Bosch Rexroth, a global leader in drive and control technologies, has officially launched its groundbreaking TS 7plus, an advanced fully electric roller conveyor system engineered specifically for heavy-payload manufacturing lines. This introduction marks a significant evolution in industrial material handling, addressing the growing demands for efficiency, precision, and sustainability in sectors handling substantial loads.
The company asserts that the TS 7plus stands as the world’s inaugural freely configurable, fully electric transfer system capable of handling impressive loads up to 3,000 kg. This innovation is strategically targeted at critical assembly operations within the automotive, battery manufacturing, and aerospace/defense industries, where the precise and reliable movement of heavy components is paramount.
Engineering for Enhanced Performance and Reliability
The design of the TS 7plus represents a considerable leap from its predecessor, the TS 7 system. It incorporates modular sections that utilise solid or hollow rollers, which are approximately 50% larger in diameter. This increase in roller size plays a crucial role in reducing the number of moving parts per meter of the conveyor, a design choice Bosch Rexroth highlights as a direct contributor to improved system availability and operational uptime.
Designed for versatility, the system accommodates standard workpiece pallets measuring up to 2,200 x 3,000 mm. Its minimum transport height is set at 350 mm, allowing for both longitudinal and transverse conveying, which offers greater flexibility in factory layouts. Furthermore, the TS 7plus boasts an impressive conveyor speed of 24 meters per minute, a rate Bosch Rexroth notes as significantly faster than that typically achieved by Automated Guided Vehicles (AGVs).
Streamlined Assembly and Maintenance
A key focus during the development of the TS 7plus was simplifying its installation and upkeep. The system features a redesigned bearing block equipped with two mounting tabs. This particular enhancement is engineered to expedite the assembly process, reduce installation time, and significantly streamline both routine maintenance and component replacement procedures. Such design considerations directly translate into reduced downtime for manufacturers.
Innovative Drive Technology for Sustainable Operations
At the core of the TS 7plus’s drive mechanism are lubrication-free king shafts coupled with bevel gears. This sophisticated design completely eliminates the need for the re-tensioning and regular lubrication typically associated with traditional chain drives. The removal of these maintenance requirements offers substantial operational benefits, including reduced labour, lower material costs for lubricants, and a cleaner operating environment.
The system’s motors are available in two power variants: 180 W and 250 W. These motors are equipped with a third-party interface, ensuring compatibility and flexibility within existing industrial ecosystems. A notable design feature allows for motors to be mounted either inside or outside the conveyor section. Internal mounting is particularly advantageous as it clears the working area of any interfering contours, thereby enhancing safety and ergonomic access for personnel.
Moreover, the integration of the bevel gear path ensures that lubricants are kept away from sensitive workpieces, a critical consideration in industries such as battery manufacturing where cleanliness and contamination prevention are paramount. This meticulous design further underscores Bosch Rexroth’s commitment to delivering advanced manufacturing solutions that meet stringent industry standards.
Intelligent Operating Modes for Energy Efficiency
The TS 7plus supports two distinct operating modes, providing adaptability for various production needs. The first is a conventional accumulation mode, which relies on stop gates to manage workpiece flow. The second, more innovative, is a segmented mode. In this configuration, each motor section of the conveyor operates only when it is required, rather than continuously.
This segmented operation mode is a cornerstone of the system’s energy efficiency. By only activating sections as needed, it dramatically cuts energy consumption over the full lifecycle of the conveyor system. This approach not only leads to significant operational cost savings but also contributes to a reduced environmental footprint. Furthermore, the ability to operate in a segmented fashion allows for the specification of smaller motors, which in turn extends their service life, enhancing the overall durability and cost-effectiveness of the electric conveyor systems.
Simplified Configuration with MTpro Planning Software
To facilitate seamless integration and customisation, the configuration of the TS 7plus is managed through Bosch Rexroth’s intuitive MTpro planning software. This powerful tool is available either as a local installation or as the browser-based MTpro Online Designer, offering flexibility to users.
The MTpro software boasts the capability to automatically generate comprehensive CAD models and detailed parts lists from standard-component builds. These outputs can then be effortlessly exported for procurement through the Rexroth Store or via certified partners. This streamlined planning process reduces design time, minimises errors, and accelerates the deployment of new heavy-payload manufacturing lines.
With its robust design, intelligent operating modes, and user-friendly configuration tools, the Bosch Rexroth TS 7plus is poised to set new benchmarks for efficiency and reliability in heavy-payload manufacturing, reinforcing the shift towards more sustainable and automated industrial processes.