Design example: Mover

Designbeispiel: Werkstückträger

The focus is on optimizing production

In the production of control units, Robert Bosch GmbH uses special workpiece carriers, so-called movers, to transport components between the various processing stations at its plant in Ansbach. The electronic parts to be transported lie on a carrier plate that is attached to the top of the mover. The movers are mounted on a guide rail and an acceleration rail running parallel to it by means of special rollers and are moved back and forth in a matter of seconds by magnetic force.

In order to optimize the cycle frequency of the production line, the speed of the mover on the magnetic track was to be increased. Since the previously used workpiece carrier consisted of five solid, conventionally milled and bolted individual parts, no design improvement could be realized on this basis to achieve the targeted transport speed. For this reason, the design professionals at FIT were commissioned by Bosch to develop an additively optimized design for the mover, which had to be one thing above all: Significantly less weight!

Der Weg vom CT-Scan zum Implantat

50 % less weight and still absolutely stable

In the production of control units, Robert Bosch GmbH uses special workpiece carriers, so-called movers, to transport components between the various processing stations at its plant in Ansbach. The electronic parts to be transported lie on a carrier plate that is attached to the top of the mover. The movers are mounted on a guide rail and an acceleration rail running parallel to it by means of special rollers and are moved back and forth in a matter of seconds by magnetic force.

To optimize the design, various iteration phases were completed in which additively manufactured prototypes of the mover were produced at FIT and tested at Bosch. The necessary design adjustments were derived from the test results and implemented. In this context, the component geometry was simultaneously designed for additive manufacturing in such a way that it could be produced with as few support structures as possible and with optimized materials. The final design convinced Bosch and was approved for production accordingly.

Vom Datensatz zum Serienbauteil

From data set to series component

The newly designed tool carrier is now additively manufactured at FIT from aluminum as a series component using laser melting (LM or PBF-LB/M). This is followed by a process-related post-processing in which the support structures are removed and the surface is blasted. The component is then milled on the functional surfaces. Finally, the milling tabs are removed and the surface is finally ground.

The production processes of the mover are accompanied by extensive quality assurance measures. For example, the aluminum powder used is regularly subjected to metallographic analysis. The mechanical properties of the components are checked on the basis of tensile and ground samples. For dimensional accuracy analysis, an optical 3D scan is performed on selected components. In addition, all parts are visually inspected by our experts before they are packed securely for transport and sent to Bosch.

Die speziellen Prozess-Anforderungen

The special process requirements

The special requirement in the project was to optimize an existing component in such a way that, despite weighing significantly less, it has better functionality and, in the end, also makes economic sense. FIT succeeded in this by developing a design that is suitable for additive manufacturing. This made it possible to save 50% weight and achieve the target speed on the conveyor line. The investment in the development and qualification of an additively designed and manufactured workpiece carrier has therefore paid off for Bosch.

Additive design is one of the central keys to optimizing components in such a way that they ensure greater efficiency in production. You can rely on the proven ADM-E solution and the experts at FIT. We are always available to provide you with advice and support.


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How to get additive design

Service

Content

Result

Definition of the framework
Together with you, we define the goals, requirements and general conditions of your design or construction project.
You will receive an offer from us with the details of the project steps, the project costs and the time of completion.
Design development/adaptation
We optimize the existing component design to suit the application and production or develop a completely new component geometry/design.
Presentation of the design/construction and determination of further steps
Design approval
We perform design simulations to verify the required component properties.

If required, we produce design or functional prototypes for testing purposes.
Presentation of the audit results and determination of further steps
Design optimization
We optimize the design according to the virtual or real test results until the optimal result for the component application as well as the planned manufacturing process is achieved.
Presentation of the final design/construction including information on the manufacturing costs of the component.

Facts about the mover

FIT solution:ADM-E (Design and engineering)
Scope of services:Topology optimization
Light weight construction
Design simulation
Design iteration
Project duration:6 weeks
FIT solution:ADM-V (Additive volume manufacturing)
Scope of services:Additive manufacturing and post-processing
Quality control
Packaging and shipping
Delivery time:6 weeks
Part dimensions:126 x 140 x 94 mm
Part weight:320 g
Lot size:40 pc
Material:Aluminum alloy (AlSi10Mg)
Technology:Laser melting (LM resp. PBF-LB/M)
Post-processing:Blasting
CNC milling
Quality control:Visual check
Optical 3D scan (samples)
Cerificate:ISO 9001

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Alexander Ervin

Your contact person

Alexander Ervin
Industry specialist mechanical engineering

+49 9492 9429 837

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