KSOFT Engineering Consultancy Services partnered with Client to deliver a robust automation solution for their battery pack assembly line. The goal was to streamline part handling operations by integrating advanced PLC logic, HMI visualization, and robotic coordination into a cohesive control system.
Our team developed and deployed a custom Allen-Bradley PLC program to manage critical assembly workflows and conveyor movements, while a user-friendly HMI interface was designed to provide operators with real-time visibility and control. We also implemented precise robot-command logic and sensor feedback mechanisms to ensure synchronized operations and reduce manual intervention.
The entire solution was successfully commissioned through remote support, enabling fast deployment, efficient troubleshooting, and ongoing system optimization without on-site programming requirements.
Trimasys Control Solutions Pvt. Ltd. is a leading industrial automation and digitalization solutions provider focused on delivering integrated control systems for modern manufacturing environments. Their expertise spans across a wide range of domains including automotive, battery manufacturing, and process industries. KSOFT supported Trimasys as an automation development partner to help implement this solution.
Freudenberg is a major global technology group supplying critical specialized components to the battery manufacturing industry, particularly for electric vehicles (EVs). While not a cell manufacturer itself, Freudenberg focuses on high-performance battery sealing solutions that ensure safety, longevity, and reliability.
The system needs PLC programming to synchronize ABB robot pick/place commands with infeed/main/outfeed conveyors via Ethernet/IP, using photoelectric/proximity sensor interlocks for precise dunnage positioning, and implementing dynamic VFD/servo speed control to eliminate robot idle time. HMI integration must provide real-time monitoring of dunnage layer status (full/empty), conveyor positions, and priority-based alarms (e.g., misalignment/jam diagnostics) via FactoryTalk View. Robot control logic must perform sequential empty dunnage layer removal after 32 parts are unloaded (4 layers × 8 parts), verified by PLC layer-counting routines.
The solution developed by KSOFT enabled precise and reliable control of all conveyor systems through Allen-Bradley PLC programming, ensuring synchronized operation with the ABB robot. The use of sensor feedback allowed the system to automatically detect dunnage and part positions, resulting in smooth robot pick-and-place cycles without manual intervention.
With optimized motor control logic, conveyor speeds were dynamically adjusted to match robotic movements, enhancing process efficiency. The custom-developed HMI provided operators with a user-friendly interface to monitor conveyor activity, issue manual controls, and track robot commands in real-time.
The system’s real-time data visibility and built-in alarm handling significantly improved operational transparency and reduced downtime by allowing faster troubleshooting. This integrated control and visualization environment delivered a stable, responsive, and maintainable automation setup tailored to the assembly line's specific needs.