The new dimension of intelligent transport
ACOPOS 6D is a maintenance-free transport system based on innovative magnetic levitation technology that enables contactless movement in six degrees of freedom. With micrometer-precise positioning (up to 1 µm) and the ability to carry up to 40 kg payload per shuttle, it fundamentally transforms production workflows.
The intelligent system eliminates wear, maintenance and downtime completely, while also reducing space requirements by up to 75%. ACOPOS 6D enables an unmatched density of up to 69 individually controllable shuttles per square meter.
Thanks to full integration into the B&R automation portfolio and intuitive software, engineers can configure complex, multidimensional layouts within minutes and commission them faster. ACOPOS 6D turns every available square meter of your production space into an intelligent production area – for efficient, flexible and future-proof systems.
All benefits at a glance
No wear
Levitating shuttles generate no friction. This means there is no abrasion and no wear parts that could contaminate sensitive products like pharmaceuticals or food.
Easy setup
Shuttles are instantly identified by the controller using a globally unique ID, allowing positions to be assigned right away. No referencing sequences are needed, so production can start immediately.
100% simulation-ready
Fully integrated graphical design in the ACOPOS 6D Launch Pad software means hardware testing can be reduced to a minimum. ACOPOS 6D offers virtually unlimited design possibilities while remaining easy to set up. You can design layouts and processes virtually, and throughput calculation works automatically. Algorithms also optimize paths and energy consumption – for planning the ideal machine process with maximum productivity.
Minimal space requirements
With ACOPOS 6D, you can combine different shuttle sizes, segments and offsets. This gives machine builders the flexibility to arrange all process stations in the absolute smallest possible space. Software features like the weighing function of each shuttle completely eliminate the need for separate weighing stations. Complex process stations are a thing of the past, as ACOPOS 6D shuttles can take over multidimensional movements.
Integrated collision avoidance
Collision avoidance implemented directly in the firmware prevents individual shuttles from crashing into each other. This allows programmers to fully focus on the process flow.
Shared coordinate system
Native compatibility with the coordinate systems used by ACOPOStrak, SuperTrak, robotics and vision systems makes it possible to combine different transport systems and process components.
Global service
Support with layout, design, commissioning and optimization through B&R’s global service network for assistance, training and spare parts.
Simple diagnostics and optimization
With ACOPOS 6D Monitor and Industrial IoT integration, diagnostics and optimization are possible anywhere – on-site or remotely.
The ACOPOS 6D package combines the most comprehensive software ecosystem with the widest range of hardware in planar technology, making it the ideal solution for machine builders looking to implement future-proof, modular and highly dynamic production processes.
Function and components
Technical specifications
ACOPOS 6D Series 3 is optimized for compact machine layouts and offers high repeatability with minimal space requirements – ideal for applications with tightly grouped shuttles. ACOPOS 6D Series 4, on the other hand, is designed for higher payloads and is suitable for transporting large parts over longer distances.
| ACOPOS 6D | Series 3 - designed for tight installation conditions | Series 4 - built to carry more – designed to install faster |
|---|---|---|
| Shuttle size | 10 Shuttle sizes (120x120 – 450x450mm) | 10 shuttle sizes (160x160 – 600x600mm) |
| Shuttle payload | 0,6 - 20kg | 1,8 - 40kg |
| Segment size | 240 x 240 x 7 0mm and 480 x 120 x 70 mm | 320 x 320 x 80 mm |
| Max. speed | 3m/s | 3m/s |
| Max. acceleration | 20m/s² | 20m/s² |
| Levitation height | 0,5 – 4mm | 0,5 – 6mm |
| Positioning accuracy | < 5 µm | < 10 µm |
| Shuttle rotation | <20mrad (X,Y), <20° (Z) | <20mrad (X,Y), <20° (Z) |
| Protection class | IP67 | IP67 |
| Shuttles - Hygienic Variants | available | available |
| Segment cooling | integrated* | integrated* |
ACOPOS 6D Shuttles
Hot-swappable shuttles ensure uninterrupted transport and precise positioning in six degrees of freedom. The maintenance-free permanent magnet shuttles are available in 19 sizes (120 x 120 to 600 x 600 mm) and reach every target point with repeatability of less than 5 µm (S3) or 10 µm (S4).
Hygienic and aseptic surface options made of stainless steel (AISI 316L) are available for applications in food production or cleanrooms.
ACOPOS 6D segments
The segments can be flexibly mounted along the X and Y axes – side by side, offset or with gaps for protective covers, cable routing or process stations. This offers maximum design freedom with optimal space utilization. Individual segments can be seamlessly combined with existing conveyor belt or track systems, while narrow segments additionally enable efficient and cost-effective transport in single-lane applications. Depending on your needs, the system’s protective cover can be made from stainless steel, silicone, titanium, glass or other materials, allowing for full customization to your process requirements.
Software
With ACOPOS 6D Launch Pad, mapp 6D and ACOPOS 6D Monitor, ACOPOS 6D is seamlessly supported across the entire lifecycle – from the first concept to ongoing maintenance – ensuring efficiency, reliability and ease of use.
The web-based ACOPOS 6D Launch Pad makes it possible to intuitively create layouts and simulate processes visually – including instant virtual throughput calculation. A Traffic Manager automatically handles pathfinding and routing based on process stations. The Flight Recorder simplifies live and offline diagnostics with event triggers and a graphical replay function. The IIoT connector makes it easy to link edge applications, while a cloud or edge infrastructure provides, depending on your needs, the security of a standalone solution, virtually unlimited replay storage or flexible remote access to process flows using the ACOPOS 6D Monitor and apps for planar motor technology.
Components & Modules
Controller
Cables
Shuttles S3
Shuttles S4
Segments S3
Segments S4
References and success stories
Insights into real-world applications and partnerships: See how companies worldwide are benefiting from our solutions.