many processes, which is why these can be dispensed with. This makes new production concepts possible. This has already been impressively demonstrated with E-ssembly at Motek 2021.

The floating 2D product transport system combines the advantages of conventional transport and kinematic systems and supplements them with magnetic levitation technology. This opens up new options for product handling. This applies both to the areas inside and outside a machine as well as between the individual process steps. In inline production, this opens up design options that cannot be achieved with conventional belt conveyor systems. For example, the individual freedom of movement of automated guided vehicles is available to the user on a small scale, as individual assemblies can be transported to any location via any route within the production concept. At the same time, the positioning of a product during processing also becomes the task of the transport system for the first time. As the levitation effect replaces any mechanical guide components, a new level of flexibility is achieved.
As soon as the system is used on free travel paths with a repeat accuracy of 10 µm, it is possible to process different assemblies in a production line simultaneously and independently of the sequence and station. The movers transport the assemblies intelligently and in a cycle time-optimised manner from process station to process station. This massively increases the output and efficiency of the machines used for series production. Contactless transport also minimises the need for service, maintenance and wear parts, which is a step towards sustainability.