Author: Le Hung

In today’s rapidly evolving new energy market, the lithium battery, as one of the key drivers, has its production efficiency and technological advancements playing an important role in overall market competition. In this article, we’ll share a successfully implemented case using the FTS Intelligent Maglev Conveyor System in prismatic cell module assembly lines within the lithium battery industry. It demonstrates how smart technology is tackling traditional production challenges of efficiency and flexibility.

Customer Background and Production Line Application Requirements

The client in this case specializes in the lithium battery sector, their prismatic cell module assembly line deals with the process from raw materials into finished battery products. The production process is intricate, involving automatic material loading and transfer with AGVs, robotic vision-guided unpacking, sorting, and scanning of batteries and cooling plates, cell OCV testing, adhesive application and inspection, grouping of cells into beams, and stack formation into battery blocks. These processes pose high challenges to the conveyor system on precision, efficiency, and flexibility.

FTS Intelligent Maglev Conveyor: A Game-Changing Solution

To overcome these challenges, the customer introduced the FTS Intelligent Maglev Transport System, bringing revolutionary improvements to the prismatic cell module assembly line. This system has particularly excelled in the high-speed transfer loop for cooling plates and has demonstrated its exceptional performance as follows:

Efficient Transfer Loop: FTS’s magnetic levitation technology enables smooth, high-speed transport of cooling plates, significantly boosting overall production efficiency.

High Flexibility and Compatibility: The FTS system is customized and adapted seamlessly to different sizes of cooling plates, satisfying diverse production requirements of different battery modules, and reducing changeover time and costs.

Intelligent Control: The FTS system supports both group and bidirectional movement, and thus enhances transfer efficiency. In cases of product defects (NG), the mover can quickly retract, keeping the continuity and flexibility of the production process.

Adjustable Spacing, No Fixtures Needed: The conveyor system’s spacing can be limitlessly adjusted without the additional fixtures required, simplifying operations and improving production flexibility.

Quick Changeover: When switching cooling plates, the system only requires parameter change, eliminating the need for physical components change. This significantly reduces changeover time and improves the line’s ability to quickly adapt to market demands.

The FTS Intelligent Maglev Conveyor System helped the customer overcome challenges of traditional conveyor lines. It also delivered significant improvements in production efficiency and cost savings through its flexibility, smart control, and superior performance. This successful practice underscores the vast potential of FTS maglev technology in automatic lithium battery production lines, offering valuable references for other industries. As technology continues to evolve, FTS will continue to demonstrate its unique value across various fields, driving manufacturing toward greater intelligence and efficiency.

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Based in East China,
Reaching Out Worldwide

FHS Group is based in East China, with a global layout. FHS Group has after-sales service outlets and partners in many countries and regions around the world, and has set up subsidiaries in the U.S.A., Germany and Hungary, and maintains after-sales team and partners in France, Spain, the Czech Republic, Romania, Mexico, Poland, Hungary, South Korea, India and other countries.

Leading in Intelligent Manufacturing
and Multi-Industry Development

Founded in 2010 and headquartered in Kunshan, Jiangsu Province, FHS Group is a global one-stop smart manufacturing solution provider. There are more than 2,000 employees, of which R&D team accounts for more than 60%. The business scope covers new energy, auto parts and life sciences and other intelligent manufacturing fields, providing intelligent, digital, flexible intelligent manufacturing production solutions and core equipment data services.

Continuous Management Optimization
for High-Quality Industry Development

FHS Group is committed to promoting digital, modular and lean management. We have a strong grasp of a number of core technologies, including control perception, laser processing technology and digital information technology. This allows us to consolidate our absolute competitive advantage as an enterprise. By continuously enhancing systematic management and optimizing our supply chain, project management, and talent development systems, we support rapid business growth. We are dedicated to breaking new ground in cutting-edge technologies and exploring innovative solutions in intelligent manufacturing, driving high-quality development across the industry.

In today’s era of advanced industrial automation, the FTS Intelligent Maglev Transport System has become the preferred solution for industries aiming to modernize and boost efficiency. Renowned for its great efficiency, high precision, low noise, and other exceptional performance, it sets a new standard in industrial transportation. Recognized as the system’s core configuration tool, iFTS Studio Configuration Software revolutionizes system deployment, enhances operational stability, makes it easy to configure transport systems and delivers unprecedented agility and intelligence to users, empowering them to adapt to dynamic industrial demands with ease.

Based on the advanced iFCS control platform, iFTS Studio offers full lifecycle management—covering system planning, design, commissioning, operation, and maintenance. With this software, engineers can easily achieve customized configuration to cater to different application scenarios. By a user-friendly GUI with robust debugging capabilities, the software reduces the technical barrier to system deployment and maintenance, broadens the adoption of the FTS Smart Maglev Conveyor System across industries and accelerates the shift toward intelligent manufacturing.

Why Choose iFTS Studio Configuration Software?

System Configuration Function： System Setup with Easy Graphical Parameterizations

With a simple GUI, iFTS Studio makes system setup quick and intuitive. Users can easily design conveyor paths by dragging and dropping track and workstation components, while features like offline loading, importing, and exporting ensure seamless configuration migration and backup. The software also supports various track topologies —such as straight paths, loops, and diverging— flexibly adapting to diverse applications.

System Monitoring: Real-Time Monitoring, Comprehensive System Status Presented

The software offers comprehensive monitoring tools, providing real-time updates on mover and motor integrated module status. If a fault occurs, iFTS Studio generates alerts instantly and provides actionable troubleshooting steps. Historical data and communication logs are provided further to identify the root causes and resolve problems efficiently and straightforwardly.

Parallel Debugging: Accelerating Delivery and Improving Efficiency

One of the most impressive features of iFTS Studio Configuration Software is its support for multi-terminal parallel debugging. A single controller can accommodate up to 20 terminals simultaneously, significantly improving debugging efficiency and reducing system delivery cycles. Each terminal operates independently during the debugging process, ensuring non-interference and enhancing system safety and stability. Terminal configuration is flexible, allowing users to freely allocate terminal intervals and use independent accounts for login and management. Additionally, wireless connectivity eliminates cumbersome cables, making debugging more convenient and efficient.

Waveform Display: Real-Time Data for Precise Analysis

The integrated oscilloscope function provides real-time visual monitoring of mover position, enabling the users to more precisely analyze the system operation status, identify issues promptly, and facilitate problem-solving.

Parameter Writing: One-Click Operation for Rapid Deployment

IFTS Studio simplifies parameter setup with a one-click writing function. Users can set parameter values directly through the interface, allowing for rapid deployment and on-the-fly adjustments. This reduces configuration time and enhances overall efficiency.

System Simulation: Sandbox Practice for Advance Planning

With its built-in simulation feature, iFTS Studio allows users to test and optimize system operations without interrupting actual production. By identifying potential issues early, the software ensures smooth and efficient performance when the system goes live.

IFTS Studio Configuration Software is a game-changer in configuring and optimizing the FTS Intelligent Maglev Transport System. By improving stability, simplifying operations, and lowering maintenance costs, it empowers businesses to achieve greater productivity, flexibility, and competitiveness in the era of intelligent manufacturing.

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Based in East China,
Reaching Out Worldwide

FHS Group is based in East China, with a global layout. FHS Group has after-sales service outlets and partners in many countries and regions around the world, and has set up subsidiaries in the U.S.A., Germany and Hungary, and maintains after-sales team and partners in France, Spain, the Czech Republic, Romania, Mexico, Poland, Hungary, South Korea, India and other countries.

Leading in Intelligent Manufacturing
and Multi-Industry Development

Founded in 2010 and headquartered in Kunshan, Jiangsu Province, FHS Group is a global one-stop smart manufacturing solution provider. There are more than 2,000 employees, of which R&D team accounts for more than 60%. The business scope covers new energy, auto parts and life sciences and other intelligent manufacturing fields, providing intelligent, digital, flexible intelligent manufacturing production solutions and core equipment data services.

Continuous Management Optimization
for High-Quality Industry Development

FHS Group is committed to promoting digital, modular and lean management. We have a strong grasp of a number of core technologies, including control perception, laser processing technology and digital information technology. This allows us to consolidate our absolute competitive advantage as an enterprise. By continuously enhancing systematic management and optimizing our supply chain, project management, and talent development systems, we support rapid business growth. We are dedicated to breaking new ground in cutting-edge technologies and exploring innovative solutions in intelligent manufacturing, driving high-quality development across the industry.

Amid the rise of intelligent manufacturing, maglev transport systems have become the “rising stars” of industrial automation, recognized for their low friction, high efficiency, and high flexibility. Among their numerous advantages, load capacity is undoubtedly one of the core metrics for evaluating system performance. It not only determines whether the system can bear diversified production needs, but is also the solid foundation for maintaining production efficiency and stability.

Why Does Load Capacity Matter?

For manufacturing enterprises, load capacity directly impacts production efficiency, cost control, and operational safety. Whether transporting lightweight electronic components or heavy industrial equipment weighing several tons, a transport system capable of accommodating various loads enables greater flexibility, lower maintenance costs, and enhanced competitiveness. Therefore, choosing a maglev transport system with excellent load capacity is a critical step for enterprises to upgrade intelligent manufacturing.

Flexible Transport System (FTS): Leading the Way in Load Capacity

The FTS maglev transport system, backed by advanced technology and innovative design, excels in load capacity, providing manufacturing enterprises with a reliable, flexible, and efficient solution.

1. Wide Load Range for Comprehensive Applications

The FTS maglev transport system caters to the full range of production requirements covering both lightweight and heavy-duty by offering a remarkable load range from 1 kg to 5000 kg. Its product lineup includes FTS Light Thrust Diverge Series (FTS-LT), FTS Medium Thrust Series (FTS-MT) and FTS High Thrust Series (FTS-HT). This comprehensive range ensures that each system precisely meets specific production scenarios, whether for intricate assembly tasks or large-scale material handling.

2. Customized Solutions for Maximum Flexibility

FTS is well aware of the uniqueness of each production scene. To address diverse load requirements, FTS offers in-depth customization services. From adapting to specific load shapes, sizes, and weights to enabling simultaneous or independent movement of multiple movers, this flexibility of FTS endows the production line with more possibilities and brings more optimized production transportation to enterprises.

3. Intelligent Monitoring for Stability and Efficiency

Equipped with the proprietary iFTS control system, the FTS continuously monitors and optimizes load conditions in real time, maintaining peak performance. Its intelligent scheduling capabilities allow for rapid adjustments to production demands, optimizing workflows. Seamless integration with production management systems enables intelligent material scheduling and efficient resource allocation, driving production with higher precision and productivity.

4. Exceptional Speed and Performance

For example, the FTS-MT, with a typical load of 15 kg, achieves speeds of up to 5 m/s and a peak thrust of 580 N. At this load, it can accelerate at 2 g, significantly enhancing transport efficiency, reducing production cycle time, and boosting economic returns. Even at high speeds, the system demonstrates outstanding stability and reliability, further highlighting its exceptional load-handling performance.

By combining prominent load capacity with customization, intelligence, and efficiency, the FTS maglev transport system is leading the innovation in industrial automation. As maglev technology continues to evolve and expand into new applications, FTS will unlock even greater value for the manufacturing industry in the future.

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Based in East China,
Reaching Out Worldwide

FHS Group is based in East China, with a global layout. FHS Group has after-sales service outlets and partners in many countries and regions around the world, and has set up subsidiaries in the U.S.A., Germany and Hungary, and maintains after-sales team and partners in France, Spain, the Czech Republic, Romania, Mexico, Poland, Hungary, South Korea, India and other countries.

Leading in Intelligent Manufacturing
and Multi-Industry Development

Founded in 2010 and headquartered in Kunshan, Jiangsu Province, FHS Group is a global one-stop smart manufacturing solution provider. There are more than 2,000 employees, of which R&D team accounts for more than 60%. The business scope covers new energy, auto parts and life sciences and other intelligent manufacturing fields, providing intelligent, digital, flexible intelligent manufacturing production solutions and core equipment data services.

Continuous Management Optimization
for High-Quality Industry Development

FHS Group is committed to promoting digital, modular and lean management. We have a strong grasp of a number of core technologies, including control perception, laser processing technology and digital information technology. This allows us to consolidate our absolute competitive advantage as an enterprise. By continuously enhancing systematic management and optimizing our supply chain, project management, and talent development systems, we support rapid business growth. We are dedicated to breaking new ground in cutting-edge technologies and exploring innovative solutions in intelligent manufacturing, driving high-quality development across the industry.

With the rapid development of contemporary technologies, smart manufacturing has become the mainstream trend of industrial progress. As a global intelligent manufacturing enterprise integrating intelligent, digital and flexible production solutions and data services, FHS Group, with its forward-looking technical vision and excellent R&D capabilities, has been deeply engaged in new energy, medical devices, automotive automation and other fields for many years, established various model projects and led the development and innovation of the industry.

With FHS Group’s accumulation in intelligent manufacturing and precise insights into future trends in this industry, the FTS (Flexible Transport System) is launched based on deeply understanding of the intelligent conveying field. This system adopts advanced magnetic levitation technology to realize the low-friction movement of the conveying line, greatly reducing friction loss and noise pollution while improving the overall system stability and operation efficiency.

The existing product series in three configurations is to cater to various industrial needs:

FTS-HT (High Thrust): Engineered for heavy load applications.

FTS-MT (Medium Thrust): Ideal for medium and small load requirements.

FTS-LT (Light Thrust): Designed for light load and diverging/merging tasks.

These solutions are highly adaptable, cost-effective, and tailored to deliver exceptional performance, earning high praise and recognition worldwide.

Repetitive Positioning Accuracy: A Critical Benchmark

Among many performance indicators of maglev conveyors, the repetitive positioning accuracy is a decisive factor. It reflects the system’s ability to consistently return to the same position during repeated operations, which directly indicates the stability and reliability of the conveyor system and plays a decisive role in ensuring the continuity of the production line and the quality of products. In the era of smart manufacturing, with the increasing requirements for production efficiency and product precision, the importance of repetitive positioning accuracy has become more and more prominent.

From the customer’s perspective, the repetitive positioning accuracy is directly related to production efficiency and product quality. In high-precision required industries such as precision manufacturing, semiconductor production, and pharmaceutical manufacturing, any slight position deviation may lead to unqualified products or even cause serious production accidents. Therefore, when customers choose maglev conveyors, they often regard repetitive positioning accuracy as the primary consideration factor. A conveyor with high repetitive positioning accuracy can ensure the stability and consistency of products during the production process, thereby improving production efficiency and product quality while reducing production costs.

What Sets the FTS Apart

The FTS Intelligent Maglev Conveyor System performs excellently in terms of repetitive positioning accuracy, which is attributed to its careful design in multiple aspects such as mechanical structure, sensor accuracy, control system, and application environment.

Refined Mechanical Structure

The FTS system incorporates a V-shaped high-precision grinding guide rail that ensures optimal parallelism and rigidity. Hardened surfaces enhance its extremely strong wear resistance, while dual-row bearing rollers minimize radial clearance, guaranteeing exceptional mechanical accuracy.

Self-developed Linear Encoders

FHS Group has independently developed high-precision linear encoders built on advanced displacement sensing technology. These encoders feature cutting-edge surface mount process technology, rigorous factory acceptance testing, and highly efficient temperature compensation algorithms. Together, these innovations ensure industry-leading performance in positioning and repeatability.

High-Precision Control System

The system’s integrated motor controller is equipped with advanced torque ripple suppression algorithms and high-precision current sampling circuits. These features minimize operational fluctuations and errors, further enhancing accuracy and stability.

Optimized Environmental Design

By adopting high-power-density motor technology, the FTS system reduces heat generation, limiting the impact of temperature fluctuations. Additional features, such as wide-temperature guide rails and temperature compensation algorithms, maintain consistent performance in varied environments.

The FTS Intelligent Maglev Conveyor System not only improves production efficiency and product quality but also reduces losses and costs associated with positioning errors. Its outstanding performance underscores FHS Group’s commitment to advancing intelligent transport solutions. As the smart manufacturing industry continues to evolve, the FTS system is poised to unlock new opportunities and applications, solidifying FHS Group’s reputation as an innovator and industry leader.

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Based in East China,
Reaching Out Worldwide

FHS Group is based in East China, with a global layout. FHS Group has after-sales service outlets and partners in many countries and regions around the world, and has set up subsidiaries in the U.S.A., Germany and Hungary, and maintains after-sales team and partners in France, Spain, the Czech Republic, Romania, Mexico, Poland, Hungary, South Korea, India and other countries.

Leading in Intelligent Manufacturing
and Multi-Industry Development

Founded in 2010 and headquartered in Kunshan, Jiangsu Province, FHS Group is a global one-stop smart manufacturing solution provider. There are more than 2,000 employees, of which R&D team accounts for more than 60%. The business scope covers new energy, auto parts and life sciences and other intelligent manufacturing fields, providing intelligent, digital, flexible intelligent manufacturing production solutions and core equipment data services.

Continuous Management Optimization
for High-Quality Industry Development

FHS Group is committed to promoting digital, modular and lean management. We have a strong grasp of a number of core technologies, including control perception, laser processing technology and digital information technology. This allows us to consolidate our absolute competitive advantage as an enterprise. By continuously enhancing systematic management and optimizing our supply chain, project management, and talent development systems, we support rapid business growth. We are dedicated to breaking new ground in cutting-edge technologies and exploring innovative solutions in intelligent manufacturing, driving high-quality development across the industry.