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ACOPOStrak

The flexible transport system for ultimate production effectiveness

ACOPOStrak-versatile-transport-system

ACOPOStrak is a revolution in adaptive manufacturing that extends the economy of mass production down to batches of one. Parts and products are transported quickly and flexibly from processing station to processing station on independently controlled shuttles.

ACOPOStrak is a generational leap in intelligent, flexible transport systems. Its absolutely unique design delivers decisive technological advantages for adaptive, connected manufacturing. Produce small batches efficiently and benefit from the higher margins of personalized products. Extend your digital transformation to include motion control and mechanical design.

Smart-factory motion control brings you key advantages: maximum availability, high-speed transport and positioning, rapid changeover and fault-tolerant high quality. ACOPOStrak boosts your overall equipment effectiveness (OEE), multiplies your return on investment (ROI) and accelerates your time to market (TTM).

ACOPOStrak – Flexible transport system with high-speed diverters

Unique design

The unique combination of features gives you a clear competitive edge:

High-speed diverters

High-speed-diverters_icon

Track morphs into any form

Track-design-felibility

Hot-swappable shuttles

Hot-swappable-shuttles

Maximum productivity

High-productivity-design

Smart system software

Smart-System-Software

Food-grade design

Flexibles-Transportsystem-hygienisches-Design

Decisive technological advantages

The decisive technological advantages enable your adaptive machine:

Merge product flows

ACOPOStrak-merging-product-flows

Divide product flows

ACOPOStrak-dividing-product-flows

Fault tolerance

ACOPOStrak-fault-tolerance

Parallel processing

Parallel-processing-load-balancing_710

Scalable machinery

ACOPOStrak-scalable-machines

Reduced footprint

footprint

High-speed diverter is pivotal

The absolutely unique high-speed ACOPOStrak diverters pass shuttles from one track circuit to another at full production speed.  This opens up entirely new possibilities for making manufacturing systems more agile and responsive.

ACOPOStrak diverters make it easy to divide and merge product flows. Fully electronic actuation means they are 100% free of wear and maintenance.

  • Highlights
  • Fully electronic diverter technology
  • 100% wear free
  • Divide and merge product flows at full speed
High-speed-diverters_ACOPOStrak-BnR

Maximum productivity

Compose custom sets in real time 
ACOPOStrak diverters let you group products into custom sets – such as a six-pack of different beverages – in real time and with no changeover.

Maximum production speed
The diverters pass shuttles from track to track reliably at full speed without any compromise in productivity.

Sorting on the fly
ACOPOStrak diverters allow you to sort out individual defective products as soon as they are identified, saving the additional waste of further processing – including primary and secondary packaging materials. This opens up new dimensions of resource efficiency and boosts the quality factor of your OEE.

ACOPOStrak-hot-swappable-shuttles

Hot-swappable shuttles

ACOPOStrak shuttles are hot-swappable and can be replaced in seconds – without any tools – for unprecedented availability. To switch products, the operator simply places the wheels of a new shuttle on the guides, and it is held in place by the force of permanent magnets alone. Include a pit lane in the track layout, and changeover and service can be performed with zero downtime. 

Parallel-processing-load-balancing_710

Parallel processing

The product flow can be divided, pass through multiple processing stations and then merge further down the line. Time-critical processes are accelerated, cycle times are reduced and productivity increases.

  • Merge product flows

  • Divide product flows

  • Rapid changeover

  • Parallel processing

  • Fault tolerance

Merge product flows

Divide product flows

Rapid changeover

Parallel processing

Fault tolerance

Build your competitive edge

In addition to the diverters, ACOPOStrak has other features that help optimize overall equipment effectiveness (OEE).

Intelligent fault handling
If there is a problem with one valve in a bottling line, the bottles are simply no longer sent to that valve. The defective valve does not result in waste, which makes a big difference in the OEE quality factor.

Highly dynamic
ACOPOStrak is capable of 5 g acceleration and reaches top speeds in excess of 4 meters per second with a minimum product pitch of only 50 millimeters. The high-performance system lets you boost productivity and maximize your ROI.

Scalable machinery

ACOPOStrak can be expanded flexibly by adding track modules and processing stations. This in turn gives your machine the scalability to adapt to changes in demand. That's true investment security that multiplies your returns. ACOPOStrak gives you more output per square meter of machine footprint.

Highly profitable, even in mass customization
Individualized processing, zero-downtime changeovers and modular track segments that morph into any form: ACOPOStrak has everything it takes to enable mass customization in batches of one. It will boost your OEE, accelerate your ROI and shorten your time-to-market.

ACOPOStrak 04
ACOPOStrak is capable of accelerating at over 5 g and achieves top speeds in excess of 4 meters per second.

Track morphs into any form

Your ACOPOStrak design
The versatile ACOPOStrak transport system grants you complete design freedom: Arrange track segments to perfectly match the needs of your site and your processes. All types of open and closed track circuits can be laid out on a grid as needed. The core of the track system is a linear motor assembled from four types of modular segments: a straight segment, a 45° segment and two 22.5° segments – one curved to the right, the other to the left. With its modular, flexible design, ACOPOStrak inspires highly innovative machine designs that adapt to the needs of your manufacturing processes. 

 

  System components:

Systemkomponenten mit pdf logo

Guide rails

  • Shuttle
    Straight guide
    45°
    90°
    135°
    180°
    Shuttle
     
    Gerade
     
    45Grad
     
    90Grad
     
    135Grad
     
    180Grad
     
    Track length
    660 mm
    900 mm
    1340 mm
    1580 mm
    1620 mm

Segments

  • Straight segment
    Curved segment (right)
    Curved segment (left)
    Circular arc segment
    ACOPOStrak_straight-segment0073
     
    ACOPOStrak_circular-arc
     
    ACOPOStrak_curved02
     
    ACOPOStrak_Circular-arc_richtig
     
    Radius
    305.58 mm
    Angle
    22.5°
    45°

Smart system software

Developers also benefit from process-oriented programming. They simply describe the rules that define the product flow on the track, rather than having to program a multitude of axes and shuttles individually. Autonomous traffic control with integrated collision avoidance takes further work off the hands of developers.

  • Highlights
  • Intuitive process flow programming
  • Integrated collision avoidance
  • 3D visualization/simulation
  • Autonomous shuttle traffic control

Faster to market
We provide an extensive range of software functionality to get ACOPOStrak up and running with minimal time and effort. Sophisticated simulation functions let you test your application code early in development before deploying it on the real hardware. This shortens your development times considerably and helps you get your machine to market faster.

Smart-System-Software_710
Flexibles-Transportsystem-hygienisches-Design

Food-grade design

ACOPOStrak is protected by stainless steel housing that meets the stringent hygiene requirements of primary packaging.

footprint

Reduced footprint

  • Highlights
  • Compact production systems
  • Integrated motor/electronics units
  • Minimized cabinet space requirements

Facts and figures

  • Technical data
    Specifications
    Maximum track length
    >100 m
    Maximum number of shuttles
    >250
    Minimum product pitch
    50 mm
    Speed
    >4 m/s
    Acceleration
    >50 m/s²
    DC bus voltage
    60 V
    Segment dimensions (W x H)
    80 mm x 85 mm
    Segment housing
    Stainless steel (meets primary packaging requirements)
    Certifications
    CE, UL
    Mounting orientation
    Any

System topology

ACOPOStrak-system-topologiepng

References: ACOPOStrak in action

Krones: Bottling on demand

Makro Labelling: Revolutionizing rotary labeling

Weiss: Fastlane ONE

World premiere live at SPS IPC Drives 2017

Important download info

Download the ACOPOStrak folder:

Folder-ACOPOStrak
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