Two Vollert crane systems referred to as train handlers have been unloading freight cars with e-car batteries in parallel operation on a travelling distance of 107 m at the ŠKODA plant in Mladá Boleslav since mid-2022. They are equipped with four fork tines and a lifting force of up to ten tons each. After opening of the car doors, the train handlers will independently determine the position of the battery transport racks, taking out two racks at a time. Manoeuvring space is ensured by the crane tracks on stands with a crane bridge and a control unit that is travelling along. The limited structure gauge and narrow space has led to suspended installation of the trolley with hydraulic lifting device in order to save space. A pivoting unit permits depositing of the battery racks at an angle of 90° on the subsequent conveyor track towards the ŠKODA production.
Securely loading and unloading migrating trains
“Automation of train loading and unloading clearly accelerates processes. We are about three times as fast as we would be in manual operation of two forklifts. That is also due to the fact that we alternate the return of empty transport racks to the trains,” Jochen Keinath, head of surface technology sales at Vollert, explains. The accident and damage risk are also much reduced, both for the cars and on the sensitive batteries. This is made possible by the reliable safety system used in the Vollert train handlers. It ensures safe interaction between man and technology while also reliably recognising the actual placement of the trains. Once the train has arrived, the train handlers will perform a reference run along the cars, similar to that of a parking assistant. They also keep checking the car position while loading later, since these will “migrate” as their weight changes. That means that the deflection will cause them to move in height and length alike. Vollert’s train handlers adjust their own position accordingly.
Flexibility in spite of automated processes
In order to perform loading speedily, the train handlers will usually pick up two transport racks at a time. The process must remain flexible nevertheless – e.g., if there is an odd number of transport units. Therefore, the fork tines can be automatically adjusted sideways, moved together and apart, and fully folded up hydraulically to permit individual transport as well.
Highest reliability for just-in-time production
In addition to greatest safety, reliability is vital in the automotive industry. The two train handler systems by Vollert are designed redundantly to avoid standstill of the plant in any case. They can supply the entire loading area individually as well. A secured maintenance position for each train handler permits free movement on the shared crane track in that case. Beyond this, simple maintenance was very important to ŠKODA, along with short repair times and easy accessibility and replacement of components.
Vollert designed the two train handlers using decades of know-how in track loading since the intralogistics experts have already developed similar plants for loading of beverage crates, aluminium coils, or fertilisers. Vollert can derive its knowledge of sensitive battery handling from its fully automated battery change stations for automated guided vehicles (AGV) in harbour logistics, where Vollert fully automatically replaces twelve-tons-heavy battery trays within five minutes, taking them to a high-bay warehouse for charging.
