Design and simulation of a flexible production line using Acopostrak technology

This thesis focuses on the design and simulation of a flexible production line based on B&R's ACOPOStrak technology, developed to address the demands of modern production for customization and adaptability. The system combines modularity and advanced motion control, enabling a dynamic and efficient production flow. The designed line integrates filling, capping and sorting stations to manage bottles containing different products, optimizing processes through defect detection sensors and customized stop-and-restart mechanisms. An innovative system was implemented to allow production to continue even in the event of station malfunctions, enhancing operational resilience. Thanks to the modularity of the ACOPOStrak system, the project enables shuttles to be added or removed without interrupting production, ensuring both safety and reliability. The use of simulation tools allowed for the verification of the design solutions’ effectiveness and their applicability to real industrial scenarios. This work demonstrates how flexible automation can meet the challenges of modern production, offering scalability, reduced downtime, and improved quality control.