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!

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.

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.