The Bosch Rexroth TS 2plus transfer system is a versatile and robust solution for economic production in assembly lines. It is designed to transport workpieces between various processing stations. The system is highly adaptable to specific production conditions and individual layouts due to its modular design and a wide range of available components.
Function Description
The TS 2plus transfer system conveys workpieces on workpiece pallets (WTs) using continuously moving belts, toothed belts, flat top chains, accumulation roller chains, or rounded belts. Workpieces are processed while on the pallets, and information regarding destination and processing status is stored in the pallet's memory. Stop gates (VE) halt the workpiece pallets at manual or automatic stations while the conveyor continues to move, allowing for the creation of small buffers. Once processing is complete, the workpiece pallet is released to the next station. The pneumatic stop gate can be opened manually or via a station control. At the end of the assembly process, the finished workpiece is removed from the pallet.
The system supports various layouts, including rectangular, linear, and U-shaped configurations, with or without lifts. It also allows for shunt systems, where workpiece pallets are temporarily diverted from the main circuit for independent processing before being reintegrated.
Important Technical Specifications
- Permissible Load: Single loads up to 60 kg, sum of loads up to 240 kg.
- Reverse Operation: Permissible up to 1200 mm.
- Lift above Transportation Level: Up to 240 mm.
- Process Force: Up to 100 N.
- Reproducing Accuracy: ±0.05 mm.
- Pneumatic Connection: Required (4-6 bar).
- Operating Temperature: +5 to +40°C (reduced load at -5 to +60°C).
- Workpiece Pallet Dimensions: From 80 x 80 mm (TS 1) up to 1243 x 1243 mm (TS 2plus).
- Conveying Media: Polyamide belts, toothed belts, plastic flat top chains, steel flat top chains, accumulation roller chains (with polyamide or steel rollers), and Vplus accumulation roller chains.
- Section Loads: Up to 250 kg for belt/toothed belt, up to 400 kg for flat top chain, and up to 1200 kg for accumulation roller chain. Vplus accumulation roller chains can achieve conveying speeds 2.5 times higher than the nominal chain speed, with special considerations for speeds above 9 m/min.
- Track Width (b): Directly related to workpiece pallet dimensions (bWT and lWT). Different for longitudinal and transverse conveyors if the pallet is rectangular.
- Gravity Center Position: The load should be positioned centrally on the workpiece pallet, and the height of the gravity center (hS) should not exceed 1/2 bWT (with bWT ≤ lWT).
- Materials: Primarily non-rusting or corrosion-protected steel, brass, aluminum alloys, polyurethane, polyamide (some with additives for electrical/mechanical properties), UHMW polyethylene, NBR, or Viton for seals.
- ESD Compatibility: Almost all components are ESD-compatible or available in ESD-compatible design.
- Compressed Air Consumption: Varies by unit, e.g., block cylinders (59 cm³), lift position units (249-1321 cm³), and stop gates (5-16 cm³).
Usage Features
- Flexibility: The modular design allows for easy adaptation to specific production tasks and individual layouts.
- Conveying Media Options: Four combinable conveying media (polyamide belt, toothed belt, flat top chain, and accumulation roller chain) can be selected based on assembly process requirements.
- Workpiece Pallet Sizes: Pallets are available in various sizes (from 160 x 160 mm to 1040 x 800 mm) to match product dimensions.
- High Load Capacity: Supports maximum loads up to 70 kg per workpiece pallet.
- Special Units: Includes specific units for curves, transverse conveyors, positioning, and drive units. Predefined macro modules minimize planning and design effort.
- Layout Planning Software (MTpro): A software program is available to assist with planning assembly systems, from product selection to configuration and ordering. It features a layout designer, CAD model generation with direct interfaces, and product configuration/order list calculation.
- Clean Room Use: Many components are tested and approved for use in clean rooms by IPA (Fraunhofer Institute for Manufacturing Engineering and Automation).
- Positioning and Orientation: Units like PE 2, PE 2/X, PE 2/XH, HP 2/L, and HD 2 provide precise positioning (±0.05 mm accuracy) and can handle vertical process forces up to 100 kN. The HD 2 lift rotate unit allows for workpiece pallet rotation by 90° or 180°.
- Transportation Control: Stop gates (VE 2, VE 2/L, VE 2/M, VE 2/S, VE 2/H, VE 2/RS, VE 2/D) are used to stop and separate workpiece pallets. Dampened stop gates (VE 2/D) are available for shock-sensitive parts. Slide stops (VA 2) are used in transverse sections for supplementary stops. Rockers (WI/M, WI 2) are used for area monitoring, accumulation pressure regulation, and workpiece pallet recognition.
Maintenance Features
- Low Maintenance: TS components generally require very little maintenance.
- Wear Reduction: Measures to reduce wear include switching off conveyor sections during idle times, selecting appropriate speeds, minimizing workpiece pallet weight, avoiding unnecessary accumulation sections, and preventing contamination by abrasive media.
- Material Resistance: Components are resistant to common industrial lubricants, greases, and cleaning agents. However, long-term contact with highly acidic or basic substances should be avoided.
- Contamination Impact: Contamination by abrasive media (e.g., sand, silicates, welding beads, pumice dust, glass shards) can significantly increase wear, necessitating reduced maintenance intervals.
- Replaceable Components: Guide profiles in conveyor sections are easily replaceable in case of wear.
- Maintenance Sections: Special maintenance sections (ST 2/C-...-W, ST 2/R-...-W) with removable covers facilitate maintenance of flat top chains and accumulation roller chains.
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