In a significant advancement for industrial automation, Bosch Rexroth has introduced the TS 7plus, an innovative fully electric roller conveyor system engineered specifically for heavy-payload manufacturing lines. Positioned as the world’s first freely configurable, all-electric transfer system capable of handling loads up to 3,000 kg, the TS 7plus is set to revolutionize assembly processes across critical sectors including automotive manufacturing, battery production, and the aerospace and defense industries.
This new system addresses a growing demand for more efficient, flexible, and sustainable material handling solutions, particularly crucial in complex production environments. Its robust design and advanced features aim to enhance operational availability and reduce the total cost of ownership for manufacturers dealing with large and heavy components, a common challenge in modern EV engineering.
Elevating Capacity and Performance in Industrial Transfer Systems
The TS 7plus builds upon the foundation of its predecessor, the TS 7 system, by incorporating substantial design enhancements. A key upgrade lies in its modular sections, which feature solid or hollow rollers approximately 50% larger than those previously used. This increase in roller size directly contributes to a reduction in the number of moving parts per meter, a design choice that Bosch Rexroth highlights as a major factor in improving system availability and reliability.
The system is designed to accommodate standard workpiece pallets measuring up to 2,200 x 3,000 mm, offering considerable flexibility for diverse manufacturing needs. Its minimum transport height of 350 mm ensures versatility for both longitudinal and transverse conveying, adapting to various factory floor layouts and process requirements. Furthermore, the TS 7plus boasts an impressive conveyor speed of 24 meters per minute, which Bosch Rexroth states is significantly faster than typical Automated Guided Vehicles (AGVs), thereby optimizing throughput and accelerating production cycles.
Streamlined Assembly and Enhanced Maintenance
Ease of installation and maintenance are paramount in high-volume manufacturing settings. The TS 7plus addresses this through a meticulously redesigned bearing block, now featuring two mounting tabs. This innovative design significantly speeds up assembly processes during initial setup and simplifies subsequent maintenance or component replacement tasks. By minimizing the time required for these operations, manufacturers can achieve higher uptime and ensure continuous production flows, which is vital for meeting aggressive production targets in EV engineering and battery manufacturing.
The reduction in maintenance complexity also translates to lower operational costs over the system’s lifecycle. Fewer specialized tools or prolonged shutdowns are needed for routine servicing, making the TS 7plus a highly practical and economical choice for demanding industrial applications. Its robust construction ensures long-term durability, a critical factor for heavy-duty operations.
Innovative Drive Technology for Unmatched Reliability
At the heart of the TS 7plus’s robust performance is its advanced drive system, which relies on lubrication-free king shafts with bevel gears. This sophisticated mechanism represents a substantial departure from conventional chain drives, which typically require periodic re-tensioning and lubrication to maintain optimal performance. The elimination of these maintenance demands not only reduces operational costs but also prevents potential downtime associated with such tasks.
The absence of chain drives and their associated lubricants also contributes to a cleaner working environment, a particularly important consideration in industries where product contamination must be strictly avoided, such as battery production or aerospace component assembly. The bevel gear path design inherently keeps lubricants away from workpieces, safeguarding product integrity throughout the conveying process.
Flexible Motor Options and Integration
Powering the TS 7plus are high-efficiency motors available in 180 W and 250 W variants. These motors are designed with a third-party interface, offering system integrators and manufacturers greater flexibility in customizing their production lines. Crucially, the motors can be mounted either inside or outside the conveyor section. Internal mounting is a particularly advantageous feature, as it clears the working area of interfering contours, maximizing space and improving safety for personnel. This thoughtful design allows for more compact line layouts and enhances ergonomic considerations for operators working alongside the conveyor system.
Intelligent Operating Modes for Energy Efficiency
The TS 7plus supports two distinct operating modes, providing manufacturers with options to optimize their processes for efficiency and sustainability. The first is a conventional accumulation mode, utilizing stop gates to manage workpiece flow. This traditional method is suitable for many standard applications where continuous product accumulation is required.
However, the system truly distinguishes itself with its segmented operating mode. In this advanced configuration, each motor section of the conveyor runs only when its operation is required, rather than continuously. This intelligent control mechanism delivers significant benefits:
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Reduced Energy Consumption: By only activating motors as needed, the segmented mode dramatically cuts energy usage over the full lifecycle of the system, contributing to lower operating costs and a smaller carbon footprint – a key objective in modern EV engineering.
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Extended Service Life: The intermittent operation reduces wear and tear on motors and mechanical components, allowing for smaller motors to be specified and extending their overall service life. This translates to fewer replacements and lower maintenance costs.
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Optimized Performance: The ability to precisely control individual segments enhances the flexibility of the production line, enabling more dynamic and adaptive manufacturing processes.
Seamless Configuration with MTpro Planning Software
To facilitate effortless system design and deployment, Bosch Rexroth provides its MTpro planning software. This comprehensive tool is available as either a local installation or a browser-based MTpro Online Designer, offering flexibility in how users access and utilize its capabilities. The software streamlines the entire configuration process, from initial planning to ordering.
A standout feature of MTpro is its ability to automatically generate detailed CAD models and comprehensive parts lists based on standard-component builds. This automation eliminates manual design efforts, reduces the potential for errors, and significantly accelerates the project planning phase. Once configured, these models and lists can be seamlessly exported directly to the Rexroth Store or shared with certified partners for procurement, ensuring a smooth transition from design to implementation.
This digital integration underscores Bosch Rexroth’s commitment to Industry 4.0 principles, providing manufacturers with tools that enhance efficiency, precision, and connectivity across their production workflows, especially relevant for the complex assembly lines often found in EV engineering.
Impact on Modern Manufacturing and EV Engineering
The introduction of the TS 7plus marks a pivotal moment for industries requiring robust, precise, and sustainable heavy-payload handling. Its all-electric design, high capacity, speed, and advanced control features make it an ideal solution for critical manufacturing processes, such as assembling large battery packs for electric vehicles, handling heavy automotive sub-assemblies, or moving substantial aerospace components during their production phases.
By offering a system that is not only powerful and efficient but also inherently cleaner and easier to maintain, Bosch Rexroth is enabling manufacturers to push the boundaries of productivity and sustainability. The TS 7plus promises to enhance operational resilience, drive down costs, and support the accelerated production demands of key sectors shaping the future of industrial technology and EV engineering.