In the run-up to SPS IPC Drives 2017, B&R practiced secrecy: only hints and promises - "We are launching a system that will revolutionize product transport in machines and systems" - were used to put off the experts. At 9:30 a.m. on the first day of the trade fair, the curtain came down: 'ACOPOStrak' is the name of the linear motor-based transport system, which Managing Director Hans Wimmer emphasizes as the "largest development project" that B&R has ever tackled."

So what new features stand out in the transport system? First of all, there's the switch: "It works purely electromagnetically and is therefore completely wear-free," says Robert Kickinger, Manager of Mechatronic Technologies at B&R. Just like a fork in the road, the switch can be used to merge or separate product flows. The switch triggers at full shuttle speed and therefore does not affect production speed. The flexible design of the system that can be realized with the switches allows all possible open and closed shapes to be built and combined with each other on the basis of a grid structure.

The track system itself is essentially a linear motor with a modular design consisting of four elements: a straight element, a 45° element and two 22.5° elements, one curved to the right and one to the left. "The 'ACOPO-Strak' enables completely new machine designs that were previously impossible to implement," says Kickinger.

The system has an acceleration of more than 5 g and achieves a maximum speed of more than 4 m/s. The minimum product distance is 50 mm. Kickinger emphasizes: "A system with these performance data in combination with switches and this design flexibility is a novelty on the market."

B&R provides extensive software functions to get the transport system up and running in a short time. The application code is fully executable in the simulation as well as on the real hardware.

The digital twin

"The user can switch between simulation and real hardware at will during development," says Kickinger. This shortens development and commissioning considerably.

The programming of the track is process-oriented. The programmer describes rules that define the product flow on the track. This is faster than programming a large number of axes or shuttles individually. In addition, the developer of the application software is relieved by integrated collision avoidance, which ensures a smooth flow of production.