Planar motor technology: The new dimension of intelligent transport
ACOPOS 6D is a planar motor transport system that enables highly flexible manufacturing concepts. Individually controlled shuttles move contactlessly in six degrees of freedom, allowing products to move, rotate and tilt freely. With micrometer‑precise positioning up to 1 µm and payloads of up to 40 kg per shuttle, ACOPOS 6D enables precise, dynamic and adaptable product transport.
The contactless principle eliminates mechanical wear, maintenance and downtime. At the same time, the system reduces space requirements by up to 75% and achieves an unmatched shuttle density of up to 69 shuttles per square meter – ideal for high‑mix, low‑volume production and mass customization.
What sets ACOPOS 6D apart is its end‑to‑end software integration. Fully embedded in the B&R automation portfolio, the ACOPOS 6D software platform seamlessly connects design, simulation, commissioning, operation and diagnostics.
Intuitive, web‑based tools enable users to configure complex planar transport layouts, simulate transport flows and commission systems faster – without extensive custom programming.
As an intelligent transport solution, ACOPOS 6D turns every available square meter of production space into a future-proof, adaptable manufacturing area.
All benefits at a glance
No wear
Levitating shuttles generate no friction. This means there is no abrasion and no wear parts that could contaminate sensitive products like pharmaceuticals or food.
Easy setup
Shuttles are instantly identified by the controller using a globally unique ID, allowing positions to be assigned right away. No referencing sequences are needed, so production can start immediately.
100% simulation-ready
Fully integrated graphical design in the ACOPOS 6D Launch Pad software means hardware testing can be reduced to a minimum. ACOPOS 6D offers virtually unlimited design possibilities while remaining easy to set up. You can design layouts and processes virtually, and throughput calculation works automatically. Algorithms also optimize paths and energy consumption – for planning the ideal machine process with maximum productivity.
Minimal space requirements
With ACOPOS 6D, you can combine different shuttle sizes, segments and offsets. This gives machine builders the flexibility to arrange all process stations in the absolute smallest possible space. Software features like the weighing function of each shuttle completely eliminate the need for separate weighing stations. Complex process stations are a thing of the past, as ACOPOS 6D shuttles can take over multidimensional movements.
Integrated collision avoidance
Collision avoidance implemented directly in the firmware prevents individual shuttles from crashing into each other. This allows programmers to fully focus on the process flow.
Shared coordinate system
Native compatibility with the coordinate systems used by ACOPOStrak, SuperTrak, robotics and vision systems makes it possible to combine different transport systems and process components.
Global service
Support with layout, design, commissioning and optimization through B&R’s global service network for assistance, training and spare parts.
Simple diagnostics and optimization
With ACOPOS 6D Monitor and Industrial IoT integration, diagnostics and optimization are possible anywhere – on-site or remotely.
The ACOPOS 6D package combines the most comprehensive software ecosystem with the widest range of hardware in planar technology, making it the ideal solution for machine builders looking to implement future-proof, modular and highly dynamic production processes.
Function and components
ACOPOS 6D Hybrid
ACOPOS 6D Hybrid combines planar motor transport technology with conventional transport systems to create highly flexible and modular manufacturing concepts.
Process‑critical and high‑value operations are handled by ACOPOS 6D, while standard transport tasks are complemented by solutions such as conveyors or robots. The ACOPOS 6D software platform automatically identifies, tracks and coordinates individual shuttles, even when they transfer between planar and conventional transport systems.
The hybrid transport architecture allows manufacturers and machine builders to reuse existing transport concepts while adding maximum flexibility exactly where it creates the greatest value. ACOPOS 6D is applied selectively, avoiding overengineering and enabling an optimal balance between flexible manufacturing and overall system cost.
Software
With ACOPOS 6D LaunchPad, mapp 6D and ACOPOS 6D Monitor, ACOPOS 6D is seamlessly supported across the entire lifecycle – from the first concept to ongoing maintenance – ensuring efficiency, reliability and ease of use.
The web-based ACOPOS 6D LaunchPad makes it possible to intuitively create layouts and simulate processes visually – including instant virtual throughput calculation. A Traffic Manager automatically handles pathfinding and routing based on process stations. The Flight Recorder simplifies live and offline diagnostics with event triggers and a graphical replay function. The IIoT connector makes it easy to link edge applications, while a cloud or edge infrastructure provides, depending on your needs, the security of a standalone solution, virtually unlimited replay storage or flexible remote access to process flows using the ACOPOS 6D Monitor and apps for planar motor technology.
ACOPOS 6D segments
The segments can be flexibly mounted along the X and Y axes – side by side, offset or with gaps for protective covers, cable routing or process stations. This offers maximum design freedom with optimal space utilization. Individual segments can be seamlessly combined with existing conveyor belt or track systems, while narrow segments additionally enable efficient and cost-effective transport in single-lane applications. Depending on your needs, the system’s protective cover can be made from stainless steel, silicone, titanium, glass or other materials, allowing for full customization to your process requirements.
ACOPOS 6D Shuttles
Hot-swappable shuttles ensure uninterrupted transport and precise positioning in six degrees of freedom. The maintenance-free permanent magnet shuttles are available in 19 sizes (120 x 120 to 600 x 600 mm) and reach every target point with repeatability of less than 5 µm (S3) or 10 µm (S4).
Hygienic and aseptic surface options made of stainless steel (AISI 316L) are available for applications in food production or cleanrooms.
Standard Variant
A reliable choice for use in controlled indoor settings. Suitable for general-purpose applications with minimal exposure to moisture and dust and without the need for additional resistance.
Thanks to its robust design and high process stability, the standard variant is ideally suited for a wide range of applications in conventional machine and system concepts. It supports flexible production processes and enables precise, contactless movement of products throughout the production flow.
In addition, the standard variant of the ACOPOS 6D shuttles is available in a wide variety of sizes, formats, and payload classes. This allows the shuttles to be optimally adapted to specific machine requirements.
Rugged Variant
Enhanced durability for demanding physical environments. Equipped with Abrasive-Ready technology to withstand high-pressure washdowns and mechanical wear. Rugged Shuttles are designed for maximum structural integrity and fully encapsulated in 300-series stainless steel. This variant is tailored for high-impact applications and heavy-duty industrial cycles, offering a substantial improvement in mechanical durability compared to the standard variant. It maintains the same symmetrical hole pattern as the standard Shuttle, ensuring full compatibility with existing workpiece carriers and mounting hardware.
Hygienic Variant
Designed specifically for food, beverage, and pharmaceutical environments where cleanliness is essential. Combines excellent hygienic properties with full waterproof ratings to eliminate potential bacteria traps during cleaning. Hygienic Shuttles meet the highest hygiene standards and are fully encapsulated in a seamless housing made from 316L stainless steel. All seams are laser‑welded and polished, resulting in a completely closed Shuttle surface. This allows the hygienic Shuttles to be cleaned using water or hydrogen peroxide. Rounded Shuttle edges support easy and effective cleaning.
Hygienic Shuttles are available in two versions with different surface finishes:
- Ra < 1.6 µm is typically used in areas with limited product contact or robust cleaning procedures, and is frequently applied on outer surfaces or non‑product‑contact zones in hygienic systems.
- Ra < 0.8 µm features a smoother surface that minimizes microscopic crevices where bacteria or contaminants could accumulate, improving cleanability. In food, dairy, and pharmaceutical industries, Ra 0.8 µm is often considered the minimum requirement for surfaces in direct contact with product.
High Temperature Variant
Engineered to withstand extreme thermal stress and medical‑grade cleaning procedures. This is the only variant offering excellent autoclave capability, enabling it to endure repeated high‑temperature sterilization cycles. It provides maximum protection against corrosive substances and aggressive industrial cleaning agents.
High Temperature Shuttles deliver the same trusted hygienic properties as the Hygienic variant, combined with increased durability specifically developed for autoclave sterilization. Designed to tolerate high‑temperature, high‑pressure steam environments, this version ensures reliable reusability and compliance with stringent sterilization standards. It is therefore ideally suited for clinical, laboratory, and other applications where repeated sterilization is required.
Chemical Resistant Variant
Maximum protection against corrosive substances and aggressive industrial cleaning agents. The only variant offering excellent acid and chloride resistance, making it well suited for chemical processing and demanding sanitation cycles. Chemical‑resistant Shuttles are encapsulated in a superalloy housing to withstand:
- Aggressive mineral acids especially at high temperatures where stainless steel would dissolve, such as Hydrochloric Acid (HCl), Sulfuric Acid (H2SO4), Phosphoric Acid (H3PO4), Nitric Acid (HNO3), Hydrofluoric Acid (HF);
- Chlorine and Halogens, such as Wet Chlorine Gas, Hypochlorites, Chlorine Dioxide (ClO2), Ferric and Cupric Chlorides, Brine and Seawater;
- Organic Acids and Compounds, such as Acetic Acid & Acetic Anhydride, Formic Acid, Chloroacetic Acid, alcohols, ketones, and esters;
- Other specialized Industrial Environments, such as Sour Gas (H2S), Flue Gas Desulfurization (FGD), and Green Death.
Technical specifications
ACOPOS 6D Series 3 is optimized for compact machine layouts and offers high repeatability with minimal space requirements – ideal for applications with tightly grouped shuttles. ACOPOS 6D Series 4, on the other hand, is designed for higher payloads and is suitable for transporting large parts over longer distances.
| ACOPOS 6D | Series 3 - designed for tight installation conditions | Series 4 - built to carry more – designed to install faster |
|---|---|---|
| Shuttle size | 10 Shuttle sizes (120x120 – 450x450mm) | 10 shuttle sizes (160x160 – 600x600mm) |
| Shuttle payload | 0,6 - 20kg | 1,8 - 40kg |
| Segment size | 240 x 240 x 7 0mm and 480 x 120 x 70 mm | 320 x 320 x 80 mm |
| Max. speed | 3m/s | 3m/s |
| Max. acceleration | 20m/s² | 20m/s² |
| Levitation height | 0,5 – 4mm | 0,5 – 6mm |
| Positioning accuracy | < 5 µm | < 10 µm |
| Shuttle rotation | <20mrad (X,Y), <20° (Z) | <20mrad (X,Y), <20° (Z) |
| Protection class | IP67 | IP67 |
| Shuttles - Hygienic Variants | available | available |
| Segment cooling | integrated* | integrated* |
Components & Modules
Controller
Cables
Shuttles S3
Shuttles S4
Segments S3
Segments S4
Software components and versions
References and success stories
Insights into real-world applications and partnerships: See how companies worldwide are benefiting from our solutions.