10.30.2025 / 5-minute read

Heavy-Duty Auto-Turn Platform for Automotive Manufacturing

Overview

We recently collaborated with a leading global automotive components manufacturer, delivering a fully customized solution for their newly built automated production line.

The client needed a system capable of safely and accurately flipping 4-ton fuel cell stacks by 90 degrees between two workstation positions, while ensuring seamless integration with their existing automation system.

If you are exploring automation upgrades involving material flipping, precise positioning, or production line integration, contact us today.
We are ready to engineer the optimal customized solution for your needs.

Basic Parameters

Item	Specification
Table Dimensions	2600 mm × 2000 mm + 2000 mm × 1500 mm
Flipping Angle	90°
Load Capacity	4000 kg
Equipment Class	Standard (Non-Explosion Proof)
Structural Design	—
Stroke Height	—
Infeed/Outfeed Direction	—

Component	Specification
Base Frame	J160 × 80 × 4
Table Frame	J160 × 80 × 4
Table Top Plate	4 mm steel plate
Hydraulic Cylinder	Φ100-80
Hydraulic Power Pack	7.5 kW
Hydraulic Pipeline	Φ27

Challenges

High Load Capacity with High Positioning Precision
The fuel cell stacks are high-value and highly engineered components. The turning platform must manage a 4,000 kg load while ensuring a stable and precise rotation (verticality ≤ 3 mm) with zero product damage risks.
Strict Automation Integration Requirements
The platform must communicate with the MES in real time, providing workstation status, completion signals, and fault alarms to achieve fully automated production cycles.
Limited Installation Space
The platform height in horizontal position must be ≤ 441 mm, ensuring easy loading/unloading and compact layout with no major ground reconstruction.
Harsh Industrial Environment
Continuous operation requires high reliability, low maintenance, and noise level ≤ 75 dB for improved workplace conditions.

Our Solution

1️⃣ Robust Heavy-Load Structural Design

Frame built with J160×80×4 structural steel
Table equipped with galvanized wear-resistant plates, enhancing durability and corrosion resistance

2️⃣ Precise and Efficient Hydraulic Drive

Equipped with Φ100-80 hydraulic cylinders and a 7.5 kW power pack
Rotation completed within ≤ 30 seconds, with adjustable speed
Smooth and stable movement without impact

3️⃣ Intelligent and Reliable Automation Control

Core control by Siemens PLC
Electrical components from Schneider Electric
Fully supports production line automation, providing 5 integrated control signals:
- Normal operating status
- Fault alarm
- Position A feedback
- Position B feedback
- Rotation completion
Dual-mode control: Jog / Automatic
Built-in phase-loss and leakage protection for enhanced safety

4️⃣ User-Friendly & Noise-Control Design

Integrated control cabinet + hydraulic power unit for reduced footprint
Optimized hydraulic and structural design ensures low-noise operation ≤ 75 dB
Customized finish in RAL1018 (table) and RAL9002 (base), blending into the modern industrial environment