Standardized construction kit for heavy-duty transport: roller conveyor TS 7plus transports up to 3,000 kg through assembly lines

• World’s first freely configurable, fully-electric transfer system for heavy loads
• Highly available standard components replace individual projects
• Segmented operation increases energy efficiency

Battery packs for e-mobility, e-axles, and other heavy components demand new concepts for material flow in assembly. Commonly used, customized individual projects are very complex, while automated guided vehicles (AGVs) often increase transport times. Bosch Rexroth is closing this gap with the new roller conveyor TS 7plus. Based on a standardized construction kit, the heavy-duty transfer system efficiently transports workpieces weighing up to 3,000 kg through assembly lines.

The transfer systems TS 1, TS 2plus, and TS 5 from Bosch Rexroth are widely used in the automotive industry across the world. They move small and medium-sized workpieces through assembly lines in a highly efficient manner. The transfer system TS 7plus is the world’s first solution to apply this modular approach to workpieces weighing up to 3,000 kg. The standard dimensions of the workpiece pallets are up to 2,200 x 3,000 mm.

TS 7plus transports material via conveyor rollers on freely configurable modular sections with lift/transverse, rotary, and positioning units, as well as stop gates. The 350mm minimum possible transportation height for both longitudinal and transverse conveying helps facilitate manual processes and improves ergonomics for employees.

The conveyor section consists of either solid or hollow rollers, which are approximately 50 percent larger than the previous TS 7 system. The reduced number of moving parts per meter increases availability and the newly designed bearing block enables faster assembly with two screw points in the profile, as well as easy replacement for maintenance.

Lubrication-free king shaft

Unlike chain drives, the tried-and-tested drive via king shafts operates without lubrication and requires minimal maintenance. The motor’s torque is transmitted to the conveyor rollers via bevel wheels, thus minimizing contamination of the workpieces. The bevel wheels also require no re-tensioning or maintenance.

In conventional accumulation operation, stop gates keep the workpiece pallets at defined stations. With the alternative segmented operation, the motors for section transport, rotary units, and lift/transverse units run only when required. This increases energy efficiency across the entire life cycle and significantly reduces the total cost of ownership. In addition, the motors can be designed smaller and benefit from a longer service life due to their demand-based operation. As part of its system portfolio, Bosch Rexroth offers motors with outputs of 180 W and 250 W for the TS 7plus, as well as an interface for the use of third-party motors.

High conveyor speed, no interfering contours

The motors can be placed on either the outside or inside of the section. With internally mounted motors, there are no interfering contours that could otherwise hinder employees or protrude into travel paths. With a conveyor speed of up to 24 m/min, the system achieves significantly shorter transport times than automated guided vehicles (AGVs), for example.

CAD-free configuration with planning software MTpro

The intuitive planning software MTpro assists in the configuration of transfer systems, and guides users quickly and easily through the whole process. Bosch Rexroth offers the planning software as a locally installable full version and as an installation-free web version in the form of MTpro online Designer. The software automatically creates CAD models and parts lists from builds, which can be transferred to the Rexroth Store or to certified partners.