PROJECTEnquire ↗Handling & automation
Two gantry manipulators, conveyor interfaces and battery flow control for automotive production in Mladá Boleslav. The reference covers handed-over engineering and partial delivery stages.
Delivery scope & origin
Engineering and partial delivery stagesEMKO project portfolio. Supplier at the time of delivery: EMKO HOLDING s.r.o.
The project in context
The project addressed automated supply of an assembly line with batteries held in handling frames. It combined stacked storage, three-axis handling, delivery of loaded frames to production and the return of empty carriers. The scope included engineering milestones, a prototype, mechanical supplies and integration work interfacing with the existing conveyor system.
The work combined mechanical and conveyor engineering, electrical design, controls and machinery safety. It progressed through prototyping, engineering handovers, manipulator testing and subsequent on-site integration.
The mechanical arrangement uses two gantry manipulators to move frames along three axes. Each carries a gripper with two moving jaws. The layout has six loading locations and two rows of storage positions, providing a total of 12 mechanical positions for stacks.
The upper chain-conveyor level carries battery-loaded frames towards the assembly line, while the lower level returns empty frames. A cross-transfer table with a lift connects the system to the existing conveyors. The layout also includes three unloading positions and dedicated positions for non-standard handling.
The control design links frame and battery identification to assembly-line requests. The functional description covers occupancy tracking, first-in, first-out retrieval and selection of an approved alternative battery type according to the production call-off. It also addresses empty-frame routing and procedures for unreadable codes or non-standard handling.
Operation is divided into three areas with HMI panels: conveyors and the transfer point, the loading area with the main manipulator, and the unloading area with the second manipulator. Interfaces to adjacent equipment are specified through PN/PN couplers between separate Profinet networks.
The handed-over engineering milestones progressed from the frame and safety concepts through a loading-station prototype and a 3D model to electrical design, information architecture and mechanical manufacturing documentation. These were followed by the approved technical specification and the manipulator factory acceptance test in June 2024.
Integration work continued at the installation site in 2025. It included laser measurements of elevation interfaces and tests of stack loading, identification, retrieval and sequence control. Selected scenarios verified FIFO order and retrieval of an alternative battery type; these individual tests relate to specific system functions.
Engineering and partial delivery stages were handed over, followed by measurements and tests of selected functions on the installed equipment. The stated scope and financial band relate to those stages and do not establish final operational acceptance of the complete system.
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