This product is an intelligent flexible assembly conveyor line engineered specifically for new energy vehicle (NEV) manufacturing. It integrates three core modules: overhead EMS conveyors, floor-based skid conveyors, and chassis marriage systems. Designed for mixed-model production of Battery Electric Vehicles (BEVs) and Plug-in Hybrid Electric Vehicles (PHEVs), the system prioritizes high cycle rates, precision, and flexibility. It facilitates automated logistics from body shop to final assembly, supporting annual production capacities ranging from 100,000 to 300,000 units.
1. Product Positioning
As core logistics equipment for the electric vehicle assembly line, this system utilizes a modular design to support rapid deployment and scalability. Main and sub-lines are customized to fit facility layouts, accommodating the wheelbase and load requirements of mainstream NEV platforms. The structure is reinforced specifically for handling heavy components such as battery packs and e-drive systems.
2. Core Functionality
Body In White (BIW) Overhead Conveyance & Buffering
The EMS (Electrified Monorail System) overhead conveyor transfers welded BIW shells from the body shop to the assembly shop. It supports online buffering and automatic transfer. The track system utilizes high-strength steel, with a unit load capacity of up to 800 kg, variable speed (5–20 m/min), and a stop positioning accuracy of ±2 mm.
Floor Conveyor Circulation
The skid conveyor system transports the vehicle body between workstations, facilitating modular assembly of doors, seats, and instrument panels. The conveyor height is set at 800 mm, with adjustable station pitches. Drive power ranges from 5.5–7.5 kW, meeting the demands of continuous operation.
Chassis & Battery Pack Marriage
Dual-lift AGVs or EMS carriers execute the precise docking of the body and chassis modules. Equipped with vision positioning systems, the lift mechanisms achieve an alignment accuracy of ±0.5 mm, ensuring zero deviation for battery pack mounting holes. AGVs offer a lift capacity of ≤2000 kg and support both magnetic nail and laser navigation.
Multi-Model Flexible Changeover
Utilizing skid ID recognition and PLC-based intelligent scheduling, the system enables seamless mixed-model production across different platforms. Automatic width-adjustment mechanisms at key stations reduce changeover time to under 3 minutes, significantly boosting line utilization (OEE).
Safety & Quality Traceability
The line is equipped with safety light curtains, emergency pull cords, and anti-collision devices. Critical stations integrate torque management systems, with data uploaded in real-time to the MES for full assembly process traceability.
3. Technical Specifications
| Category | Parameter | Specification |
|---|---|---|
| Floor Conveyor | Load Capacity | ≤ 3500 kg |
| Speed | 0.5 – 12 m/min | |
| Positioning Accuracy | ± 1.0 mm | |
| Drive Power | 5.5 – 7.5 kW | |
| Overhead (EMS) | Load Capacity | ≤ 800 kg |
| Speed | 5 – 20 m/min | |
| Incline Capability | ≤ 5° | |
| Positioning Accuracy | ± 2.0 mm | |
| AGV Marriage | Lift Capacity | ≤ 2000 kg |
| Lift Stroke | 1200 – 1800 mm | |
| Navigation | Magnetic Nail / Laser | |
| Repeatability | ± 5.0 mm | |
| Control System | Main Control | Siemens S7-1500 PLC |
| Communication | Profinet / Industrial Ethernet | |
| Diagnostics | Remote Monitoring & Logging |
4. Core Advantages
- Flexible & High Efficiency: Supports mixed-model production with rapid changeovers; OEE ≥ 90%.
- Precision & Reliability: Critical marriage accuracy up to ±0.5 mm; MTBF ≥ 2000 hours.
- Smart Connectivity: PLC-MES data exchange enables end-to-end digital control.
- Safety & Durability: Key components rated IP65; noise emission ≤ 75 dB; service life ≥ 10 years.
5. Service & Support
We provide comprehensive support, including conceptual design, manufacturing, installation, commissioning, and operator training. The equipment comes with a 12-month warranty and lifetime technical support. Spare parts are stocked in key regions to ensure a 24-hour response time.