www.ptreview.co.uk
22
'26
Written on Modified on
Bosch Rexroth launches world’s first modular heavy-duty transfer system
TS 7plus roller conveyor transports up to 3,000 kg with flexible configuration, improved energy efficiency, and reduced system complexity.
www.boschrexroth.com
Assembly automation, e-mobility production, and intralogistics increasingly require efficient handling of large and heavy components such as battery packs and e-axles. In this context, Bosch Rexroth AG has introduced the TS 7plus transfer system, a modular roller conveyor designed to transport workpieces weighing up to 3,000 kg through assembly lines.
The TS 7plus is positioned as the world’s first freely configurable, fully electric transfer system for heavy loads based on a standardized construction kit. It extends the modular transfer system concept—previously applied to smaller components—to significantly larger and heavier workpieces.
Modular system for heavy-duty transport
Unlike conventional custom-built solutions, the TS 7plus is based on standardized components, enabling faster planning and implementation of assembly line sections. The system supports workpiece pallet sizes up to 2,200 × 3,000 mm and integrates various functional modules such as lift-and-transfer units, rotary stations, and positioning systems.
This modular approach provides:
- Reduced engineering effort: Standard components replace project-specific designs
- Flexible configuration: Adaptable layout for different assembly requirements
- Shorter implementation times: Simplified planning and system integration
The use of standardized modules addresses the complexity typically associated with heavy-load transport systems.
Optimized mechanics for availability and maintenance
The conveyor system uses rollers that are approximately 50% larger than those in previous designs, reducing the number of moving parts per meter and increasing system availability. A redesigned bearing block allows faster assembly and easier maintenance through simplified mounting and replacement.
The drive system is based on a king shaft mechanism rather than chain drives, offering:
Optimized mechanics for availability and maintenance
The conveyor system uses rollers that are approximately 50% larger than those in previous designs, reducing the number of moving parts per meter and increasing system availability. A redesigned bearing block allows faster assembly and easier maintenance through simplified mounting and replacement.
The drive system is based on a king shaft mechanism rather than chain drives, offering:
- Lubrication-free operation: Reduced maintenance requirements
- Lower contamination risk: Clean operation for sensitive components
- Stable torque transmission: Via bevel gears without re-tensioning
These features contribute to improved reliability and lower lifecycle costs.
Energy-efficient segmented operation
In addition to conventional accumulation operation, the TS 7plus supports segmented operation, where only the required sections are activated during transport. This demand-based control reduces overall energy consumption and extends component lifespan.
Benefits include:
Energy-efficient segmented operation
In addition to conventional accumulation operation, the TS 7plus supports segmented operation, where only the required sections are activated during transport. This demand-based control reduces overall energy consumption and extends component lifespan.
Benefits include:
- Lower energy usage: Motors operate only when needed
- Extended service life: Reduced mechanical stress on components
- Optimized motor sizing: Smaller motors can be used efficiently
Bosch Rexroth provides motor options with outputs of 180 W and 250 W, along with interfaces for third-party motor integration.
Ergonomic design and high transport performance
The system is designed with a minimum transport height of 350 mm, supporting ergonomic manual operations alongside automated processes. Motors can be mounted internally to avoid protruding components, improving safety and accessibility for operators.
With conveyor speeds of up to 24 m/min, the system enables faster transport compared to alternatives such as automated guided vehicles (AGVs), particularly in fixed assembly environments.
Digital planning and configuration
To support system design, Bosch Rexroth provides the MTpro planning software, available as both a local application and a web-based tool. The software enables:
Ergonomic design and high transport performance
The system is designed with a minimum transport height of 350 mm, supporting ergonomic manual operations alongside automated processes. Motors can be mounted internally to avoid protruding components, improving safety and accessibility for operators.
With conveyor speeds of up to 24 m/min, the system enables faster transport compared to alternatives such as automated guided vehicles (AGVs), particularly in fixed assembly environments.
Digital planning and configuration
To support system design, Bosch Rexroth provides the MTpro planning software, available as both a local application and a web-based tool. The software enables:
- CAD-free configuration: Automated generation of layouts and components
- Integrated parts lists: Direct transfer to ordering systems
- Simplified planning workflows: Faster design of complex transfer systems
This digital approach streamlines engineering processes and reduces time from concept to implementation.
Scalable solution for modern assembly lines
The TS 7plus builds on Bosch Rexroth’s established transfer system portfolio, extending modular automation concepts to heavy-duty applications. By combining standardized components, energy-efficient operation, and digital planning tools, the system addresses the growing need for scalable and flexible material flow solutions in industries such as automotive and e-mobility.
Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.
www.boschrexroth.com
Scalable solution for modern assembly lines
The TS 7plus builds on Bosch Rexroth’s established transfer system portfolio, extending modular automation concepts to heavy-duty applications. By combining standardized components, energy-efficient operation, and digital planning tools, the system addresses the growing need for scalable and flexible material flow solutions in industries such as automotive and e-mobility.
Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.
www.boschrexroth.com
