Bosch Rexroth TS Conveyor System Selection Guide, 7 Series Precise Matching Scenarios, Modular Design Reconstructs Production Line Efficiency

When an automotive battery pack assembly line is forced to slow down to 5m/min due to a 3-tonne load, and when the yield of a medical precision device assembly falls below 90% due to a ±0.3mm error - these are exactly the times when theBosch Rexroth TS Conveyor System Cracks the Dilemma with Modular DNAIn this article, we'll take a closer look at how to choose the right TS series. In this article, we will explain in depth how to choose the right TS series, so that the conveyor system can be changed from a cost centre to a performance engine.

First, the soul torture: why 90% users choose the wrong conveyor line? The key in the load and scene mismatch

Selection failure is often due to three major cognitive blind spots:

• ​Blindly chasing high loads: New energy battery module line mistakenly purchased TS 7 (3-tonne class), but only TS 5 (400kg class) was actually required.Wasted investment in equipment 37%​
• ​Neglect of environmental adaptation: Medical cleanrooms use ordinary chain conveyors, particulate contamination leads to product obsolescence.
• ​underestimate the need for expansion: 3C production line was not reserved for interfaces, and it took 3 weeks to dismantle the whole line when increasing production.

​ask and answer questions for oneself: How to avoid these pitfalls?Bosch Rexroth covers all scenarios with 7 product families-From 3kg micro-components to 3 tonnes of power cells, like customised surgical solutions for patients of different sizes.

Secondly, 7 product lines are accurately matched: full scene coverage from grams to tonnes.

1. Lightweight precision assembly: TS 1 series

• ​Limit parameters: 3kg load/±0.015mm accuracy/80-160mm pallet
• ​core value: Avoidance of 0.1 μm level tremors in hearing aid patches.Yield increased to 99.6%​
• ​Applicable Scenarios::
  • Medical: Pacemaker Electrode Welding
  • Electronics: Hard disc drive head assembly
  • ​Clean room needs: ISO Class 6 certification (particulates ≤ 352,000/m³)

2. All-rounder: TS 2 series (including China special edition TS 2S)

• ​technology breakthrough point::
  • Imported version TS 2plus: flat top chain load 240kg.18m/min high speed without stopping​
  • Chinese version of TS 2S.Localised Cost Reduction 30%160-1200mm pallets are plug and play.
• ​Measured Advantages::
  

  Motor production line of a car company: compatible with 5 models of trays.Changeover time from 72h to 8h​

3. The king of reloading: TS 5 & TS 7

Three, the five golden rules: selection to avoid the pit guide

▎ Rule 1: Load calculations against "false alarms"

• ​lesson learnt through blood and tearsA factory misinterpreted 40kg static load = dynamic load, and the inertial impact caused chain link deformation during emergency stop.
• ​countermeasures: Dynamic load = static weight x acceleration factor (1.5-3 times)
  

  Battery pack transport when selecting TS 7.3 tonnes x 2.5 = 7.5 tonnes impact resistant design​

▎ Rule 2: Environmental suitability is a matter of life and death.

• ​antistatic: Surface resistance 10⁴-10⁹Ω required for ECU assembly (standardised across TS)
• ​cleanness::
  • TS 1: ISO Class 6 (medical chips)
  • TS 2: ISO Class 7 (automotive electronics)
• ​high temperature scenario: TS-PV toothed belt resistant to 160°C (preferred for battery welding lines)

▎ Rule #3: Flexibility extends to look at interfaces

• ​Workstation Expansion: TS 2S supports flexible increase and decrease of 14-112 workstations
• ​Load escalation: TS 5 Load from 200kg to 400kg by adding a roller module.

▎ Rule 4: Precision decay control

• ​invisible killer: TS 2 accuracy attenuation of ±0.005mm for each additional 1m of line body
• ​crack programme: Additional auxiliary positioning modules every 2.5 metres for lines over 6 metres in length

▎ Rule #5: Digital tools increase efficiency

​MTpro planning softwareRealisation:

• 3D modelling of 50m line body in 3 hours (traditionally takes 3 weeks)
• Automatic generation of BOM list directly connected to SAP system

IV. Benchmarking Case: How to Rewrite the Manufacturing Equation by Choosing the Right TS

▎ Case 1: New energy connector giant assembly

• ​challenge: 1900mm width + 36m/min speed + ISO6 cleanliness
• ​programme: TS-PV toothed belt system
• ​results-based::
  • Maintains ±0.1mm synchro accuracy at 3 tonnes of thrust
  • ​Annual savings of $2.1 million in quality control costs​

▎ Case 2: Modular production line for panoramic sunroofs

• ​dilemma: 40m line body compatible with 5 models, 72h downtime for change of model
• ​programme: TS 2plus mixed conveying (roller chain + belt section)
• ​(of ball sports) break through a defense::
  • 1470 x 1960mm pallet carrying 200kg of glass
  • ​Offline commissioning compresses changeover to 8h​

personal viewpoint

The real disruptive power of Bosch Rexroth lies in the fact thatDeconstructing the physical laws of conveyor systems with modular genes--While the TS 1 is manipulating pacemaker electrodes with ±0.015mm precision, the TS 7 is rewriting the battery manufacturing beat with 3 tonne loads. This seamless coverage from grams to tonnes is a testament to the underlying logic of modern manufacturing.Flexibility is efficiency, precision is capacityThe localisation strategy of the TS 2S is accelerating the chemistry between "German precision" and "Chinese speed". What is more noteworthy is that the localisation strategy of its China special edition TS 2S is accelerating the chemical reaction between "German refinement" and "Chinese speed". In the next ten years, the battle for the transmission and distribution system will be a double helix race of "data + module" - and the enterprises that choose the right TS series today have already buried the acceleration engine on the track.

: Bosch Rexroth Conveyor Systems Portfolio
: TS 2 S China Edition Technical Specifications
: Automotive Electronics Assembly Case
: TS 7 Heavy Duty Conveyor System
: TS 1 Precision Conveyor System