English (UK) 
简体中文 Is your workshop being tormented by these problems: you want to upgrade the clean production line, only to find that the equipment can't fit into the existing plant? It's hard to fix the cleanliness, but the conveyor line in the drying room starts to rust and go on strike? Don't worry, let's break it down and talk about it today...How on earth did Rexroth's modular line body manage to be as steady as an old dog in an ISO6 clean room and an 1%RH dry room?!
🔍I. Why do extreme production environments have to use modular line bodies?
Just look at the new energy battery factory - the humidity in the cell assembly workshop must be pressed toBelow 1% RH(equivalent to 1/10 of the humidity of desert air), otherwise the electrode material becomes waste in seconds; and the medical chip workshop is even more ruthless, with no more than 35,200 0.5 micron particles per cubic metre (ISO6 standard), which is ten times cleaner than the operating theatre.
Conventional conveyor lines go straight to the ground here:
- Metal Roller Chain Rust: Dry room 1% RH environment, ordinary bearings rusted to death in a week
- Lubricant contaminationISO6 workshop strictly prohibits the volatilisation of oil and grease, ordinary chain lubricant will scrap the whole batch of products in minutes.
- Catastrophe modification: Want to expand production? Sorry, please stop production for three months and tear down the walls.
And the modular design of Rexroth line bodies, such as the TS2-PV series, gives you three big kills straight away:
- Parts are fully compatible: 90% parts are common to standard TS2, no need to wait for imported spare parts for maintenance.
- Plug and Play Environment Kit: ISO6 clean kit, anti-static belt, stainless steel bearings, as easy as changing a mobile phone case
- Zero waste of spaceMinimum 80x80mm tray fits into lab corners, supports up to 3 metre wide battery packs.
To put it bluntly.Modularity = the Lego of the production line industry, putting together "Transformers" that can withstand any perverse environment.!
🧩Modular design practice: like Lego to deal with ISO6 cleanroom
✅ Core trick: Flush, no-dead-angle structure
Think about it. What's a cleanroom's biggest fear? --Dead ends hide the grey!The edge radius of the Rexroth profile is so small that it's negligible, and the joints are so tight that not even a hair can get stuck in them (seriously, I've measured the gap with a vernier caliper and it's <0.1mm). Even better is the surface coating:
| character radical | Processing | Cleaning Advantage |
|---|---|---|
| Aluminium profile frames | Anodising + Nano-coating | Alcohol wipes away all particles ✅ |
| roller bearing | Stainless steel + ceramic plating | Never rusts, no metal precipitation ✅ |
| toothed belt | Anti-static polyurethane | Friction does not produce particles ✅ |
📌real-life exampleA medical sensor factory renovated its old workshop and created an ISO6 island in an ISO8 workshop - with a laminar flow hood attached to the Rexroth wire.Saved $3 million in purification and air-conditioning renovation!
✅ Cleanroom Just-In-Time: Air Movement Black Technology
ISO6 is not just "clean", it's alsoMore than 180 air changes per hour(Changing your air conditioner 5 times an hour in your house is considered fierce). How does Rexroth break the mould? --Turn the line body into a duct!
make a copy ofBasic framework ├─ top reserved FFU interface → direct insertion of filter (99.995% particle filtration efficiency) ├─ Side panel integrated air guide groove → guide airflow vertical downward blowing └─ Skeleton tray base → 0 turbulence exhaust air, do not interfere with precision workpieceA chip factory measured data: in the TS2-PV line above the installation of two groups of FFU.Particle count in the working area pressed to 1020 particles/m³(The ISO6 standard is 35,200), which is directly enough to reach the ISO5 threshold!
🏜️III.1% RH Dry Environment Survival Guide: Anti-static is a Life Saver
The scariest thing about the drying room is actuallyelectrostatic discharge-Humidity 1% when the human body static voltage can rush to 15kV, enough to break through the circuit board! Rexroth's response was textbook:
- System-wide ESD protectionFrom the belt material to the roller bearing, the surface resistance is stable at 10⁶-10⁹Ω, and the static electricity is not discharged.
- Humidity fluctuation compensation: Stainless steel bearings carry 1% RH rust, ceramic-coated rollers thoroughly insulated
- Energy assassin turned energy-saving king: Conventional drying line energy consumption 7.5 kW/h, modular programme down to 5.2 kW/h -Enough electricity to run three milk tea shops.(based on 24-hour operation)
📌the lesson of a car crashA battery factory used ordinary wire to get a cheaper price, and as a result, static sparks exploded continuously in the drying room.Ternary material burned right through the roof... It was only later that the ESD kit was changed to solve the problem!
⚡Fourth, the secret of cost plummet: modularity is the real "master of the gouge".
The most common pitfalls for newcomers: Thinking that buying equipment is a "one-shot deal"! The truth is--It's the hidden costs that swallow the gold::
| Cost type | Traditional Custom Line Body | Rexroth modular line body |
|---|---|---|
| Loss of retrofit downtime | 90 days of production value down the drain | 48 hours to fix the extension ✅ |
| Spare parts inventory | Stock up on 20 specialised parts | Stock up on TS2 generic parts only ✅ |
| Energy bills | 7.5kW/h | 5.2kW/h ✅ |
| Environmental adaptation | Scrap and rebuy the whole line | Add the kit and keep using it ✅ |
👉Talking Human Edition: Five years for a 30-metre line.Modular programme saves $2 million-enough for a down payment on a suite in a second-tier city!
🚀V. The future is here: adaptive modularisation is disrupting manufacturing
After ten years of automation, I see through a trend.Next-generation modularity is not just about "being able to put things together", it's about "being able to think".! For example:
- Environment Sensing Module: Real-time monitoring of particle count/humidity, automatic speed reduction for exceeding the standard
- AI Life Prediction: Early warning of malfunctions based on bearing friction sounds.Maintenance window accurate to ±2 hours
- Magnetic Levitation Expansion Kit: Maglev unit superimposed on an existing track at 80m/min.
Exclusive views:.The winners of the next decade will not be the "fastest" or "cleanest" lines, but rather the old platforms that are infinitely compatible with new technologies, like Lego baseboards! The winner of the next decade will never be the "fastest" or "cleanest" line!Why is the Rexroth TS2 series still being upgraded after fifteen years? Because it leaves a "back door" for technology iteration. While your peers are still tearing down walls to change production lines, your workshop is just changing modules like an iPhone case... that's the real Industry 4.0!
