Bosch Rexroth Unveils Heavy-Payload TS 7plus Conveyor

Bosch Rexroth announced the release of an upgraded conveyor system that combines heavy-part bearing transportation with precision in part assembly to meet the growing demand for goods across the e-mobility, aerospace/defense, and battery industries. The TS 7plus transfer system features a 3000 kg payload capacity, fully electric operation, and a modular design that accommodates changes in manufacturing requirements, from mixing pallet sizes to reconfiguring lines for changing battery sizes.

The 3000 kg payload conveyor is ideal for transporting battery cells and/or e-axles for e-mobility. Image used courtesy of Bosch Rexroth

Limitations of existing conveyor technologies

Traditionally, large, weight-bearing roller conveyors handle heavy goods and components but lack the precision required to place them. Why is this a hurdle for battery assembly? Well, during the assembly process, robots pick and place cells with millimeter precision, and heavy-duty roller conveyors require costly auxiliary "lift-and-position" stations for halting pallets, ensuring that battery cells can be picked and deposited into battery housing within docked pallets with utmost precision. If pallets and the battery housing are misaligned by just over a millimeter, robots can misalign the battery cells and crash onto the housing, causing costly damage. In the world of e-mobility, robots are used to weld busbars, and if the alignment is off by a fraction of a millimeter, the weld will be compromised, potentially creating a fire hazard.

Double- or twin-strand conveyors require significant maintenance and lubrication, and they are rigid and noisy. In terms of rigidity, an entire mechanical overhaul would be required if the line layout changes for a new battery model, making twin-strand conveyors a less-than-optimal choice for an ever-changing electric vehicle (EV) market.

The MTpro Online Designer software helps customers construct CAD models and curate part lists for transfer to certified partners or to the Rexroth Store. Image used courtesy of Bosch Rexroth

How the Bosch Rexroth TS 7plus helps tackle these limitations

Bosch Rexroth’s TS 7plus is designed to combine heavy-duty transportation with accurate assembly to provide a solution to the challenges posed by conventional conveyor methods.

The presence of a king shaft drive eliminates the need for a conventional double-strand accumulation roller chain. The roller chain system requires continual, messy lubrication of individual links and the removal or addition of links if damaged or chains need shortening or extending. These chains can also stretch over time, causing the pallets to stop a few millimeters short of their intended and important position. The king shaft drive of the TS 7plus is fixed directly to the rollers via bevel gears. The metal-gear connection ensures no slip, and specific roller sections can be stopped to place pallets exactly where they need to be. The bevel gears do not require retensioning or maintenance, and the king shaft drive is self-lubricating, maintaining cleanliness and reducing maintenance and downtime.

Other key technical features include a transport height of 350 mm, a conveyor speed of up to 24 m/min, and workpiece carrier dimensions of up to 2,200 x 3,000 mm. Both 180W and 250W motors are available. Customers can use the MTpro planning software to curate their transfer system virtually, and the MTpro Online Designer to set up assembly layouts.

The TS 7plus leverages internally mounted motors, eliminating protrusions that might otherwise impede the activities of manufacturing line workers. With a conveyor speed of 24 m/min, the TS 7plus speeds up pallet transport times, which Bosch Rexroth says competes with automated guided vehicles.

For automation experts seeking to upgrade heavy-duty part conveyance, visit Bosch Rexroth’s booth (#2810) at Automate 2026.