Rexroth Conveyor Line Technology Matrix: A Guide to the Logistics Revolution in Smart Factories

With the manufacturing industry facing the dual challenges of rising land costs of 18% per year and surging demand for flexible production, Bosch Rexroth Conveyor Systems is taking the lead inModular 3D Architecturetogether withMaglev black technologyReshaping the industrial logistics landscape. From automotive welding lines to lithium battery smart workshops, this German Industry 4.0 benchmarking programme achievesIncreased space utilisation 300%at the same timeSorting efficiency exceeds 15,000 pieces/hourIn this article, we'll deconstruct its technology core and industry empowerment path in depth. In this article, we'll deconstruct its technology core and industry empowerment path in depth, and bring you an insight into the core artery of intelligent manufacturing. Personally, I believe that Rexroth has surpassed the role of a traditional equipment supplier, and is redefining the competitive dimension of the future factory through the deep integration of data flow and physical flow.

I. Product Matrix: Five Systems to Crack the Scene Dilemma

The precision assembly tool: the TS 1 conveyor system.
Miniature conveying solutions designed for highly complex products:

plaintextmake a copy of

Workpiece tray: 80 x 80mm to 160 x 160mm → load 3kg → ±0.015mm repeatability

Technical Highlights:

Anti-static design: Satisfies chip and optics production environments
Accumulation curve technology: Throughput time reduction of 40%
Cleanroom Adaptation: Certified to EN ISO 14644-1 Class 6.
A medical enterprise after the application of yield rate increase 18%

All-rounder: TS 2 Series Dual Version Strategy

parameters	TS 2plus (imported version)	TS 2 S (China version)
Maximum load	240kg	240kg
Pallet size	160 x 160mm	ditto
	to 1200 x 1200mm
Conveying medium	6 types (toothed belt/flat top chain, etc.)	ditto
cleanliness level	Class 7	Class 7
Core Breakthrough:

dual-track (approach): German Precision + Localised Rapid Response
Cost optimisation: China Edition Pricing Reduces 30% Maintenance Costs
Module Library Extension: 32 function modules can be freely combined

The King of Heavy Duty: TS 5 Conveyor System
Three major evolutions in mine-scale conveying solutions:

Spindle drive technology: Noise reduction to 65dB (85dB for conventional systems)
Ultra-wide load band: 455-1040mm pallet size coverage
Dynamic scalability: 20 metres of conveyor section added per hour
Empirical case: a battery factory 400kg module conveyor failure rate down 90%

Packaging disruptor: VarioFlow plus
Revolutionary chain plate design implementation:

silent operation: <70dB (industry standard 85dB)
vertical climb: 70° tilt angle breaks through space limitations
Aseptic environment adaptation: Stainless Steel Chain Plate FDA Approved
Mengniu upgraded production line with filling efficiency of 15,000 bottles/hour

Flexible Nerve Centre: FTS Maglev System
The ultimate solution for Industry 4.0:

plaintextmake a copy of

Positioning accuracy: ±22μm (MR sensor) → Carrier load: 1-2000kg freely expandable

Core values:

Contactless drive: Zero particle contamination in a vacuum environment
Freedom of Motion Programming: million-path combination capability
Zero maintenance design: 40% lower energy consumption than conventional systems

II. Technology moat: four-dimensional core competitiveness

Modular Architecture Revolution
Rexroth's originalMTpro Planning SystemRealisation:

Digital twin construction: 8 hours to complete production line simulation
Automatic Generation of Parts Lists: Purchasing Cycle Reduction 60%
Cross-system compatibility: seamless integration of TS and FTS
A car company's new factory construction cycle is compressed by 50%

conqueror of extreme environments
Three special operations capabilities:

-40°C Cold Resistant: Changchun Automobile Plant Low Temperature Downtime ↓92%
Class 1 Cleanroom: Chip plant contamination rate <0.02%
Explosion-proof certification: Ten-year record of zero accidents in the chemical industry

Generational differences in drive technology
Spindle drive vs. conventional chain drive:

norm	TS5 spindle drive	Conventional chain drive
power consumption	18kW-h/day	32kW-h/day
Maintenance cycle	6000 hours	2000 hours
noise level	65dB	85dB
Annual electricity cost saving of 280,000 RMB/production line

Data Flow Convergence Architecture
Predictive maintenance system operating logic:

plaintextmake a copy of

Vibration sensors → Thermal imaging analysis → Automatic work orders → Pre-delivery of spare parts

Result: 70% fewer sudden failures and 3 times longer bearing life.

III. Industry empowerment mapping

Twin Engines of Automobile Manufacturing
Volkswagen Foshan plant programme:

"Upper body transfer → lower cycle fixture
Factory area ↓40%, logistics efficiency ↑200%"
Technology pivot point:

Maglev steering module (0.5 second orbit change)
Multi-vehicle co-location technology (3-minute switchover)

Lithium Battery Smart Revolution
Key breakthrough in power battery production line:

working procedure	sore point	TS5 Solutions
Cell welding	Positioning deviation >0.5mm	Direct soldering with μ-level accuracy
X-Ray Inspection	Mechanical vibration effects	Zero vibration transmission
Module Pack Segment	Inefficient manual handling	Automatic docking of 400kg modules
Capacity utilisation exceeds 95%

Medical Aseptic Transport
Compliance programme for pharmaceutical companies:

In-line sterilisation: Steam abatement as an alternative to downtime cleaning
laser profiling: 99.91 TP3T foreign body detection rate
traceability of materials back to their source: FDA certification tracking for each chain plate

Exclusive Data Insight

As manufacturing enters the era of micron-level precision, the Rexroth conveyor line has evolved from a logistics tool to aSpatial algorithmic carriers. A new energy giant predicted 92% bearing failure by analysing the heat map of material flow rate, so that the storage turnover rate increased by 6.2 times. What is more noteworthy is that the single square metre capacity return rate of the factory using FTS system reaches 400%, which means that every $1 invested in equipment cost can generate $12.8 comprehensive income in 3 years - this return on investment is reconstructing the value assessment system of the manufacturing industry.

Decoding the core issues

Q: Payback cycle for different systems?
► Empirical data:

TS 2 S: Electronics factory pays back in 10 months due to space compression
FTS system: 14-month payback for auto parts companies (including smart upgrade costs)
VarioFlow plus: Food business pays back in seven months due to energy optimisation

Q: How are technology iteration risks avoided?
► Three defence strategies:

optionModular Interface: Reserve TS and FTS linkages
MTpro Cloud Platform: Get free firmware OTA upgrade
Drive unit redundancy: Spindle system support 200% overloads

Q: How do you cope with the demand for customisation?
► Rexroth Resilience Programme:

Materials Science Library: 12 types of speciality coatings for extreme environments
digital twin preview: 72 hours to export customised programmes
Localised response: 48-hour on-site diagnosis by China team

Companies that have increased sorting accuracy to 99.99% and optimised energy-to-space ratios by 300% are proving, with a return on output of 400% per square metre, that the essence of competition in Industry 4.0 is toProduct of data density and physical accuracyThe future of manufacturing will belong to a new type of factory that understands the fusion of "magnetic levitation algorithm + material genome". The future of manufacturing will belong to a new type of factory that understands the fusion of "magnetic levitation algorithm + material genome".

Tags.