What are Bosch Rexroth transfer systems and what industrial applications do they serve?

Bosch Rexroth transfer systems are modular conveyor and handling solutions designed for automated material flow in manufacturing environments. These systems utilize components like hub-rotation units (HD series), curve segments (KU series), and track profiles (SP/ST series) to create continuous transport paths for workpieces through production processes. Primary applications include automotive assembly lines, electronics manufacturing, pharmaceutical packaging, and general industrial automation where precise positioning and smooth material transfer between workstations is critical. The modular design allows configuration of complex transport layouts including 90-degree and 180-degree directional changes, vertical lifting operations, and synchronized multi-station processing.

What are the key technical specifications to consider when selecting Bosch Rexroth transfer system components?

Critical selection parameters for Bosch Rexroth transfer systems include track profile dimensions such as the SP 2/R-100 16X6070mm and ST 2/R-H 12X6070mm variants, which determine load capacity and system compatibility. Hub-rotation units are available in multiple sizes (SIZE1, SIZE2, SIZE3) with rotation angles of 90 degrees and 180 degrees, accommodating different workpiece handling requirements. Track profile types include R-series for standard applications and C-series for curved sections, with width specifications ranging from 12mm to 16mm cross-sections. The TS 2plus and TS 5 system families offer different performance classes, with belt mounting toolsets enabling flexible installation configurations for various production line layouts.

Which international standards and certifications apply to Bosch Rexroth transfer systems?

Bosch Rexroth transfer systems comply with ISO 12100 machinery safety standards for automated handling equipment and ISO 13849 for safety-related control system performance. The systems meet EN 60204-1 electrical equipment safety requirements for industrial machinery and are designed according to ISO 4762 specifications for mechanical fastening components. ESD-compliant versions satisfy IEC 61340-5-1 standards for electrostatic discharge protection in electronics manufacturing environments. Additionally, these systems conform to CE marking requirements under the Machinery Directive 2006/42/EC, ensuring compliance with European industrial safety regulations for automated production equipment.

What are the main differences between TS 2plus and TS 5 transfer system variants?

The TS 2plus system features smaller profile dimensions with components like the SP 2/R-100 series using 16mm cross-sections, making it suitable for lighter workpiece handling and compact production lines. The TS 5 system utilizes larger hub-rotation units (HQ 5 series) and heavier-duty track profiles designed for higher payload capacities and more demanding industrial applications. Track profile variations include R-series for straight sections and C-series for curved installations, while hub units differ in rotation capabilities with HD 2/H offering standard lifting operations and HQ 5/XH providing extended horizontal movement ranges. The TS 5 system also incorporates electric cross-transport units (EQ 2/TR 90) for automated workpiece transfer between parallel conveyor lines.

What are the installation requirements and system compatibility considerations for Bosch Rexroth transfer systems?

Bosch Rexroth transfer systems require mounting on rigid machine frames with flatness tolerances within 0.5mm per meter to ensure smooth operation of track profiles and rotation units. The modular design allows connection between TS 2plus and TS 5 components through standardized mounting interfaces, though mixing system types requires careful attention to load capacity matching. Installation utilizes the BELT MOUNTING TS1 toolset for precise alignment of conveyor belts and drive components. Electrical connections follow standard 24VDC control voltage requirements with M12 circular connectors for sensor integration and fieldbus communication. System integration supports common industrial protocols including PROFINET and EtherCAT for seamless connection to existing automation infrastructure.

What are the safety ratings and operating conditions for Bosch Rexroth transfer systems?

Bosch Rexroth transfer systems operate within ambient temperature ranges of -10°C to +60°C with relative humidity up to 95% non-condensing conditions. Standard components achieve IP54 protection rating against dust ingress and water splashing, while optional IP65-rated versions are available for harsh industrial environments. The systems support maximum conveyor speeds up to 2.0 m/s depending on configuration, with payload capacities ranging from 25kg for TS 2plus systems to 75kg for TS 5 variants. Safety features include integrated emergency stop capability conforming to Category 3 safety requirements per ISO 13849, with optional safety light curtain integration for personnel protection during automated operation.

What maintenance schedule and service life expectations apply to Bosch Rexroth transfer systems?

Bosch Rexroth transfer systems require monthly visual inspections of belt tension, track alignment, and rotation unit operation under normal industrial conditions. Lubrication of hub-rotation units should occur every 2000 operating hours using ISO VG 32 synthetic gear oil, while belt replacement intervals typically range from 8000 to 12000 operating hours depending on load conditions and operating speed. The mechanical components are designed for 10 million operation cycles under rated load conditions, corresponding to approximately 8-10 years of continuous industrial service. Annual calibration of position sensors and drive motor parameters ensures maintained precision, with complete system overhaul recommended every 15-20 years or 50 million operation cycles to maintain original performance specifications.

Transfer systems Bosch Rexroth - TEC

Assembly Technology Bosch Rexroth

Bosch Rexroth transfer systems - TS 1, TS 2plus, and TS 5 - are precision pallet-conveyor platforms engineered for cycled and power-and-free assembly lines. The TS 2plus handles workpiece carriers up to 2,000 mm x 1,000 mm with a conveyor speed range of 6-18 m/min and a maximum load of 250 kg per workpiece carrier, while the TS 5 is designed for heavier pallets up to 500 kg and integrates directly into transfer-line architectures compliant with ISO 11161 (safety of machinery - integrated manufacturing systems). The TS 1 entry-level series addresses lightweight automation cells with compact 1-track topology, supporting cycle times down to 3 s and lane widths from 90 mm to 210 mm.

As an authorised distributor for Bosch Rexroth assembly technology, esd.equipment stocks 826 line items across the TS 1, TS 2plus, and TS 5 transfer-system families - covering profiles, drive units, workpiece carriers, stops, lifting units, and peripheral modules. All conveyor components conform to DIN EN ISO 4414 / 4413 (pneumatic/hydraulic circuit requirements) and are compatible with Bosch Rexroth's ActiveMover and VarioFlow + platform interfaces.

Transfersystem Bosch Rexroth TS 1 1-track pallet conveyor, lane width 90-210 mm, cycle time from 3 s, lightweight automation cells Transfersystem Bosch Rexroth TS 2plus Dual-track, carrier up to 2,000 x 1,000 mm, max. 250 kg/carrier, 6-18 m/min, ISO 11161 Transfersystem Bosch Rexroth TS 5 Heavy-duty pallet conveyor, up to 500 kg/carrier, transfer-line integration, VarioFlow + compatible

Key technical advantages - Bosch Rexroth Transfer Systems at a glance

⚙ 3 platform series - TS 1 / TS 2plus / TS 5 for light to heavy-load assembly lines

↕ Up to 500 kg/carrier - TS 5 heavy-duty workpiece carriers with overload protection

🛠 6-18 m/min conveyor speed - adjustable drive units for cycled and power-and-free operation

⚡ Cycle time from 3 s - TS 1 compact stops and lift units for high-frequency stations

🛡 ISO 11161 / DIN EN ISO 4414 - safety-of-machinery and pneumatic circuit compliance

✓ 826 line items in stock - profiles, drives, carriers, stops, and peripherals available ex-stock

Bosch Rexroth Transfer Systems - TS 1 vs. TS 2plus vs. TS 5 technical comparison

Criterion	TS 2plus	TS 1	TS 5
Topology	Dual-track pallet conveyor	Single-track pallet conveyor	Dual-track heavy-duty conveyor
Max. carrier load	250 kg	ca. 20 kg	500 kg
Carrier size (max.)	2,000 x 1,000 mm	240 x 160 mm	1,200 x 800 mm
Conveyor speed	6-18 m/min	ca. 4-12 m/min	ca. 4-14 m/min
Min. cycle time	ca. 4 s	3 s	ca. 6 s
Typical application	Mid-volume assembly, electronics, automotive	Lightweight PCB / small-parts assembly	Heavy powertrain, large-body assembly
Norm compliance	ISO 11161, DIN EN ISO 4414	ISO 11161	ISO 11161, DIN EN ISO 4413
VarioFlow + interface	Yes - direct coupling	Via adapter module	Yes - direct coupling

Bosch Rexroth Transfer Systems - Product overview

Series	Application	Key spec	Highlight
TS 1	Lightweight small-parts and PCB assembly	Lane width 90-210 mm, ca. 20 kg max. load	Compact footprint, 3 s cycle time, low tooling cost
TS 2plus	Mid-volume electronics and automotive sub-assembly	250 kg/carrier, 6-18 m/min, carrier to 2,000 x 1,000 mm	Power-and-free operation, direct VarioFlow + coupling
TS 5	Heavy powertrain, large-body and engine assembly	500 kg/carrier, carrier to 1,200 x 800 mm, ca. 4-14 m/min	Robust steel frame, direct ISO 11161 / DIN EN ISO 4413 compliance

Typical application areas: Electronics and PCB manufacturing (IPC-A-610, IEC 61340-5-1), automotive body and powertrain assembly (IATF 16949, VDA 6.3), mechanical engineering and machine assembly (ISO 11161, DIN EN ISO 4414), medical device production (ISO 13485), aerospace sub-assembly (AS9100), semiconductor back-end packaging (SEMI S1/S2)

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Authorised Bosch Rexroth Distributor TS 1, TS 2plus, TS 5 - genuine components, full series coverage

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826 Line Items Ex-Stock Profiles, drive units, workpiece carriers, stops, and lifting modules

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Norm-Compliant Transfer Technology ISO 11161, DIN EN ISO 4414 / 4413 - certified for integrated manufacturing systems