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TS 1 Modular Conveyors for

Flexible Manufacturing
Version

Handle pallet payloads up to 3.0 kg (6.6 lbs.)

3.0

1-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

Introduction

TS 1 Modular Conveyors

Liability:
In no event can the manufacturer accept warranty claims or liability claims for damages resulting
from improper use or misuse of the equipment or as a result of changes made to the equipment
other than those authorized by the manufacturer. The manufacturer will accept no claim in which
non-original spare parts have been used.

2008, Bosch Rexroth Corporation


All rights are held by ROBERT BOSCH GMBH and BOSCH REXROTH CORPORATION, also
regarding patent claims. We reserve the right to make technical changes at any time without
notice. Errors and omissions excepted.

8981 500 282 01/08

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

1-1

Introduction

Quick Reference to Catalog Sections

Introduction

Workpiece Pallets

Belt Drive Components

Transverse Conveyors

Curve Units

Lift-Transfer Units

Positioning Units

Stop Gates

Proximity Switch Brackets

Technical Data

Part Number Index

1
2
3
4
5
1
6
7
8
9
10
11

1-2

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Introduction

Table of Contents

Section 1: Introduction

1-4 - 1-7
1-8

System overview
Customer support services

1-9
1-10

Application photos
How to use this catalog

Section 2: Workpiece pallets and components


2-2
2-3

Assembled workpiece pallets


Dimensional Data - WT1/K

2-4
2-5

Dimensional Data - WT1/S


Dimensional Data - WT1/P

3-6
3-6
3-7
3-8 - 3-9
3-10

FP1 Belt guide profile


GT1 Transport belt
Belt welding kit
Leg sets
Foundation brackets

5-6 - 5-7
5-8 - 5-9
5-10

KU1/180 Curve
KU1/360 Curve
Accumulation Control, KU1/.... Curves

6-6 - 6-7
6-8 - 6-9

EQ1/T Tandem lift-transverse conveyor


EQ1/TE Lift-transverse conveyor

Section 3: Belt drive components


3-1
3-2 - 3-3
3-4
3-5
3-5

UM1 Belt return units


AS1 Belt drive units
ST1 Conveyor sections and cross links
Connection links
SP1 Conveyor section profiles

Section 4: Transverse conveyors


4-2 - 4-3
4-4 - 4-5
4-6 - 4-7

BS1 Transverse conveyors


BS1/T Transverse conveyors
BS1/M Mid-mount transverse conveyor

Section 5: Curve units


5-1
5-2 - 5-3
5-4 - 5-5

KE1/90-0 Curve
KE1/180-0 Curve
KU1/90 Curve

Section 6: Lift-transfer units


6-2 - 6-3
6-4 - 6-5

HQ1/U Lift-transfer unit


EQ1/TR Tandem lift-transfer unit

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

1-3

Introduction

Section 7: Positioning units


7-1
7-2 - 7-3

PE1, PE1/P Positioning unit


HP1 Lift-position unit

Section 8: Stop gates


8-1
8-2
8-3

VE1 Stop gates


VE1/D Cushioned stop gate
VE1/DB Cushioned lift-position stop gate

8-4
8-5

VE1/DA Cushioned transfer stop


AL1 Stop rail

10-3
10-3
10-4

Stop gate pneumatic diagrams


CE Declaration
Conversion charts.

Section 9: Proximity switches and brackets


9-2
9-3
9-4
9-5

SH1/U Vertical sensing switch brackets


SH1/S Horizontal sensing switch brackets
SH1/M Horizontal sensing bracket for curves
Proximity switches

Section 10: Technical data


10-1
10-2
10-2
10-3

Pallet loading
Pneumatic summary
Lift-transfer unit pneumatic diagrams
Positioning unit pneumatic diagrams

Section 11: Part Number Index


11-1

Part Number Index

1-4

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Introduction

TS 1 - The choice for small products, or small spaces

The TS 1 assembly conveyor is part of


the larger family of TS (Transfer Systems)
from Bosch Rexroth which include
TSplus and TS4plus. Like all TS products, the TS 1 is a workpiece palletbased, non-synchronous, conveyor
designed to improve manufacturing
productivity and product quality while
allowing for maximum assembly flexibility.
With your choice of three different pallet
sizes, and a range of positioning and
transfer modules, TS 1 is a precision
assembly conveyor that's ideal for small
products or subassemblies.

TS 1 flexibility: easy to specify


and use
All TS 1 components are pre-engineered
and modular. That means you can mix or
add accessory modules as required. The
system can easily be expanded,
reconfigured or relocated as your needs
change. You can phase in your investment as time and budget permit. Start
with a simple conveyor for basic assembly and grow into a fully automated,
progressive assembly system. As
production requirements change, TS 1
gives you the flexibility to add manual or
automatic workstations.
Modularity also simplifies system design
and assembly. As a result, you can be
more responsive to changing market
demands. Installation and maintenance
are also simplefurther reducing up-front
as well as ongoing costs.

The workpiece pallet


heart of the TS 1 conveyor
TS 1 conveyors transport parts on
workpiece pallets. The workpiece pallets
(three sizes, from 80 x 80 mm to 160 x
160 mm) ride on the conveyor transport
belts. This transport method has many
advantages for product assembly
applications, including:

Positioning. Pallets can be positioned at


workstations to 0.015 mm (.0006")
when used with a Rexroth Lift-Position
Unit, permitting precision assembly
operations.
Mounting. Pallets can be tooled with
fixtures to secure parts for manual or
automated operations. Identification and
data carrying devices (used to coordinate
assembly sequences, identify model
types, etc.) are also commonly mounted
to pallets.
Stopping. Pallets can be stopped on the
leading or trailing edgeregardless of
pallet orientation on the conveyor. Pallets
can also be accumulated in queue and
released one at a time.
Sensing. Exciter plates on the pallet
bottom and sides work with conveyormounted proximity switches to sense
pallet presence.

The workpiece pallet can be accessed


from all sidesallowing maximum
flexibility in automated or manual
workstation placement around the
conveyor.

SECTION 3
Drive Belts

SECTION 5
Curve Units

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

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1-5

Introduction

Planning the System Layout

When planning a system layout it is very


important to consider the individual
requirements of the assembly operation.

SECTION 7
Lift-Position and
Positioning Units

Pallet payload and size, cycle time,


process flow, product changes, pallet
fixturing and floor space are a few of the
parameters that determine the best
configuration for your assembly system.

TS 1 is the ideal choice for assembling


or testing small products or subassemblies, especially when floor space is at a
premium.

SECTION 4
Transverse Conveyors
SECTION 8
Stop Gates

SECTION 3
Drives

SECTION 9
Proximity Switches
and Brackets

SECTION 3
Conveyor Section
Components
SECTION 2
Workpiece Pallets
SECTION 6
Lift-Transfer Units
SECTION 3
Leg Sets
SECTION 3
Return Units

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Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Introduction

Numerous configuration possibilities


Choose the TS 1 configuration
that best suits your application
or facility

With TS 1, you have the freedom to


select the configuration best suited to
your layout and production requirements.
Rectangular, parallel, in-line, systems
using KE1 or KU1 curve units to
maintain pallet orientation and serpentine
systems are all possible with TS 1.
Space constraints and process complexity often dictate which configuration(s)
will work best.

Parallel

Serpentine
Track
Roller

Return

Return
Curve

Return
Drive

Rectangular
A parallel configuration, while similar to a
rectangular system, uses tandem lift
transfer units or curve units to connect
the conveyor sections.

Transverse
Conveyor

Transverse
Conveyor

Drive

Drive

Return

Curve
Drive

Serpentine conveyors uses multiple


drives and returns, straight conveyor
sections and KE1/90 or KU1/90 curves
all connected together by transverse
conveyors. Serpentine lines adapt to
space or production requirements which
often dictate the need for an unusual
layout.

Drive
Return

Lift-Transfer
Units

A rectangular configuration consists of


two straight parallel conveyor lines and
uses drives, returns and lift-transfer units.
The two parallel lines are connected at
the ends by BS 1 transverse conveyors.
Rectangular configurations are commonly
used in larger systems, where many
different operations must be performed
during the assembly process. As an
alternative, KE1/90 or KU1/90 curve units
can be used to configure a rectangular
line in which the workpiece pallet needs
to maintain leading edge orientation.

These are just some of the possibilities


with TS 1 pre-engineered conveyors. No
matter what the assembly requirement,
Rexroth modular components make
manufacturing truly flexible.

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

17

Introduction

Further tailor your system to


match specific assembly
requirements

Operation 1

Operation 2

Cycle-independent stations can be used to balance assembly operations with


differing cycle times.

With TS 1 assembly conveyors, workpiece pallets can be selectively routed to


off-line manual or automated stations.
These cycle-independent stations allow
you to accommodate fluctuating production quantities and to balance cycle times
between workstations. This, in turn,
permits manual and automated workstations to be combined on the same line.
Cycle-independent stations are constructed using standardized modules and
therefore are easily added to the main
conveyor.

Applications for TS 1

Station A

Station B

The TS 1 system can be used in precision


assembly and testing applications with a
total pallet payload up to 3.0 kg (6.6 lbs).
This makes it excellent for use in the
assembly of small automotive and
electronic components.

Typical types of products that can be


assembled using TS 1 include:

Fluctuations in production quantity can be easily accommodated by bypassing


assembly workstations.

B
A
A

Station A
A

Station B
B

Different products can also be processed simultaneously.

Automotive components
Ink-jet Cartridges
Hard drives
Small subassemblies
Electronics
Medical Devices

18

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Introduction

Complete support: before, during and after


installation

Every assembly project has its challenges. But you dont have to meet them
alone. Bosch Rexroth offers the most
comprehensive program of customer
support available anywhere, from do-ityourself projects to turnkey installations.
Now that youve taken the first step by
requesting this catalog, well help you
with all the restfrom the initial quote and
installation, to servicing your line years
from now.

Application engineering
from experts, or via CAD
Whatever your application, our application engineers have probably worked on
it. Theyll carefully review your requirements cycle time, payload, floor space,
process flow and devise the best
conveyor layout to meet them.
If youd rather design the system yourself,
our FMSsoft program makes it easy. It
not only creates a 3-D layout based on
your parameters, but generates a bill of
materials to simplify ordering. This userfriendly program works on any CAD
system using AutoCAD Release 2000
or later.
Whichever you prefer, well respond
quickly with a detailed quotation and
answer any questions you may have.
And well work with you directly, or
through your local Bosch Rexroth
systems integrator, to schedule delivery
and installation when you need it.

Systems integrators make


Bosch expertise their business

After-sale service assures


your continued success

For large projects, Bosch Rexroth


integrators provide total support on a
local basis, putting years of expertise
with Rexroth products to work for you.
They offer complete project management
of automated assembly systems,
including engineering, manufacturing,
installation, and debugging. We work
closely with our network of integrator
partners, providing them with the latest
in product information, as well as
software and service training.

The Bosch Rexroth commitment


continues long after your system is up
and running. Our highly qualified,
experienced staff of service experts is
always available for maintenance
questions, spare parts orders, field
service, and more. Were also happy to
provide training in the installation or
maintenance of any Rexroth products,
either in your facility or at our headquarters in Buchanan, Michigan.

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

19

Introduction

Documentation that answers


(and anticipates) your questions
Of course, you dont want to call Rexroth
every time you have a question. Fortunately, our approach to documentation
ensures that you wont have to. Product
catalogs (like this one) make planning
and ordering easy, with detailed specifications and dimensions, 3-D illustrations
and part numbers.

Application Photos

When your system arrives, everything you


need to know for set-up and operation
comes with it. And if youd like to know
which spare parts to keep on hand, well
send you an exploded-view spare parts
catalog or a customized spare parts list
just for your system.

More available on-line


In a hurry? The latest news,
products, application ideas and
more are all just a click away, on
the Bosch Rexroth Corporation
website. Youll find your local
authorized integrator there, too, at:
www.boschrexroth-us.com. Visit
today, and see why it pays to
specify Rexroth.

110

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Introduction

Getting started using this catalog

This catalog describes every module


needed to construct a TS 1 assembly
conveyor. The modules are organized in
the order that you would most likely
specify your system. Figure 1 lists some
common Rexroth acronyms used in this
catalog and their definitions.
What your order should include
In order for us to process your order as
quickly and accurately as possible,
please make sure you specify:

you specify your options, a 15-digit part


number unique to those options you have
specified will be created. This part
number provides customer service with
the information they need to build and
service your module to the exact specifications on your order.

For example, to order 10 assembled


WT1/P workpiece pallets (pages 2-2)
measuring 120 mm square, with
bushings, and aluminum plate, your
purchase order would include:
Module name: Workpiece Pallet
Quantity: 10
Part number: 3842 530 444
Additional info: (None required.)

If you need application assistance, have


any questions about ordering, or want to
identify the integrator nearest you, call us,
toll-free:

Modules such as drive units, transverse


conveyors and positioning modules
require you to specify the base 10-digit
part number as listed, and then select
from a list of options when ordering.
These options include such things as
voltage/frequency, conveyor speed,
motor location, and conveyor width. As

10-digit part number


Name of the module
Quantity
Other ordering parameters as
needed

1-800-322-6724
In Canada

1-905-335-5511

Rexroth Terms and Definitions


Nominal Height:
Distance from floor to top
of transport media.

Transport Level

Nominal
Height

Transport Level:

= Workpiece pallet
= Nominal width
= Nominal length
= Workpiece pallet width
= Workpiece pallet length
= Lift transfer unit width
= Lift transfer unit length

WT
B
L
B WT
L WT
BQ
BL

150

Main Conveyor Section

L
Workpiece
Pallet

= Load Carrying capacity in Kg

BQ

WT

BWT

BL

Lift Transfer
Unit

= Pallet Flow

LWT
T-Slot:
The longitudinal slot in the extruded
aluminum profiles of the conveyor

WT
L

T-Bolt and T-Nut:


Hardware used to secure components
and accessories to the T-slots of a profile

LWT

B
T-Slot

Line Flow
Profile

Figure 1

T-Bolt

T-Nut

BWT

Transverse
Conveyor

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

2-1

Workpiece Pallets

Section 2- Workpiece Pallets

The workpiece pallet acts as a carrier for


workpieces through the conveyor system.
With fixturing, it serves to hold the
workpiece for processing at a workstation. Positioning bushings allow the pallet
to be located in a station with an
accuracy of 0.015 mm (.0006") when
used with a lift-position unit. Mechanical
or RF identification and data storage
modules can also be mounted to the
support plate.

WT1/K
Assembled Plastic
Workpiece Pallets
2-2 to 2-3

Workpiece pallets are ordered fully


assembled in nylon, nylon with steel
support plate, or aluminum with
positioning bushings.

WT1/S
Assembled Steel Workpiece
Pallets
2-2 to 2-4

WT1/P
Assembled Aluminum
Workpiece Pallets with
Bushings
2-2 to 2-5

2-2

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Workpiece Pallets

Assembled Workpiece Pallets

Exciter Block

Model WT1/K, WT1/S, WT1/P


Accumulation Bumpers

TS1 workpiece pallets are available in


three standard sizes and three different
versions to perfectly match each
application. Each pallet is equipped with
replaceable wear strips for prolonged
pallet life. Exciter flags on the bottom
surface are used for pallet detection
when using vertically mounted proximity
switches. Optional exciter blocks may be
added to the top of the pallets if proximity
sensing from the side is required. Up to
four exciter blocks may be mounted on
the pallet. Urethane accumulation
bumpers may also be added to the WT1/
K and WT1/S pallets by sliding them in
the preformed dovetail slots. Pallets use
the traditional Rexroth stop tunnel
technology which permit pallets to be
stopped on either the leading or trailing
edge, allowing a single stop gate to
singularize a line of accumulated pallets.
All pallets have two adjacent sides
equipped with tapered positioning
bushings, and the two opposing sides
have locating grooves which engage
either the PE1 or PE1/P positioning
module, depending on pallet style.

Wear
Plates

The WT1/K workpiece pallet is molded


of PA66 nylon. It is suitable for use with
all TS1 transport and positioning
modules except for the HP1 Lift Position
Unit. This economical version of the
pallet is ideal to transport product when
limited station repeatability is required.
Each pallet comes with the wear strips
and bottom exciter plates installed.
Optional urethane accumulation
bumpers and/or exciter blocks may be
added by the user. The small arrow in the
lower left hand corner is the reference
corner for dimensioning and subsequent
machining if necessary. Four holes are
provided to allow easy attachment of
part fixtures or tooling.
The WT1/S workpiece pallet has a 5mm
thick steel plate permanently molded into
a PA66 nylon base. It incorporates all of

the features of the WT1/K pallet with the


added benefit of a solid steel surface for
mounting part fixtures or tooling. This
pallet cannot be used with the HP1 Lift
Position Unit, but does provide improved
repeatability with the PE1 Positioning
Module.
The WT1/P is constructed of an aluminum frame, UHMW-PE nylon wear strips,
and also includes four positioning
bushings. This pallet provides the
maximum possible repeatability with both
PE1/P and HP1 positioning modules.
The table below lists the empty pallet
weight and maximum total weight,
including payload. For repeatability data
with the PE1, PE1/P and HP1. Please
refer to pages 7-1 and 7-2 respectively.

Ordering Information for Workpiece Pallets WT1/K, WT1/S, WT1/P


Size

Weight
kg

Max. Total
Weight kg.

Part Number

WT1/K

PA66

80 x 80 mm
120 x 120 mm
160 x 160 mm

0.075
0.135
0.225

1.5
2.2
3.0

3842 527 122


3842 527 123
3842 527 124

WT1/S

PA66 frame with


Steel
Mounting Plate

80 x 80 mm
120 x 120 mm
160 x 160 mm

0.165
0.430
0.830

1.5
2.2
3.0

3842 526 849


3842 526 850
3842 526 851

Aluminum frame,
80 x 80 mm
UHMW-PE Wear Strips, 120 x 120 mm
(4) Bushings
160 x 160 mm

0.205
0.440
0.760

1.5
2.2
3.0

3842 530 443


3842 530 444
3842 530 445

Model

WT1/P

Pallet Material

Exciter Block, lot size 10

3842 532 814

Accumulation Bumpers (use with WT1/K or WT1/S pallets), lot size 20

3842 532 813

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TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

2-3

Workpiece Pallets

Dimensional data for WT1/K


8 H7 Measurement Contact
Locating Groove, 2X
0.3 A
H

F 0.2

B 42

WT1/K

4x 4.3

Pallet Size (b) F


80
19
WT1/K 120
39
59
160

F 0.2
B 42

H
0.4
0.3
0.3

K
N/A

0.5

B1
16.5

5.5 0.1
12

B
0.1
2

32

8 H7 Measurement Contact

32
12

32
12

32

SW 10

12

10

50

130

90
79

159
10

5.5
80

120

NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

16.5

119

160

24

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Workpiece Pallets

Dimensional data for WT1/S


8 H7 Measurement Contact

B 42

B 28

Locating Groove, 2X

F 0.1

WT1/S

4x 4.3 0.05

F 0.1

Pallet Size (b)


80
WT1/S 120
160

B 42

E
F
G
H
K
0.25 19 0.20 0.20
0.25 39 0.25 0.25 N/A
0.25 59 0.30 0.30

B1
16.5

5.5 0.1
12

B
0.1
2

32

8 H7 Measurement Contact

32
12

32
12

32

SW 10

12

10

50
130

90

79

159

80

16.5

5.5

10

119

120

NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

160

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25

Workpiece Pallets

Dimensional data for WT1/P


Measurement
Contact 8h7

5.5

5.5

10

16.5

Pallet

Size (b)
A
80
80 x 80
WT1/P 120 x 120 120
160 x 160 160

Measurement
Contact 8h7

4x12

5.5

0.03

5.5

B
38
78
118

C
19
39
59

4x 6 F7

E 0.03

F
G

Pallet

Size (b)
D
50
80 x 80
WT1/P 120 x 120 90
160 x 160 130

NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

E
38
78
118

F
32
32
32

G
12
12
12

3-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

Section 3- Belt Drive Components

The TS 1 belt drive powers the transport


belt along the conveyor sections while
the return units route the belt back
through the return channel of the belt
profile. Drives and returns can also be
linked together end-to-end to create
extended conveyor lines of almost any
length. Drive units have various speed,
voltage, and motor mounting positions.

Connection links are used in the side 8


mm T-slots of the conveyor section
profile to extend the conveyor to the
required length. Cross links, attached to
the inside 8 mm T-slot, keep the conveyor rails parallel and should be used at
500 mm intervals.

Leg sets support the conveyor and are


constructed of rugged extruded aluminum profile. The T-slotted design of the
profile provides a convenient mounting
location for control systems as well as a
wide variety of other components.
Belt welding equipment makes it easy to
bevel, pre-tension, and weld the transport
belt during installation

3
Belt Drive components in this section can be configured into any
of the basic line layouts below.
Drive

Return

Return

Drive

Drive

Return

In-Line

Parallel

Return

Drive

Drive

Return

Rectangular

UM1
Belt Returns
3-1

AS1
Belt Drives
3-2 to 3-3

ST1
Conveyor Sections
and Cross Links 3-4

FP1 and GT1


Belt Guide Profile
and Transport Belt
3-6

Belt Welding Kits


3-7

SZ1/L and SZ1/D


Leg Sets
3-8 to 3-9

SP1
Connection Links and
Conveyor Section Profile
3-5

Foundation Brackets
3-10

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

3-1

Belt Drive Components

Belt Return Module


Model UM1

A return unit is required for each belt


drive unit to direct or return the
continuous loop of belt from the center
channel in the conveyor rail back up to
the transport level. The width of both the
drive and return units should be specified
to match the width of the workpiece
pallet.
All hardware needed to mount the return
unit to a conveyor section is included.
For non-standard width please contact
our applications engineering department.

Ordering Information for Belt Return Unit UM1


Specify part number,
then select from
the options below.

Your
Choices are:

Return Unit Width (B)*

80, 120, 160

* Return unit width must match workpiece pallet.

Dimensional data for UM1


B+1

B+25

AS1-UM1 Connection Kit

AS 1
UM 1

Use this kit when connecting sequential


drive and return units to keep the workpiece
pallet moving between the two conveyor
sections. The kit consists of two round belts
and installation instructions.

Ordering Information for AS1-UM1 Connection Kit


Description
AS1-UM1 Connection Kit

Part Number
3842 521 260

Part Number
3842 999 760

Your selection:

32

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Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

Belt Drive Module

80

Model AS1

The AS1 drive module powers the


conveyor belts. The motor is side
mounted on either the right or left side
and can be oriented in four different
positions 90 apart.

Nominal speeds of 9, 12, 15, and 18 m/


min are available for a number of
standard voltages (see table 3-1). Line
widths are 80, 120 and 160 mm and the
maximum line length between drive and
return units is 12 meters at a maximum
load of 80 kg.
The AS1 drive module includes all
hardware required to mount it to a belt
conveyor section, as well as fasteners to
connect drives and returns end to end.
For non-standard width, speed or
voltages please contact our applications
engineering department.

Outboard Mounted
Motor position

Outboard Mounted
Motor orientation

180
Transport direction

Transport direction

270

90
0

Ordering Information for Belt Drive Unit AS1


In addition to part
number, please specify:

AS1
Drive Unit
3842 999 759
Your
choices are:

Your
selection:

Drive Unit width (B)

80, 120, 160

__________mm

Nominal speed*

9, 12, 15, 18

________m/min.

Motor voltage/frequency

See Table 3 - 1

______V ____Hz

Motor Orientation

0, 90, 180, 270

______________

Motor Position

L, R

______________

* Full load conveyor speeds vary depending on motor frequency. See Table 3-1
To omit motor, specify 000V 00Hz.

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

33

Belt Drive Components

s
ter
me
.0
2
kg
=1
.0
gth = 80 F
en
d
L
a
F
x.
Lo
Ma Max. F

Technical data for AS1


Nominal conveyor speed
Permissible loading weight
Maximum conveyor unit length
Motor RPM at 50 Hz
Motor RPM at 60 Hz
Motor, electrical specifications

=
=
=
=
=
=

See table 3-1


80 kg
12 m (39 ft.)
1400
1700
See table 3 - 1

Electrical data for AS1


Full Load Amps @
Actual Speed
Nom.
208/60 240/60 380/50 415/50 480/60 575/60
60 Hz
HP
M/min 50 Hz
0.6
0.9
0.8
9.3
1.6
1.3
0.7
9.1
0.25
9
0.6
0.8
0.7
0.9
12.5
0.25
1.6
1.3
11.3
12
0.8
0.6
0.9
1.3
0.7
1.6
15
0.25
15.1
15
0.6
0.8
0.9
1.6
0.7
0.25
1.3
N/A
18.2
18
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 3-1

Dimensional data for AS1

130

B+25

260
200

B +1

66

50

123

310

121
177

34

Bosch Rexroth Corp.

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TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

QV 1 Cross Connector
5
0
0

Conveyor Section

Le
ng
t

Model ST1

The conveyor section is the structural


element that supports and guides the
workpiece pallet. Each section consists
of two anodized aluminum belt profiles,
and two snap-in belt guide profiles. The
snap-in guide profiles serve as wear
strips and as a bearing surface for the
belt. Conveyor section profiles are
available in lengths up to 6000 mm

3
The 8 mm T-slot in each side and the
bottom of the aluminum profile allows
conveyor modules or peripheral devices
to be attached using T-bolts or T-nuts,
eliminating the need for special machining.

Ordering Information for Conveyor Sections ST1


Description

Part Number

Conveyor section ST1 (specify length < 200 > 6000)

3842 999 779/....

* To order conveyor sections 200-6000 mm long, please specify desired length at the end of the
part number. For example, to order a standard 2000 mm belt conveyor section, your part
number should look like this: 3842 999 779/2000.

Dimensional data for ST1


B+15
B30

QV1 cross connectors (not included


see below) must be used every 500 mm
to maintain proper belt section width and
alignment.

Cross Connectors

0
3
b-

31.5

FP 1

Model QV1
Cross connectors must be used to
maintain conveyor section width and
alignment. QV1 cross connectors should
be used every 500 mm as well as over
each leg set. Order cross connectors
according to line width. Includes
connection hardware.
Material:
Plastic PA6

22

.5

Ordering Information for Cross Connectors QV1


Description

Part Number

Cross Connector, B = 80

3842 521 342

Cross Connector, B =120

3842 521 343

Cross Connector, B =160

3842 521 344

8981 500 282 01/08

TS1 Assembly Conveyors

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

35

Belt Drive Components

Connection Link
Connection links join conveyor sections
end-to-end. Two connection links are
required to join a conveyor section, one
on each rail. They are made of galvanized
steel for strength and come with all
required fastening hardware

50
6

40

16

Material:
Zinc chromated steel

M6
10Nm

Ordering Information for Connection Links


Description

Part Number

Connection Link, one

3842 518 427

Conveyor Section Profile


5

22.5
16

Model SP1
SP1 conveyor section profile is a natural
color anodized aluminum extrusion. The 8
mm T-slot on both sides and the bottom
allows the mounting of conveyor modules
or peripheral devices using T-bolts or Tnuts eliminating the need for additional
machining.

55
8
22.5

Profile is available cut-to-order up to


6100 mm long, or as full uncut lengths.

Ordering Information for Conveyor Section Profile SP1


Description

Part Number

Single uncut stick, L=6100 mm

3842 529 940

Cut-to-length, specify length 100 mm to 6000 mm*

3842 992 934/...mm

* To order conveyor section profiles 100-6000 mm long, please specify desired length in 1 mm
increments at end of part number. For example, to order a 2051 mm conveyor section profile,
your part number should look like this: 3842 992 934/2051.

36

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

Belt Guide Profile


22
6.5

Model FP1
11

FP1 guide profile functions as both a


guide for the workpiece pallet and a
bearing surface for the transport belt. The
guide profile mechanically snaps in place
on the conveyor section profile.

Material:
Black, electrically conductive
polyethylene

Ordering Information for Belt Guide Profile FP1


Description

Part Number

Single uncut stick, L=2000 mm

3842 521 520

Cut-to-length, specify length 50 mm to 2000 mm*

3842 992 943/....mm

* To order belt guide profiles 50-2000 mm long, please specify desired length in 1 mm increments
at end of part number. For example, to order a 1027 mm belt guide profile, your part number
should look like this: 3842 992 943/1027.

Transport Belt

15
1.75

Model GT1
Electrically conductive, GT1 belt is used
to transport the workpiece pallets. In
normal operation, the belts run continuously, carrying the pallets on their
surface. The low coefficient of friction
between the belt and pallet allows pallets
to be stopped and accumulate on the
conveyor while the belts continue to run.
Transport belt is available in 50 meter
rolls or pre-cut to any desired length in 1
mm increments up to 50 meters.
When installing or replacing belts, they
must be tensioned and welded to create
a continuous loop in each conveyor
section. Tensioning ensures proper
positive contact with the drive pulleys.
Use the belt welding kit on page 3-7 to
tension, grind and weld the belt ends.

Ordering Information for Transport Belt GT1


Description

Part Number

Transport Belt, Anti-static, specify length*

3842 521 166

* To order belt in lengths up to 50 meters, please indicate desired quantity in .001 meter
increments after the part number. For example, to order 43.485 meters of belt, your part
number should look like this: 3842 521 166 Qty. = 43.485

How to calculate belt length


To calculate the length of belt needed, please refer to the formulas below.
Two belts are required per conveyor section.

Conveyor Section Length


400 2000
2001 12000

Required belt length


((2 x LS + 918) x 0.988) + 40 [ mm]
((2 x L S + 918) x 0.985) + 40 [ mm]

Conveyor Section Length, LS mm

[mm]

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

37

Belt Drive Components

Belt Welding Kit

Tensioning
Device

The belt welding kit provides all of the


components necessary to join TS1
transport conveyor flat belt. The kit
includes a belt tensioning device, a
beveling tool to grind the ends of the belt
for welding and a heating press to
thermally weld the belt ends. A thermometer, cleaning agent, adhesive and brush
are also included.

3
To cut welding time in half, a second
heating press is recommended for
welding two adjacent belts at the same
time.
NOTE: This kit is for flat belts only and
not intended for use on toothed or round
transport belts.

Belt Grinder
Belt Heating Press, 110VAC, 60Hz

Ordering Information for Belt Welding Kit


Description

Part Number

Belt Welding Kit for belts up to 17,300 mm long.


Includes: tensioning device, belt grinder, heating press, adhesive, brush, and thermometer.

R980 023 725

Belt Heating Press, 110VAC, 60Hz

8981 017 989

Belt Ginder, 110VAC, 60Hz

R980 024 059

38

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

Leg Sets
Model SZ1/L, SZ1

SZ1 legsets are used to support the


conveyor sections. Each leg set consists
of aluminum extrusions, leveling feet with
mounting gussets and hardware. Leg
sets are anchored to the floor with
foundation brackets, ordered separately,
on page 3-10.

Leg sets must be used at each drive and


return unit, and at maximum 2000 mm
intervals along the conveyor sections.
Legsets should also be used as a
supporting element where two conveyor
sections are joined together.

SZ1

SZ1/L

Two leg sets are available.


Single leg sets, SZ1/L are used to
support a single lane at drives, returns,
section joints, and whenever additional
support is needed.
Parallel leg sets, SZ1 are used to
support two parallel lanes of a conveyor.
SZ 1/L

Ordering Information for Leg Sets SZ1/L


Specify part number,
then select from
the options below.

Your
Choices are:

Width (B)

80, 120, 160

Height (H)

H = < 200 > 1200

Part Number
3842 999 702
Your selection:
_____________ mm
_____________ mm

Ordering Information for Leg Sets SZ1/D


Specify part number,
then select from
the options below.

Your
Choices are:

Width, (B)

80, 120, 160

Line Spacing, (A)


Height, (H)

60, 135
H = < 200 > 1200

Part Number
3842 999 703
Your selection:
_____________ mm
_____________ mm
_____________ mm

8981 500 282 01/08

TS1 Assembly Conveyors

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Bosch Rexroth Corp.

39

Belt Drive Components

Dimensional data for SZ1/L

62.5

SZ 1/L
B SZ

45
B SZ = B WT+15

Dimensional data for SZ1


B SZ
A

62.5

SZ 1

45
B SZ = 2 x(B WT+15)+a

310 Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Belt Drive Components

Foundation Brackets

Foundation brackets secure the leg sets to


the floor after the conveyor has been
leveled and aligned. Foundation brackets
should be used on leg sets at drive and
return units, and at intermediate positions
as shown below.

19mm T-Bolt Kit


10

43

175.5

SW13

The die-cast aluminum bracket has a natural


aluminum finish and includes two 19 mm Tbolt fastening kits. The cover cap, available
separately, provides a clean finished
appearance and also prevents dirt accumulation in the bracket. Order the anchor bolts
separately.

.5

SW13

85

8 mm Anchor Bolt

76

8 (5/16")

73

Cover Cap

8 (5/16")

Ordering Information for Foundation Brackets


Description

Part Number

Die-cast Aluminum Foundation Bracket (includes two T-bolt fastening kits)


8mm Anchor Bolt, one
45 x 180 Cover Cap only, for foundation brackets
45 x 45 Cover Cap only, for standard leg set gussets

3842 527 535


3842 526 560
3842 523 585
3842 523 563

Recommended foundation bracket placement


2 m typ.

Return End

2 m typ.

2 m typ.

Foundation Bracket

Drive End

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

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41

Transverse Conveyors

Section 4- Transverse Conveyors

Transverse conveyors are designed to


transfer pallets over short transfer
distances (e.g. between two rectangular
lines) or as cycle independent workstations. They are equipped with a drive and
return and the toothed transfer belts are
available in standard or antistatic
versions. All units are reversible.

Different motor electrical options, motor


mounting positions, transport speeds
and belt section length and width
configurations allow you to order
transverse conveyors to suit your
assembly requirements.

BS1
Transverse Conveyor
4-2 to 4-3

BS1/T
Transverse Conveyor
4-4 to 4-5

BS1/M
Mid-mount Transverse
Conveyor
4-6 to 4-7

42

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Transverse Conveyors

Transverse Conveyor

30

Model BS1

Transverse conveyors are used to transfer


workpiece pallets between parallel
conveyor sections. They can also be
configured to construct cycle independent workstations, or small systems with
short conveying lengths. The unit itself is
modular and comes with its own inboard
or outboard mounted drive motor and
gearbox with pre-installed toothed belts.

Workpiece pallet movement can be


reversed if desired. The maximum payload
capacity is 30 kg in the normal direction
and 15 kg in reverse operation.
Transverse conveyors are available in any
length from 250 mm to 5000 mm in 5 mm
increments. Specify conveyor width,
length, conveyor speed, motor voltage/
frequency, and motor position when
ordering.

Outboard Mounted
Motor Orientation

Motor Position
L

180

Primary Pallet
Flow

Pallet
Flow

270
0

Transverse conveyors are fully assembled


and include all required mounting
hardware.

Ordering Information for Transverse Conveyor BS1


Specify part number,
then select from
the options below.

Your
Choices are:

Part Number
3842 999 898
Your selection:

Width (B)

80, 120, 160

_______________ mm

Belt Type

Non-Antistatic (N)
Antistatic
(A)

__________________

Length (L)

250 to 5000
(in 5 mm increments)

_______________ mm

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 4-1

_______ V _______Hz

Motor Orientation
Motor Position

0, 180, 270
L, M**, R

__________________
__________________

* Full load conveyor speeds vary depending on motor frequency. See Table 4-1
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
270 motor orientation only available when Length (L) > 400mm.

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

43

Transverse Conveyors

Technical Data for BS1


Nominal belt speed
Load Capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

= see Table 4-1


= 30 kg (15 kg reverse)
= 1400
= 1700
= see Table 4-1

Electrical data for BS1


Nom.
M/min
6
9
12
15
18

Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4

60 Hz
6.7
8.3
13.3
16.6
N/A

Full Load Amps @


HP
.125
.125
.125
.125
.125

208/60 240/60 380/50 415/50 480/60 575/60


.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
N/A
.43
.38
.40
N/A

Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-1

B + 28
B+1
B 45
27

B + 125

B + 28

Dimensional data for BS1

110

285

77.3
72

B+1

44

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Transverse Conveyors

Transverse Conveyor

30

Model BS1/T

Transverse conveyors are used to transfer


workpiece pallets between parallel
conveyor sections. They can also be
configured to construct cycle independent workstations, or small systems with
short conveying lengths. The unit itself is
modular and comes with its own inboard
or outboard mounted drive motor and
gearbox with pre-installed toothed belts.

The BS1/T is specially designed to drive


KE1/90-0 and KE1/180-0 curves via an
auxiliary output pulley on the return end.
Since curve units are not reversible, the
BS1/K should not be used in reverse
operation.

Outboard Mounted
Motor Orientation

In normal operation the load capacity for


transverse conveyors is 30 kg. In addition
positioning and control modules can be
mounted on the module.
Transverse conveyors are available in any
length from 320 mm to 5000 mm in 5 mm
increments. Specify conveyor width,
length, conveyor speed, motor voltage/
frequency, and motor position when
ordering.
BS1/T Transverse conveyors are fully
assembled and include all required
mounting hardware.

Motor Position
L

180

Primary Pallet
Flow

Pallet
Flow

270
0

Ordering Information for Transverse Conveyor BS1/T


Specify part number,
then select from
the options below.

Your
Choices are:

Part Number
3842 999 899
Your selection:

Width (B)

80, 120, 160

_______________ mm

Belt Type

Non-Antistatic (N)
Antistatic
(A)

__________________

Length (L)

320 to 5000
(in 5 mm increments)

_______________ mm

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 4-2

_______ V _______Hz

Motor Orientation
Motor Position

0, 180, 270
L, M**, R

__________________
__________________

* Full load conveyor speeds vary depending on motor frequency. See Table 4-2
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
g270 motor orientation only available when Length (L) > 400 mm

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

45

Transverse Conveyors

Technical Data for BS1/T


Nominal belt speed
Load Capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

= see Table 4-2


= 30 kg (15 kg reverse)
= 1400
= 1700
= see Table 4-2

Electrical data for BS1/T


Nom.
M/min
6
9
12
15
18

Full Load Amps @

Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4

60 Hz
6.7
8.3
13.3
16.6
N/A

HP
.125
.125
.125
.125
.125

208/60 240/60 380/50 415/50 480/60 575/60


.34
.38
.40
.43
.58
.58
.34
.40
.38
.43
.58
.58
.34
.40
.38
.43
.58
.58
.34
.40
.38
.43
.58
.58
N/A
.40
.38
.43
N/A
.58

Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-2

B + 125

B 40

B + 28

Dimensional data for BS1/T

110
L

285

72

B+1

4-6

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Transverse Conveyors

Mid-mount Transverse Conveyor

30

Model BS1/M

Transverse conveyors with mid-mounted


motors and gearboxes are used to
transfer workpiece pallets between
parallel conveyor sections. They can also
be configured to construct cycle
independent workstations, or small
systems with short conveying lengths.
The unit itself is modular and comes with
its own inboard or outboard mounted
drive motor and gearbox with preinstalled toothed belts.

Mounting the drive in the center of the


conveyors length rather than at its end
makes the BS1/M more compact, making
it more suitable for areas with limited
clearance. In addition, positioning and
control modules can be mounted at the
very ends of the module.

Outboard Mounted
Motor Orientation

180

Primary Pallet
Flow

Workpiece pallet movement can be


reversed if desired. The maximum
payload capacity is 30 kg in the normal
direction and 15 kg in reverse operation.

Motor Position

Pallet
Flow

90

270

Ordering Information for Transverse Conveyor BS1/M


Transverse conveyors are available in any
length from 280 mm to 5000 mm in 5 mm
increments. Specify conveyor width,
length, conveyor speed, motor voltage/
frequency, and motor position when
ordering.
Transverse conveyors are fully assembled
and include all required mounting
hardware.

Specify part number,


then select from
the options below.
Width (B)
Transverse Conveyor
Length (L)
Section 1 Length (L1)
Nominal belt speed (m/min)*
Motor Voltage/frequency
Motor Orientation
Motor Position
Belt Type

Your
Choices are:
80, 120, 160
280 to 5000
(in 5 mm increments)
80 to 2450
(in 5 mm increments)
6, 9, 12, 15, 18
See Table 4-3
0, 90, 180, 270
L, M**, R
Non-Antistatic (N)
Antistatic
(A)

Part Number
3842 999 900
Your selection:
_______________ mm
_______________ mm
_______________ mm
_____________ m/min
_______ V _______Hz
__________________
__________________
__________________

* Full load conveyor speeds vary depending on motor frequency. See Table 4-3
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
g270 motor orientation only available when Length (L) > 400 mm

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

4-7

Transverse Conveyors

Technical data for BS1/M


Nominal belt speed
Load Capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

= see Table 4-3


= 30 kg (15 kg reverse)
= 1400
= 1700
= see Table 4-3

Electrical data for BS1/M


Actual Speed

Nom.
M/min
6
9
12
15
18

50 Hz
6.9
8.2
11.0
13.7
16.4

60 Hz
6.7
8.3
13.3
16.6
N/A

Full Load Amps @


HP
.125
.125
.125
.125
.125

208/60 240/60 380/50 415/50 480/60 575/60


.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
N/A
.43
.38
.40
N/A

Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-3

B+1

B 45

B + 28

Dimensional data for BS1/M

27
L2

110

L1
L

285

72

77.3

B+1

5-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

Curve Units

Section 5- Curve Units

Curve units provide a 90 or 180


change in pallet direction while maintaining leading edge orientation. Curve units
help lower cost by reducing control
complexity and system requirements
compared to the use of lift transfer units.
Rotation direction is selected at time of
ordering and is non reversible.

The KE1 curves use a round polyurethane belt to pull pallets through the
curve and can transfer up to 5 kg. 180
units are available for parallel conveyor
line gaps of 60 and 135 mm. Accumulation must be avoided through the curve
on all KE1 modules.

KE1/0-90
90 Curve
5-1

KU1/90
90 Curve
5-4

The KU1 curves use a flat polyurethane turntable to pull pallets through
the curve and can transfer up to 30
kg. 360 units combine the functionality of two 180 curve sections and
two transverse conveyors all powered
from one motor. KU1 curve units are
capable of passing multiple pallets
through the curve as long as the load
carrying capacity of the unit is not
exceeded.

KE1/0-180
180 Curve
5-2

KU1/180
180 Curve
5-6

KU1/2X180
2X180 Curve
5-8

8981 500 282 01/08

8981 500 282 01/08

TS1 Assembly Conveyors

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

51

Curve Units

90 Curve

Model KE1/0-90

These curves provide a 90 change in


pallet direction while maintaining leading
edge orientation. 90 Curve units are
non-powered and are driven directly from
a UM1 Return Unit or BS1/T Transverse
Conveyor. Specify mounting type at
ordering.
A round polyurethane belt is used to pull
the pallet through the curve, and curves
can be specified for right or left rotation.
Note: Once the direction of rotation has
been selected (L or R), drive direction is
not reversible.
Note: The KE1/0-90 is not suitable for
ESD applications.
The KE1/0-90 is delivered partially
assembled and includes all necessary
mounting hardware to fasten to a BS1/T,
UM1 or AS1.

Ordering Information for Curve Unit KE1/0-90


Specify part number,
then select from
the options below.
Nominal Line Width (B)

Your selection:
___________________

80, 120, 160

___________________

L, R

Direction of Rotation

A
Mounting Type

Part Number
3842 999 764

Your
Choices are:

AS1

AS1

BS1/T

UM1 BS1
Pallet Flow

Pallet Flow

___________________

(specify A, B, C, or D)

BS1
BS1/T
or
BS1/T
Pallet Flow

UM1

Pallet Flow

Dimensional data for KE1/0-90

90

Left Rotation

b +38
2

b +55

91

b+1

b +38
2

b +55

91

BS/UM

Right Rotation

90

75

52

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Curve Units

180 Curve

Model KE1/0-180

These curves provide a 180 change in


pallet direction while maintaining leading
edge orientation. 180 Curve units are
non-powered and are driven directly from
a UM1 Return Unit or BS1/T Transverse
Conveyor. Specify mounting type when
ordering.

A round polyurethane belt is used to pull


the pallet through the curve, and curves
can be specified for right or left rotation.
Note: Once the direction of rotation has
been selected (L or R), drive direction is
not reversible.
Note: The KE1/0-180 is not suitable for
ESD applications.
The KE1/0-180 is delivered partially
assembled and includes all necessary
mounting hardware to fasten to a BS1/T,
UM1 or AS1.

Ordering Information for Curve Unit KE1/0-180


Part Number
3842 999 765

Specify part number,


then select from
the options below.

Your
Choices are:

Nominal Line Width (B)

80, 120, 160

________________ mm

Line Spacing "A"

60, 135

________________ mm

Direction of Rotation

L, R

___________________

A
AS1

Mounting Type
AS1

Your selection:

B
BS1/T

UM1 BS1
Pallet Flow

Pallet Flow

___________________

(specify A, B, C, or D)

BS1
BS1/T
or
BS1/T
Pallet Flow

UM1

Pallet Flow

8981 500 282 01/08

TS1 Assembly Conveyors

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53

Curve Units

90

75

90

75

Dimensional data for KE1/180-0

BS / UM
b + 55

91

BS / UM

(b + 1) +15 + a

2 x (b + 1) + a + 50

(b + 1) +15 + a

a+15
Left Rotation

b+1

Left Rotation

2 x (b + 1) + a + 50

a+15

Right Rotation

b+1

Right Rotation

b+1

91

b+1

b + 55

54

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Curve Units

90 Curve

30

Model KU1/90

The KU1/90 curve provides a 90


change in pallet direction while maintaining leading edge orientation.
Curves also reduce controls complexity
and system cost compared to the use of
lift-transfer units.
The KU1/90 combines the functionality
of one 90 curve section and two
transverse conveyors all powered from a
single motor and gearbox.

A flat polyurethane turntable is used to


pull the pallet through the curve. Curves
can be specified for right or left rotation.
Note: Once the direction of rotation has
been selected (L or R), drive direction is
not reversible.
The infeed section (L1) and outfeed
section (L2) are available in lengths of 0
mm, or in any length from 150 to 5000
mm in 5 mm increments. When
ordering also specify: conveyor width,
belt speed, motor voltage/frequency,
direction of rotation, motor position, and
belt type. Depending on length, the in/
outfeed conveyor sections are available
with either a standard (N) or an antistatic (A) belt. The turntable is made
from polyurethane.

KU1/90
L1 = 0mm, L2 = 2000mm

KU1/90
L1 = 0mm, L2 = 0mm

Ordering Information for Curve Unit KU1/90

Specify part number,


then select from
the options below.
Width (B)
Section 1 Length (L1)
Section 2 Length (L2)

KU1/90 curves can be mounted end-toend to either an AS1/UM1 conveyor


section or a BS1 transverse conveyor.
Order connection kits separately. Note:
Depending on the system layout, two
connection kits may be required for
each KU1/90 module.

_______________ mm
_______________ mm

6, 9, 12, 15, 18

_____________ m/min

See Table 5-1

_______ V _______Hz

L, R

Direction of Rotation

Belt Type

_______________ mm

0 or 150 - 5000
(in 5 mm increments)
0 or 150 - 5000
(in 5 mm increments)

Nominal belt speed (m/min)*

Motor Mounting Position**

Your selection:

80, 120, 160

Motor Voltage/frequency
The KU1/90 is shipped partially
assembled. The curve, L1 conveyor
section, and L2 conveyor section are
shipped as separate units.

Part Number
3842 999 986

Your
Choices are:

I = Inboard
A = Outboard
Non-Antistatic (N)
Antistatic
(A)

__________________
__________________
__________________

* Full load conveyor speeds vary depending on motor frequency. See table 5-1.
** See Dimensional data for KU1/90 (Page 5-5).
Non-antistatic (N) belt is available on L1 or L2 only when length is 150mm or greater.

Ordering Information for Connection Kits


Description
KU1 to AS1/UM1 Connection Kit
KU1 to BS1 Connection Kit (when KU1 L1 or L2 > 0 mm)
KU1 to BS1 Connection Kit (when KU1 L1 or L2 = 0 mm)
KU1 to KU1 Connection Kit

Part Number
3842 528 855
3842 530 095
R980 024 552
R980 024 552

8981 500 282 01/08

TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

55

Curve Units

Technical data for KU1/90


Nominal belt speed
Load capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

=
=
=
=
=

see Table 5-1


30 kg
1400
1700
see Table 5-1

Electrical data for KU1/90


Nom.
M/min
6
9
12
15
18

Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4

60 Hz
6.7
8.3
13.3
16.6
N/A

Full Load Amps @


HP
.125
.125
.125
.125
.125

208/60 240/60 380/50 415/50 480/60 575/60


.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
N/A
.43
.38
.40
N/A

Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 5-1

L1

Dimensional data for KU1/90

I = Inboard

L2

74

L = Left
Rotation

110

14

20

R = Right
Rotation

A = Outboard

85
92
300

128

35

B (mm)
80
120
160

E
162
202
240

F
165
203
243

G
372
435
492

56

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Curve Units

180 Curve

30

Model KU1/180

The KU1/180 curve provides a 180


change in pallet direction while maintaining leading edge orientation.
Curves also reduce controls complexity
and system cost compared to the use of
lift-transfer units.
The KU1/180 combines the functionality
of one 180 curve section and two
transverse conveyors all powered from a
single motor and gearbox.

A flat polyurethane turntable is used to


pull the pallet through the curve. Curves
can be specified for right or left rotation.
Note: Once the direction of rotation has
been selected (L or R), drive direction is
not reversible.
The infeed section (L1) and outfeed
section (L2) are available in lengths of 0
mm, or in any length from 150 to 5000
mm in 5 mm increments. When
ordering also specify: conveyor width,
belt speed, motor voltage/frequency,
direction of rotation, and belt type.
Depending on length, the in/outfeed
conveyor sections are available with
either a standard (N) or anti-static (A)
belt. The turntable is made from
polyurethane.

KU1/180
L1 = 2000mm, L2 = 1000mm

KU1/180
L1 = 0mm, L2 = 0mm

Ordering Information for Curve Unit KU1/180


Specify part number,
then select from
the options below.
Width (B)
Section 1 Length (L1)
Section 2 Length (L2)

80, 120, 160


0 or 150 - 5000
(in 5 mm increments)
0 or 150 - 5000
(in 5 mm increments)

Nominal belt speed (m/min)*


Motor Voltage/frequency

KU1/180 curves can be mounted endto-end to either an AS1/UM1 conveyor


section or a BS1 transverse conveyor.
Order connection kits separately. Note:
Depending on the system layout, two
connection kits may be required for
each KU1/180 module.

_______________ mm
_______________ mm
_______________ mm
_____________ m/min

See Table 5-2

_______ V _______Hz
__________________

A = Outboard

A (outboard)
__________________

Non-Antistatic (N)
Antistatic
(A)

__________________

Motor Mounting Position**


Belt Type

Your selection:

6, 9, 12, 15, 18

L, R

Direction of Rotation
The KU1/180 is shipped partially
assembled. The curve, L1 conveyor
section, and L2 conveyor section are
shipped as separate units.

Part Number
3842 999 987

Your
Choices are:

* Full load conveyor speeds vary depending on motor frequency. See table 5-2.
** Motor can only be mounted in the outboard position (see Dimensional data pg. 5-7).
Non-antistatic (N) belt is available on L1 or L2 only when length is 150mm or greater.

Ordering Information for KU1/180 Mounting Kit


Description
KU1 to AS1/UM1 Connection Kit
KU1 to BS1 Connection Kit (when KU1 L1 or L2 > 0 mm)
KU1 to BS1 Connection Kit (when KU1 L1 or L2 = 0 mm)
KU1 to KU1 Connection Kit

Part Number
3842 528 855
3842 530 095
R980 024 552
R980 024 552

8981 500 282 01/08

TS1 Assembly Conveyors

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

57

Curve Units

Technical data for KU1/180


Nominal belt speed
Load capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

=
=
=
=
=

see Table 5-2


30 kg
1400
1700
see Table 5-2

Electrical data for KU1/180


Nom.
M/min
6
9
12
15
18

Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4

60 Hz
6.7
8.3
13.3
16.6
N/A

Full Load Amps @


HP
.125
.125
.125
.125
.125

208/60 240/60 380/50 415/50 480/60 575/60


.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
.58
.43
.38
.40
.34
.58
N/A
.43
.38
.40
N/A

Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 5-2

5
Dimensional data for KU1/180
L1

L = Left
Rotation

L2

135

110

14

R = Right
Rotation

85
92
300

A = Outboard

128

35

B (mm)
80
120
160

F
165
203
243

G
422
505
580

58

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Curve Units

2x180 Curve

24-30

Model KU1/2x180

The KU1/2x180 curve provides a 360


transfer on a continuous closed circuit,
and maintains leading edge pallet
orientation. Curves also reduce
controls complexity and system cost
compared to the use of lift-transfer units.
The KU1/2x180 combines the functionality of two 180 curve sections and two
transverse conveyors all powered from a
single motor and gearbox. The curve is
available with either one or two drives.
Note: With one drive, the load capacity
is 24kg; with two drives, the load
capacity is 30kg.

A flat polyurethane turntable is used to


pull the pallet through the curve, and
curves can be specified for right or left
rotation. Note: Once the direction of
rotation has been selected (L or R), the
drive direction is not reversible.
The conveyor section (L1) is available in
lengths of 150 to 5000 mm in 5 mm
increments. When ordering also specify:
conveyor width, belt speed, number of
drives motor voltage/frequency, direction
of rotation, and belt type. The conveyor
sections (L1) is available with either a
standard (N) or anti-static (A) belt. The
turntable is made from polyurethane.
The KU1/2x180 is shipped fully
assembled. All required mounting
hardware is included.

Ordering Information for Curve Unit KU1/2x180


Specify part number,
then select from
the options below.
Width (B)
Length (L1)
Number of Drives (AE)
Nominal belt speed (m/min)*
Motor Voltage/frequency
Direction of Rotation
Motor Position**
Belt Type

Your
Choices are:
80, 120, 160
150 - 5000
(in 5 mm increments)
1, 2

Part Number
3842 999 988
Your selection:
_______________ mm
_______________ mm
__________________

6, 9, 12, 15, 18

_____________ m/min

See Table 5-3

_______ V _______Hz

L, R

__________________

A = Outboard

A (outboard)
__________________

Non-Antistatic (N)
Antistatic
(A)

__________________

* Full load conveyor speeds vary depending on motor frequency. See table 5-3.
** Motor can only be mounted in outboard position. See Dimensional data (pg. 5-9).

8981 500 282 01/08

TS1 Assembly Conveyors

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Bosch Rexroth Corp.

59

Curve Units

Technical data for KU1/2x180


Nominal belt speed
Load capacity 1 drive
Load capacity 2 drives
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications

=
=
=
=
=
=

see Table 5-3


24 kg
30 kg
1400
1700
see Table 5-3

Electrical data for KU1/2x180


Actual Speed
Full Load Amps @
Nom.
HP 208/60 240/60 380/50 415/50 480/60 575/60
M/min
50 Hz
60 Hz
.125
.58
.58
.43
.38
.40
.34
6
6.9
6.7
.125
.58
.58
.43
.38
.40
.34
9
8.2
8.3
.125
.58
.58
.43
.38
.40
.34
12
11.0
13.3
.125
.58
.58
.43
.38
.40
.34
15
13.7
16.6
.125
.58
N/A
.43
.38
.40
N/A
18
16.4
N/A
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 5-3

5
Dimensional data for KU1/2x180

135

L = Left
Rotation

L1

B (mm)
80
120
160

F
165
203
243

G
422
505
580

R = Right
Rotation
A = Outboard

510

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

Curve Units

Accumulation Control for KU 1/ Curves

The outer guide of the KU1/90 and KU


1/180 curve units has been designed to
withstand pallet accumulation pressure
and allow the curve modules to operate
in accumulation mode. The accumulation
pressure in a curve can easily be
reduced with the addition of an accumulation control stop gate as shown in
Figure 5-1.

bwt +10
VE 1

W I /M

The accumulation stop gate is pneumatically operated and requires no additional


control. It uses a WI1/M Rocker Stop, a
pneumatic cylinder switch, and a VE1
stop gate (Figure 5-2). All of the
components required to build the
accumulation control stop gate can be
found in Section 8 of this catalog.

Figure 5-1

WI 1/M

with Pneumatic
Cylinder Switch

VE 1

Figure 5-2

8981 500 282 01/08

8981 500 282 01/08

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61

Lift Transfer Units

Section 6- Lift-Transfer Units

TS 1 lift-transfer units vertically lift and


horizontally transfer workpiece pallets
from one conveyor section to a receiving
lift transfer unit located at an adjacent
conveyor section.

NOTE: Non oiled dry air, 58-116 PSI (4-8


bar) connected through 4 mm push-lock
plastic tubing is required on all LTUs.
Pneumatic diagrams for these units are
shown on page 10-2.

Tandem lift-transfer units use a combination of LTUs working in tandem with a


transverse conveyor or LTU to transfer
pallets from one conveyor section to an
adjacent conveyor section using one
drive motor and gearbox.

HQ1/U
Lift-Transfer Units
6-2 to 6-3

EQ1/TR
Tandem Lift-Transfer Units
6-4 to 6-5

EQ1/T
Tandem Lift-Transverse
Conveyor 6-6 to 6-7

EQ1/TE
Tandem Lift-Transverse
Conveyor 6-6 to 6-7

62

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Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Lift Transfer Units

Lift-Transfer Unit

Model HQ1/U

The HQ1/U Lift Transfer Unit is used to


transfer pallets perpendicularly off the
conveyor. It is used primarily at corners
and intersections
The HQ1/U lift plate is powered up and
down by a single lift pneumatic cylinder.
In the center or resting position the belts
on the unit are located 2.2 mm below the
nominal conveyor transport height (or
transport surface). In the raised position
the HQ1/U is lifted 4.4 mm above the
transport surface.

Ordering Information for Lift-Transfer Unit HQ1/U

For pass through applications, the HQ1/U


is lowered 8.6 mm below the transport
surface.

Specify part number,


then select from
the options below.

The HQ1/U is completely reversible


enabling pallet diversion in two directions
from a single transfer point.

Lift Transfer size- BQ x BL

The HQ1/U can be mounted to a BS1


transverse conveyor as well as the
standard ST1 conveyor section.

Your
Choices are:
80 x 80 mm
120 x 120 mm
160 x 160 mm

Part Number
3842 998 010
Your selection:
_______________ mm

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 6-1

_______ V _______Hz

* Full load conveyor speeds vary depending on motor frequency. See Table 6-1
Each LTU is equipped with steel side
guides to guide the pallets during
transfer. Each guide may be raised up
slightly to act as a pallet stop when the
transfer is in the centered, or rest,
position. Optional cushioned transfer
stops (see page 8-4) may be mounted to
the side guides to provide adjustable
cushioned stops instead of hard stops on
the transfer.

8981 500 282 01/08

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63

Lift Transfer Units

Technical data for HQ1/U


Nominal belt speed
Load Capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications
Air pressure
Cylinder diameter
Cylinder stroke
Air fittings

= see Table 6-1


= 3 kg
= 1400
= 1700
= see Table 6-1
= 4-8 bar
= 25 mm
= 13 mm
= 4 mm (5/32") push-lock

Electrical data for HQ1/U


Actual Speed
Full Load Amps @
Nom.
HP
208/60 240/60 380/50 415/50 480/60 575/60
50 Hz
M/min
60 Hz
.125
.58
.58
.43
.38
.40
.34
6.4
6
6.2
.125
.58
.58
.43
.38
.40
.34
10.2
9
9.3
.125
.58
.58
.43
.38
.40
.34
12.8
12
12.5
.125
.58
.58
.43
.38
.40
.34
15.4
15
15.6
.125
.58
.58
N/A
N/A
.40
.34
N/A
18
18.7
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 6-1

Dimensional data for HQ1/U

BQ

BQ + 55

BL - 32

+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position
8.6 Pass-through Position

BL +15

BQ +55
BQ

377

66

BL

105

64

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Lift Transfer Units

Tandem Lift-Transfer Unit

Model EQ1/TR

The EQ1/TR Tandem Lift Transfer Unit


transfers pallets perpendicularly between
closely spaced parallel conveyor sections
using three lift-transfer units and one drive
motor.
A PLC is required to control traffic and
accumulation of pallets on the EQ1/TR is
not permitted. Proximity switch installation
is required to detect pallet present and
pallet passed.

The center section of the EQ1/TR is fixed


in place at the transfer height, 2 mm
above the main line belts. The two outer
sections are normally at rest 2.2 mm
below the main line belts. Each section
can be individually actuated, via air
cylinders to raise 4.4 mm and transfer the
pallet, or lower 8.6 mm and allow a pallet
to pass through. EQ1/TR transfers can be
mounted to ST1 main line belt sections,
or a BS1 transverse conveyor. This
module is completely reversible to allow
bi-directional travel.
Each outer section is equipped with steel
side guides to guide the pallets during
transfer. Each guide may be raised up
slightly to act as a pallet stop when the
transfer section is in the center, or rest
position. Optional cushioned transfer
stops (see page 8-4) may be mounted to
the side guides to provide adjustable
cushioned stops instead of hard stops on
the transfer.

Ordering Information for Lift-Transfer Unit EQ1/TR


Specify part number,
then select from
the options below.
Lift Transfer size- BQ x BL

Your
Choices are:
80 x 80 mm
120 x 120 mm
160 x 160 mm

Part Number
3842 998 012
Your selection:
_______________ mm

Line Spacing (A)

60, or 135 mm

_______________ mm

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 6-2

_______ V _______Hz

* Full load conveyor speeds vary depending on motor frequency. See Table 6-2

8981 500 282 01/08

TS1 Assembly Conveyors

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Bosch Rexroth Corp.

65

Lift Transfer Units

Technical data for EQ1/TR


Nominal belt speed
Load Capacity
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications
Air pressure
Cylinder diameter
Cylinder stroke
Air fittings

= see Table 6-2


= 3 kg
= 1400
= 1700
= see Table 6-2
= 4-8 bar
= 25 mm
= 13 mm
= 4 mm (5/16") push-lock

Electrical data for EQ1/TR


Full Load Amps @
Actual Speed
Nom.
HP
208/60 240/60 380/50 415/50 480/60 575/60
60 Hz
50 Hz
M/min
.58
.125
.58
.43
.38
.40
.34
6.2
6.4
6
.125
.58
.58
.43
.38
.40
.34
9.3
10.2
9
.125
.58
.34
.58
.43
.38
.40
12.5
12.8
12
.125
.58
.43
.38
.40
.34
.58
15.4
15.6
15
.125
.58
.58
N/A
N/A
.40
.34
N/A
18.7
18
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 6-2

Dimensional data for EQ1/TR

B Q+59

BQ

B Q+1

B L +A+15

+4.4=Raised Position

B L +1 5

=Transport Surface
2.2 Center, Rest Position
A

8.6 Pass-through Position

354

16 0

62.5

BL
B L -30

66

Bosch Rexroth Corp.

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TS1 Assembly Conveyors

8981 500 282 01/08

Lift Transfer Units

Tandem Lift-Transverse Conveyor

30

Model EQ1/T

The EQ1/T Tandem Lift Transfer Unit


transfers pallets perpendicularly between
rectangular conveyor sections using two
lift-transfer units, one BS1/T transverse
conveyor and one drive motor.
The EQ1/T Tandem Transfer Module
combines the functionality of two lift
transfer units and a BS1/T transverse
conveyor all powered from a single drive
motor. Each EQ1/T includes all required
mounting hardware as well as the
following components.
2 Lift Transfer Units
1 BS1/T Transverse Conveyor
2 Drive connection kits
2 Protective guards

Outboard Mounted
Motor Orientation

180

Primary Pallet
Flow

Motor Position

Pallet
Flow

270

The BS1/T is used to power the two


slave driven lift transfer units. Each LiftTransfer may be operated independently
by energizing the pneumatic cylinders
with separate valves. The transfer units
are normally at rest 2.2 mm below the
main line belt height. When energized up,
the transfer raises 4.4 mm to the same
height as the BS1/T transverse belts and
the pallet is transferred. When energized
down, the transfer lowers 8.6 mm, and
the pallets are allowed to pass through
on the main line. The EQ1/T tandem
transfer module is completely reversible,
although the allowable payload is
reduced to 15 Kg in reverse operation.
Side guides on each of the transfer units
may be positioned slightly higher to stop
a pallet when the transfer is in the center
or rest position. Optional cushioned
transfer stops (page 8-4) may be added
to provide gentle stopping on the
transfer.

Ordering Information for Lift-Transfer Unit EQ1/T


Specify part number,
then select from
the options below.
Tandem Lift Transfer sizeBL x BQ

Your
Choices are:
80 x 80
120 x 120
160 x 160

Part Number
3842 998 013
Your selection:
_______________ mm

Non-Antistatic (N)
Antistatic
(A)
320 to 5000
(in 5 mm increments)

__________________

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 6-3

_______ V _______Hz

Motor Orientation

0, 180, 270

__________________

L, M**, R

__________________

Belt Type
Length (L)

Motor Position

_______________ mm

* Full load conveyor speeds vary depending on motor frequency. See Table 6-3
** Mid-mount only available on 160 mm wide modules

8981 500 282 01/08

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67

Lift Transfer Units

Technical data for EQ1/T


Nominal belt speed
Load Capacity
Transverse conveyor
Lift-transfer unit
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications
Air pressure
Cylinder diameter
Cylinder stroke
Air fittings

= see Table 6-3


= 30 kg (15 kg reverse)
= 3 kg
= 1400
= 1700
= see Table 6-3
= 4-8 bar
= 25 mm
= 13 mm
= 4 mm (5/32) push-lock

Electrical data for EQ1/T


Actual Speed
Full Load Amps @
Nom.
HP
208/60 240/60 380/50 415/50 480/60 575/60
M/min
50 Hz
60 Hz
.125
.58
.58
.43
.38
.40
.34
6
6.4
6.2
.125
.58
.58
.43
.38
.40
.34
9
10.2
9.3
.125
.58
.58
.43
.38
.40
.34
12
12.8
12.5
.125
.58
.58
.43
.38
.40
.34
15
15.4
15.6
.125
.58
.58
N/A
N/A
.40
.34
18
N/A
18.7
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 6-3

Dimensional data for EQ1/T


L

BQ+55

BL+15

110

BQ

BL+15

+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position
8.6 Pass-through Position

BL

105

295

105

66

BL

68

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Lift Transfer Units

Lift-Transverse Conveyor

30

Model EQ1/TE

The EQ1/TE Tandem Lift Transfer Module


combines the functionality of a lift transfer
unit and a BS1/T transverse conveyor
both powered from a single drive motor.
Each EQ1/TE includes all required
mounting hardware as well as the
following major components:
1 Lift transfer unit
1 BS1/T Transverse conveyor
1 Drive connection kit
1 Protective guards kit

The BS1/T is used to power the slave


driven lift transfer unit. The transfer unit is
normally at rest 2.2 mm below the main
line belt height. When energized up, the
transfer rises 4.4 mm to the same height
as the BS1/T transverse conveyor belts
and the pallet is transferred. When
energized down, the transfer lowers 8.6
mm, and the pallets are allowed to pass
through on the main line. The EQ1/TE
tandem transfer module is completely
reversible, although the allowable
payload is reduce to 15 kg in reverse
operation.
Side guides on the transfer unit may be
positioned slightly higher to stop a pallet
when the transfer is in the center or rest
position. Optional cushioned transfer
stop (page 8-4) may be added to provide
gentle stopping on the transfer.

Outboard Mounted
Motor Orientation

Motor and Lift-transfer


Position

180

Primary Pallet
Flow

L
Pallet
Flow

270

Ordering Information for Lift-Transfer Unit EQ1/TE


Specify part number,
then select from
the options below.
Tandem Lift Transfer sizeBL x BQ
Lift Transfer Position
Belt Type
Length (L)

Part Number
8981 999 259

Your
Choices are:
80 x 80
120 x 120
160 x 160
Drive end
Return end

Your selection:
_______________ mm
(D)
(R)

Non-Antistatic (N)
Antistatic
(A)
320 to 4900
(in 5 mm increments)

__________________
__________________
_______________ mm

Nominal belt speed (m/min)*

6, 9, 12, 15, 18

_____________ m/min

Motor Voltage/frequency

See Table 6-4

_______ V _______Hz

Motor Orientation

0, 180, 270

__________________

L, M**, R

__________________

Motor Position

* Full load conveyor speeds vary depending on motor frequency. See Table 6-4
** Mid-mount only available on 160 mm wide modules

8981 500 282 01/08

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69

Lift Transfer Units

Technical data for EQ1/TE


Nominal belt speed
Load Capacity
Transverse conveyor
Lift-transfer unit
Motor RPM @ 50 Hz
Motor RPM @ 60 Hz
Motor electrical specifications
Air pressure
Cylinder diameter
Cylinder stroke
Air fittings

= see Table 6-4


= 30 kg (15 kg reverse)
= 3 kg
= 1400
= 1700
= see Table 6-4
= 4-8 bar
= 25 mm
= 13 mm
= 4 mm (5/32) push-lock

Electrical data for EQ1/TE


Actual Speed
Full Load Amps @
Nom.
HP
208/60 240/60 380/50 415/50 480/60 575/60
50 Hz
M/min
60 Hz
.125
.58
.58
.43
.38
.40
.34
6.4
6
6.2
.125
.58
.58
.43
.38
.40
.34
10.2
9
9.3
.125
.58
.58
.43
.38
.40
.34
12.8
12
12.5
.125
.58
.58
.43
.38
.40
.34
15.4
15.6
15
.125
.58
.58
N/A
N/A
.40
.34
N/A
18.7
18
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 6-4

Dimensional data for EQ1/TE


L

BL+15

BQ+55

BQ

110

+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position

BL

105

295

105

66

8.6 Pass-through Position

7-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

Positioning Units

Section 7- Positioning Units

Positioning Units are used at workstations when workpiece pallets have to be


accurately positioned. Lift-position units
lift the workpiece pallet from the
conveying media so that up to 80 kg
(176 lbs.) of downward force can be
applied to the pallet.
NOTE: Non-oiled dry air, 58-116 PSI (48 bar) connected through 4 mm pushlock plastic tubing is required on all
positioning units.
Pneumatic diagrams for these units are
shown on page 10-3.

10

80

PE1/P
Positioning Unit
7-1

HP1
Lift-Position Unit
7-2 to 7-3

TS1 Assembly Conveyors

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TS1 Assembly Conveyors

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Linear Motion and Assembly Technologies

7-1

Positioning Units

Positioning Unit

10

Model PE1/P

The PE1/P positioning unit provides


repeatability up to + 0.03mm (.001) with
a WT1/S steel workpiece pallet and
+ 0.015mm (.006) with a WT1/P aluminum workpiece pallet. The PE1/P uses a
side locating pin to engage a locating hole
on the workpiece pallet frame. It can be
used at automatic or manual workstations.

Ordering Information for Positioning Unit PE1/P


(For use with WT1/S and WT1/K pallets)

Depending on pallet type, two different


versions are available. One version is designed specifically for use with the WT1/K
and WT1/S workpiece pallets. The second
version is designed to conform to the features of WT1/P aluminum workpiece pallet.

Ordering Information for Positioning Unit PE1/P


(For use with WT1/P pallets)

Specify part number,


then select from
the options below.

Your
choices are:

The positioning units mount directly to the Tslots in the bottom of the conveyor profile or
to the table top of an automatic workstation.

Positioning Unit Width (B)

80, 120, 160

NOTE: The positioning repeatability of the


PE1/P does not account for workpiece
pallet plate flatness. Please refer to Section
2 for plate flatness tolerances.

Your
choices are:

Positioning Unit Width (B)

80, 120, 160

Technical data for PE1/P


Load Capacity

= 10 kg

Pallet repeatability = 0.4 mm WT1/K


= 0.03 mm WT1/S
= 0.015 mm WT1/P
Max Allowable
Applied Force

= 100 N

Part Number
3842 998 101
Your selection:

Part Number
3842 998 102
Your selection:

Station mount dimensions*


52.5 0.2
32.5 0.3
12.5 0.2

B=...
80
120
160

Permitted Turning = 10 Nm
Moment
Stroke

= 6.5 mm

Cylinder Diameter = 25 mm
Air pressure

= 4-8 bar

Air fittings

= 4 mm

Tap M6

Dowel Hole 6.0

12.5 0.2 (B=80)


32.5 0.2 (B=120)
52.5 0.3 (B=160)

Dimensional data for PE1/P


3.5
23.5

End View
B+87

46.5
99.5

50

120
119.5

53

107. 4 5

1.05

52

45

15

119.5

Top View

23.5

1.5

B +15
B +44.5

14.5

WT 1/K: S = 0.8 mm
WT 1/S: S = 0.8 mm
WT 1/P: S = 1.5 mm

*Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

100 0.0.025

The PE1/P unit is delivered partially


assembled and includes the positioning
unit, a proximity switch for queuing
position, mounting hardware, pneumatic
fittings and 2 or 3 proximity switch holders
(depending on pallet size). Two VE1
Stops (pg. 8-1) are recommended for
each PE1. One is used as a pre-stop and
the other for a PE1/P stop.

Specify part number,


then select from
the options below.

72

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8981 500 282 01/08

Positioning Units

Lift-Position Unit

80

Model HP1

Stop Gate optional

The HP1 Lift-Position Units are used for


precision positioning of workpiece pallets
at workstations (usually automated).
Positioning pins on the HP1 engage
positioning bushings in the support plate
of the pallet to lift it up off the conveyor.
The resulting positioning repeatability is
0.025 mm (.0009") in the X and Y axis.
The air cylinders generate 785 N of
upward force (176 lbs.) at 4 bar (58psi).

The HP1 is shipped with all required


mounting hardware including pneumatic
fittings positioning pins, flow control
valves and protective cover.

Specify part number,


then select from
the options below.

Part Number
3842 999 805

Your
Choices are:

Workpiece Pallet Size, B

Your selection:

80 x 80, 120 x 120,


160 x 160

__________________
3842 524 092

Optional Hold Down Plate, Qty 2

Dimensional data for optional hold down plate


28

50

0 50

The HP1 may be powered down 8 mm to


allow pallet pass through, or powered up to
accurately position the pallet. The optional
adjustable Hold Down Plate allows the
pallet to be positively clamped in position
when raised by the HP1. Use the VE1/DB
cushioned stop, ordered separately on
page 8-2, in place of the hard stop for
sensitive assembly operations.

Ordering Information for Positioning Unit HP1

135

The lift-positioning unit can be mounted


directly to the T-slots in the bottom of the
conveyor profile or station mounted to a
machine frame.

8981 500 282 01/08

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73

Positioning Units

Technical data for HP1


Load Capacity
Positioning Accuracy
Max Allowable Applied Force
Permitted turning moment
Air pressure
Stroke Down
Stroke Up
Cylinder diameter
Air fittings

=
=
=
=
=
=
=
=
=

80 kg
0.025 mm both x and y axis
400 N
15 Nm
4-8 bar
8 mm fixed
0-50 mm adjustable
50 mm
4 mm

Dimensional data for HP1


Station Mount Dimensions*
175

L1

128

B 42

R7
.5

15

B + 13
B 32

B 42

2X 6 (H7)

D
4X M6
A

80
120
160

Stroke
(8 to 50)

200

60.5

62.5

L2

A
141
141
181

125

*Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

66

B
90
130
170

C
31
50
90

D
9.5
10
10

E
50
70
110

8-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

Stop gates

Section 8- Stop Gates

Stop gates are used to stop workpiece


pallets. Stops are pneumatically
operated and mount between the
conveyor section guide rails. Cushioned
stops are recommended where sensitive
material is being processed at higher
conveyor speeds. Cushions are adjustable for pallet payload.
NOTE: Clean dry air, 58-116 PSI (4-8
bar) connected through 4 mm push-lock
plastic tubing is required on all stop
gates. The Pneumatic diagrams for stop
gates are shown on page 10-3.

8
VE1
Standard Stop Gate
Page 8-1

AL1
Stop Rail
Page 8-5

VE1/D, VE1/DA1B
Cushioned Stop Gates
Page 8-2 to 8-3

WI1/M
Rocker Stop
Page 8-6

VE1/DA
Transfer Stop
Page 8-4

8981 500 282 01/08

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81

Stop Gates

Stop Gate
Model VE1

The VE1 is a pneumatically controlled stop


used to halt forward movement of the
workpiece pallet. In its normal position the
stop gate is spring loaded in the blocking
position. VE1 stop gates may be used to
stop pallets on either the leading or trailing
edge as shown below. Stop gates attach
to the inside T-slot of the conveyor rail.
Two plastic pins ensure that the stop is
perfectly aligned in the T-slot.

Ordering Information for Stop Gate, VE1


The VE1 is delivered completely assembled and includes a 4 mm quick
connect fitting and all required mounting
hardware.

Description

Part Number

Stop Gate

3842 522 400

Queue load, VE1


Nominal Line Speed (m/min)

Description
VE1 Queue Load (kg)

12

15

18

80

60

40

40

Dimensional data for VE1

A
Leading
Edge
4-6 Bar

B
Trailing
Edge

Mount VE1 Stop gates to the inner left-A or the inner


right-B side of the conveyor section.

82

Bosch Rexroth Corp.

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8981 500 282 01/08

Stop gates

Cushioned Stop Gate


Model VE1/D

Use the VE1/D cushioned stop to


assemble fragile or shock sensitive
components. Cushioned stops reduce
impact force by up to 80% over traditional stop gates and are infinitely
adjustable for various payloads.
The VE1/D can be mounted on the right
or left inside conveyor rail and can hold a
pallet on the leading or trailing edge.
The VE1/D is delivered completely
assembled and includes a 4 mm quick
connect fitting and all required mounting
hardware.

Ordering Information for Cushioned Stop Gate, VE1/D


Description

Part Number

Cushioned Stop Gate

3842 523 375

Queue load, VE1/D


Nominal Line Speed (m/min)

Description
VE1/D Queue Load (kg)

12

15

18

10

10

10

8
Dimensional data for VE1/D
Stroke
7

35

57

65

40

38.5

8.0 0.1

16

30
63

TS1 Assembly Conveyors

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83

Stop Gates

Cushioned Stop Gate


Model VE1/DA1B

The VE1/DA1B cushioned stop gate is


used with HP1 Lift-Position Units as an
optional stop when sensitive assemblies
are required. Cushioned stops reduce
impact force by up to 80% and are
infinitely adjustable for various payloads.

Product Bulletin

The VE1/DA1B can only be used with


the HP1 Lift-Position Unit.
The VE1/DA1B mounts on the positioning plate in the same mounting location
as the standard integral hard stop. The
stop is delivered fully assembled and
includes all required mounting hardware.

Ordering Information for Cushioned Stop Gate, VE1/DA1B


Description

Part Number

Cushioned Stop Gate Kit for use with HP1

3842 535 360

8
Dimensional data for VE1/DA1B
54

4.5

Mounting Location, HP1


DA 1/B

25

WT 1/P

31

4.2

7. 5

33.5

26

33

34

27

M5

33

84

Bosch Rexroth Corp.

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8981 500 282 01/08

Stop gates

Cushioned Transfer Stop


Model VE1/DA

VE1/DA Transfer stops are used to


cushion the impact of arriving pallets
transferring from a lateral run to a
longitudinal one and vice-versa. Cushioning is pneumatic, and is fully adjustable
depending on payload. Cushioned
transfer stops may be used on the side
rail of an EQ module for stopping pallets
on the transfer. VE1/DA stops may also
be used in conjunction with the AL1 Stop
Rail on page 8-5. A proximity bracket and
switch (ordered separately) mounted on
the side of the unit detects pallet
positioning into the VE1/DA.

Ordering Information for Cushioned Transfer Stop, VE1/DA

All required mounting hardware is


included.

Description

Part Number

Transfer Damper

3842 523 376

Queue load, VE1/DA


Nominal Line Speed (m/min)

Description
VE1S/DA Queue Load (kg)

12

15

18

10

Dimensional data for DA1


AL1 Stop Rail mounting

62

7
VE1/DA

WT 1

20
33

EQ 1/TR

7 Stroke

AL1

42
22

33
4.5
M5

M4

25

18

73

Mounting location, AL1

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85

Stop Gates

Stop Rail
Model AL1

AL1 Stop Rails are used to halt the


forward movement of arriving pallets
transferring from a lateral to a longitudinal
run.
The AL1 Stop Rail provides two locations
for attaching an SH1/K horizontal
proximity switch mounting bracket to
sense pallet presence.
The center channel is used to mount a
VE1/DA cushioned transfer stop when
required.

Ordering Information for Stop Rail, AL1


Description

Part Number

Stop Rail

3842 513 396

Dimensional Data for AL1


78

8
8

12

70

All hardware required to mount the AL1


to the conveyor line is included.

86

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Stop gates

44

TS1 Mini Rocker Stop


Model WI/M

The WI/M mini rocker stop provides an


economical method of workpiece pallet
detection and can be used (in conjunction with other components) to create
an accumulation control kit.

How it works: When the rocker is in


the rest position, air is directed to a stop
gate and pallets freely pass through.
When the rocker is actuated by a pallet,
the air is disabled and the stop gate
begins queuing pallets.

41.5

19

(91)

10.5

16.5

37

35.5

14

40

The WI/M can also be combined with an


optional pneumatic cylinder switch. In
this configuration, the actuation, which is
caused by a pallet passing by a WI/M, is
converted into a pneumatic signal. The
pneumatic accumulation control kit
(shown below) can be constructed
using of a VE1 stop gate.

Dimensional data for WI/M

22

When used for pallet detection, a 12mm


body proximity switch is required
(ordered separately). The switch is
activated when a workpiece pallet
passes in front of the rocker. In this
configuration, the WI/M has a monitoring area of 44 mm.
NOTE: Refer to the TSplus catalog for
12mm body proximity switches and
cables.

Pneumatic Cylinder Switch

29

bwt +10
VE 1

WI/M

Ordering Information for Mini-Rocker Stop, WI/M


Description

Part Number

WI/M Rocker Module (Fastening Hardware Included)

3842 530 797

Pneumatic Cylinder Switch

3842 532 151

8981 500 282 01/08

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91

Proximity Switch Brackets

Section 9- Proximity Switches and Brackets

Three types of proximity switch mounting


brackets are available. Vertical sensing
brackets sense pallet position from
underneath the workpiece pallet while
horizontal sensing brackets detect pallet
position from the side. The vertical
sensing brackets use the built in exciter
plates on the pallets and the horizontal
sensing brackets require the use of an
exciter block mounted to the surface of
the pallet.
All mounting brackets use 6.5 mm
diameter proximity switches which have a
sensing range between 3 and 4mm.

SH1/U
Vertical sensing bracket
9-2

SH1/S
Horizontal sensing bracket
9-3

SH1/M
Horizontal sensing bracket
9-4

Proximity Switches
9-5

92

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8981 500 282 01/08

Proximity Switches and Brackets

Vertical Sensing Switch Brackets


Model SH1/U

Use SH1/U vertical sensing switch


brackets along with a proximity switch
(ordered separately) to detect the
position of WT1 workpiece pallets from
underneath.
The SH1/U switch bracket is available in
two styles. One style is constructed from
ABS (transparent in color) and designed
for non-conductive applications. The
other style is constructed from PA66
(black in color) and designed specifically
for ESD-sensitive applications.

Ordering Information for Vertical Sensing Bracket SH1/U


Description

Part Number

Vertical Sensing Bracket (non-conductive)

3842 338 684

Vertical Sensing Bracket (ESD safe)

3842 536 352

Dimensional data SH1/U


20

53

39

6.5

13

13

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93

Proximity Switch Brackets

Horizontal Sensing Switch Brackets


Model SH1/S

Use SH1/S horizontal sensing switch


brackets along with a proximity switch
(ordered separately) to detect the
position of WT1 workpiece pallets from
the side. Exciter blocks (page 2-2) must
be mounted to the workpiece pallet to
enable pallet sensing.

Ordering Information for Horizontal Sensing Bracket SH1/S

The polyamide bracket is shipped with all


required mounting hardware.

Description

Part Number

Horizontal Sensing Bracket

3842 338 685

Dimensional data SH1/S

20
13

35

41

Exciter Block
See Page 2-2

40

84

72

14

94

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Proximity Switches and Brackets

Horizontal Sensing Switch Brackets


Model SH1/M
A

The SH1/M consists of a top block (A) and


bottom block (B). When mounting to a KE1
curve, KU1 curve or PE1/P positioning unit,
one top block and one bottom block are
required to create a 25.5mm tall bracket.
When mounting to an AL1 stop rail, two
top blocks are required to create a 14.5mm
tall bracket.

Use SH1/M proximity switch mounting


brackets along with a proximity switch
(ordered separately) to detect the
presence of WT1 workpiece pallets from
the side in KE1 curves, KU1 curves, PE1/P
positioning units and an AL1 stop rail.

Ordering Information for Horizontal Sensing Bracket SH1/K


Description

Part Number

Prox Switch Holder Top

3842 318 941

Prox Switch Holder Base

3842 318 942

The polyamide brackets are shipped with


all required mounting hardware.

Dimensional data for SH1/M

Dimensional data for SH1/M

(for mounting to KU1, KE1 or PE1/P)

14

18.5

25.5

18.5

11

40

KU1

40

AL1

ST 1

ST 1
7

6.5

19

14

14.7

6.5
14.7

19

WT 1

SH 1/M

WT 1
14

SH 1/M

14

25.5

(for mounting to an AL1 stop rail)

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95

Proximity Switch Brackets

Proximity Switches

Proximity switches indicate workpiece


pallet presence by detecting the exciter
plates on the sides and bottom of
workpiece pallets. These normally open,
24 VDC, short-circuit protected switches
are PNP (sourcing) and have a 6.5 mm
body. The switches have a rated sensing
range between 3mm (shielded) and 4mm
(unshielded) and have an LED indicator.

A.

C.

B.

The quick disconnect switch and plug


provides fast assembly and service. All
required hardware is included.

6.5mm x 60mm shielded


10-30 VDC, normally open,
quick disconnect
m
60 m

6.5mm x 50mm unshielded


10-30 VDC, normally open,
quick disconnect
m

50 m

90 Quick
Disconnect Plug
with 5m of 3-conductor
cable

Ordering Information for Proximity Switches


Description
A 6.5mm x 60mm prox. switch, shielded
B 6.5mm x 50mm prox. switch, unshielded
C 90 plug with 5 m of 3-conductor cable

Sensing
Application

For Use With

Sensing
Range

Vertical or Horizontal SH1/U, SH1/S, SH1/M 3.0mm


4.0mm
Horizontal
SH1/M, SH1/S

Part Number
8981 021 153
8981 018 805
8981 018 806

10-0

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Technical Data

Section 10- TS 1 Technical Data

Conveyor width
Conveyor width is determined by the size
of the workpiece pallet. Maximum payload
depends on the length of the load-bearing
edge (LWT or BWT) of the workpiece pallet.
Maximum permissible loading for the load
bearing edge is shown in Figure 10-1
Maximum permissible workpiece pallet
payload (includes pallet, fixturing,
workpiece and coding system) depends
on the supported length of the pallet as
shown in Figure 10-2.

Workpiece Pallet
load-bearing edge Maximum
Load in kg*
LWT or BWT
80

1.5

120
160

2.2
3.0

BW

LW

* Maximum load is the combined weight of all pallet components, fixture, and parts.

Figure 10-1

Never exceed the maximum load per


pallet or per drive unit. The load is
maximum when pallets are in queue as
shown in Figure 10-3.

Workpiece
pallet

Transportation speed
Preferred speed is 12 m/min on conveyor
sections and transfers. Performance data
for individual modules is based on these
speeds, although different speeds can be
selected. Transportation speed is
selected based on system cycle time,
time required by the workpiece pallet to
enter a workstation, total weight of the
pallet, and stability of the workpiece on
the pallet.

10

Supported length

Conveyor section

Conveying media

Figure 10-2

Conveying direction
Workpiece pallets should be conveyed
toward a drive unit. Reversible operation
is only possible when explicitly stated.

Transportation direction
MAXIMUM LOAD
F

NOTE: Drive capacity must be greater then the


maximum load between the drive and return unit

Figure 10-3

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Bosch Rexroth Corp.

101

Technical Data

Section 10- TS 1 System Specifications

Application

CE identification, responsibility

Materials used

The Rexroth transfer systems all form a


program of fine-tuned mechanical
components that are used to convey
separate and position workpiece pallets.
With these components, you can create
almost any system layout you need. The
systems are primarily used to convey
workpieces (on Rexroth workpiece
pallets) to and from manual or automatic
workstations on an assembly line.

Components that fall under the EC


machinery guideline are delivered with the
corresponding manufacturers
declaration. Overall responsibility for
system safety (declaration of conformity
CE identification) lies with the system
builder. The references in the assembly
instructions must be followed.

The materials used in the components


are primarily:

Planning
Transfer system planning (the
combination of components into a
modular system), set-up, initial start-up
and maintenance should only be done by
trained personnel. Rexroth offers training
courses for this purpose.

Scope of delivery small parts


The proximity switches, pneumatic
valves, and electrical and pneumatic
installation material that are necessary
for operation are usually not included in
the scope of delivery. These parts are
only preassembled if they ensure special
functional reliability or if installing them at a
later point would require too much effort.
Please note that the references for the
required flow control valve and check
valves in the pneumatic switching plan
(listed in the assembly and operation
instructions) must be followed.

Note
Examples
Installation references, pneumatic
switching plans and typical function
processes are described in the catalogs
and assembly instructions. These must
be followed when setting up and
commissioning the system.

Ambient conditions
Environmental conditions climatic
The transfer systems have been
designed for stationary use in a location
that is protected from the elements.
Operating temperature
+5 to +40C
-5 to +60C with 20% less load
Storage temperature
-25C to +70C
Relative humidity
5 to 85%, non-condensing
Air pressure
>84 kPa in accordance with installation
altitude <1400m above sea level.
Load values are reduced by 15% when
the system is set up at a location that is
over 1,400m above sea level.
Environmental conditions biological
Avoid molds, fungi, rodents, and other
vermin.
Environmental conditions chemical
Do not set up near industrial systems
with chemical emissions.
Environmental conditions physical
Do not set up near sandy or dusty
sources. Do not set up in areas that are
regularly jarred by high forces caused by
e.g. presses, heavy machinery, etc.

Non-rusting steel or steel protected


against corrosion by a special
surface
Brass
Cast or malleable aluminum alloy
Polyurethane, polyamide, some with
additives to improve electrical and
mechanical characteristics and
UHMW polyethylene
NBR or Viton for elastic seals

Media Resistant
Resistant to many common media used
in production such as water, mineral oil,
grease, and detergents. Contact your
Rexroth representative if you have any
doubts about resistance to specific
chemicals, e.g. test oil, doped oils,
aggressive detergents, solvents, or
brake fluid. Avoid long-term contact with
acidic or basic reacting materials.

Contamination
Wear may increase dramatically if the
system is contaminated due to
environmental factors, particularly with
abrasive media such as sand and
silicates, but also due to processes
running on the transfer system (e.g.
welding beads, pumice dust, glass
shards, shavings, or lost parts). In
such cases, maintenance intervals must
be substantially shorted.

10

102

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Technical Data

Functional reliability

Maintenance

Load specifications

Resistance to media and contamination


does not mean that functional reliability
is guaranteed in every case.

The TS components require very little


maintenance. If maintenance-free
operation is not feasible at economic
costs, maintenance instructions are
included in the operating manual.

Permissible loads apply for conveyor


sections only under the condition that
workpiece pallets with the maximum
permissible weight have accumulated.
Higher loads are permissible if
accumulation can be safely avoided.
Accumulation operation is not
permissible on lift transverse units.

Liquids that thicken on evaporation


and are highly viscous or adhesive
(sticky) could lead to a disruption in
function
Media with lubricating properties
may reduce the driving power that is
caused by friction if they are
transported on systems with belts
or round belts
The chain lubricant used on conveyor chains can be washed away
with solvents or detergents

Wear
With individual components, wear is
caused by the basic principle and cannot
be avoided. Constructive measures and
selection of the proper material will help
functional reliability last for the entire
service life. However, wear depends on
the operating, maintenance, and ambient
conditions of the system and the
location (resistance, contamination).

Measures to reduce wear


Such cases require special attention
when planning the system and adjusting
the maintenance intervals.

Environmental sustainability,
recycling
The materials used are environmentally
sustainable and may be recycled or
reused (if need be, by converting or
replacing components). Recyclability is
ensured by the selection of material and
the possibility to take the components
apart.

10

Pneumatic connection data


Oiled or non-oiled, filtered, dry
compressed air
Operating pressure 4 to 6 bar
Performance data is for an operating
pressure of 5 bar.

The following measures reduce wear and


the friction caused by it:
Switch off conveyor sections when
the system is not running, e.g. during
breaks, overnight, on the weekend.
Only select speeds that correspond
to the particular function.
Minimize the weight of the workpiece
pallet do not overload with
material during pickup.
Avoid unnecessary accumulation
section, e.g. by reducing the number
of workpiece pallets
Switch off accumulation sections
with heavy workpiece pallet loads if
transport is not necessary
Especially Important: Avoid contamination by abrasive media or reduce
contamination with regular cleaning.

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TS1 Assembly Conveyors

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Linear Motion and Assembly Technologies

103

Technical Data

Pneumatic Summary

NOTE: Non-oiled DRY air, 58-116 PSI (4-8 bar) connected through 4 mm push-lock plastic
tubing is required on all TS 1 pneumatic components.

Module

Bore
(mm)

HQ1/U

25

EQ1/TR

25

EQ1/T
EQ1/TE

Stroke
(mm)

Volume (cc)
per stroke

Tube Size

10

4.9

4mm

M5

10

9.8

4mm

M5

25

10

9.8

4mm

M5

25

10

4.9

4mm

M5

PE1/

25

HP1

50

58

VE1
DA1

4mm

M5

4mm

M5

3.9

4mm

M5

4.8

4mm

M5

2.2

4mm

M5

7
7

20

Module

2.9
113.9

25
16

VE1/D

Port

Tube Size (mm)

Port

Flow rate

barbed hose
connector

40l/min

Pneumatic Cylinder Switch

Lift-Transfer Unit Pneumatic Diagrams


Pneumatic diagram for HQ1/U, EQ1/T, EQ1/TE
For single Acting Lift Applications only

Pneumatic diagram for HQ1/U, EQ1/T, EQ1/TE


For Double Acting Lift and Lower Applications only
4 mm

Not
Included

10

Not
Included

4 mm

4 mm

Pneumatic diagram for EQ1/TR

Pneumatic diagram for EQ1/TR


For single Acting Lift Applications only

For Double Acting Lift and Lower Applications only


4 mm

1
2

1
5

Not
Included

Not
Included

4 mm

4 mm

104

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

Technical Data

Positioning Unit Pneumatic Diagrams

Pneumatic diagram for PE1/P, HP1


4 mm
1
2
1

2
4 mm

Not
Included

Stop Gate Pneumatic Diagrams


Pneumatic diagram, VE1,
VE1/D, and DA1

Pneumatic diagram,
Pneumatic Cylinder Switch
VE 1

10

P
4 mm

4 mm
2
R

CE Declaration
CE Declarations are not shipped with modules. When you order CE compliant
modules, please contact our applications engineering department for the latest
revision level of the manufacturer's CE declaration if required for your records.

8981 500 282 01/08

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TS1 Assembly Conveyors

Linear Motion and Assembly Technologies

Bosch Rexroth Corp.

105

Technical Data

Conversion Factors

Metric/English Conversion Chart


Measurement

Multiply

by

to get:

Linear

millimeters (mm)
inches
kilometers (km)
miles
millimeters 2 (mm 2 )
inches 2
centimeters 3 (cm3 )
inches 3
1 Liter
meter/second 2 (m/s 2)
inch/second 2
meter/second (m/s)
feet/second
kilogram (kg)
pounds
kilograms-f (kgf)
Newtons (N)
pounds-f
Newtons (N)
bar
PSI
Newton-Meters (Nm)
pound-inches
centimeters 4 (cm 4)
inches 4
kilowatts (Kw)
horsepower (HP)
Joules (J)
foot/pounds (ft/lbs)

0.03937
25.4
0.6214
1.6093
0.00155
645.16
0.06102
16.387
61.025
39.37
0.0254
3.281
0.3048
2.2046
0.4536
9.807
0.10194
4.448
0.2248
14.5
0.069
8.851
0.11298
0.02403
41.623
1.34
0.746
0.7376
1.3558

inches
millimeters (mm)
miles
kilometers (km)
inches 2
millimeters 2 (mm 2)
inches 3
centimeters 3 (cm 3)
inches 3

Area
Volume

Acceleration
Velocity
Mass
Force

Pressure
Torque
Moment of Inertia
Power
Energy

Metric Tap/Drill Specifications


Tap

Tap

Drill Size

M4

M4 x .7

3.3 mm

M5

M5 x .8

4.2 mm

M6

M6 x 1

5.0 mm

M8

M8 x 1.25

6.8 mm

M12

M12 x 1.75

10.2 mm

M16

M16 x 2

14.0 mm

inch/second 2
meter/second 2 (m/s 2)
feet/second
meter/second (m/s)
pounds
kilogram (kg)
Newtons (N)
kilograms-f (kgf)
Newtons (N)
pounds-f
PSI
bar
pound-inches
Newton-Meters (Nm)
inches 4
centimeters 4 (cm 4)
horsepower (HP)
kilowatts (Kw)
foot/pounds (ft/lbs)
Joules (J)

Temperature
Degrees Celsius

Degrees Fahrenheit

5 x (degrees F - 32)
9
(9 x degrees C) + 32
5

10

110

Bosch Rexroth Corp.

Linear Motion and Assembly Technologies

TS1 Assembly Conveyors

8981 500 282 01/08

Part Number Index

Section 11- Part Number Index

Part Number

11

Page

Part Number

Page

Part Number

Page

3842 318 941

9-4

3842 530 443

2-2

3842 999 900

4-6

3842 318 942

9-4

3842 530 444

2-2

3842 999 986

5-4

3842 338 684

9-2

3842 530 445

2-2

3842 999 987

5-6

3842 338 685

9-3

3842 530 797

8-6

3842 999 988

5-8

3842 513 396

8-5

3842 532 151

8-6

8981 017 989

3-7

3842 518 427

3-5

3842 532 813

2-2

8981 018 805

9-4

3842 521 166

3-6

3842 532 814

2-2

8981 018 806

9-4

3842 521 342

3-4

3842 535 360

8-3

8981 021 153

9-4

3842 521 343

3-4

3842 536 352

9-2

8981 999 259

6-8

3842 521 344

3-4

3842 992 934

3-5

R980 023 725

3-7

3842 521 520

3-6

3842 992 943

3-6

3842 522 400

8-1

3842 998 010

6-2

3842 523 375

8-2

3842 998 012

6-4

3842 523 376

8-4

3842 998 013

6-6

3842 523 563

3-10

3842 998 101

7-1

3842 523 585

3-10

3842 998 102

7-1

3842 524 092

7-2

3842 999 702

3-8

3842 526 560

3-10

3842 999 703

3-8

3842 526 849

2-2

3842 999 759

3-2

3842 526 850

2-2

3842 999 760

3-1

3842 526 851

2-2

3842 999 764

5-1

3842 527 122

2-2

3842 999 765

5-2

3842 527 123

2-2

3842 999 779

3-4

3842 527 124

2-2

3842 999 805

7-2

3842 527 535

3-10

3842 999 898

4-2

3842 529 940

3-5

3842 999 899

4-4

Bosch Rexroth has a conveyor to fit any application


TSplus is used
for all medium
size products
such as
computers,
automotive
components
and small appliances. It is the most
flexible of all Bosch conveyors with
your choice of configuration, speed, 26
different pallet sizes and three available
transport media. Repeatability is up to
0.05 mm.

Workpiece Pallet Size Range:


160 x 160 mm to 1040 x 1040 mm
Workpiece Pallet Load Capacity:
Up to 70 kg (154 lbs)
Transport Media:
Double Belt, Flat-Top Chain or
Roller Chain
Transport Rate:
9, 12, 15 or 18 m/min

TS4plus is
widely used in
the appliance
and automotive
industries
because of its
ability to handle
large and heavy
products like automotive drivetrain
components, ranges or even refrigerators. In precision assembly, TS4plus can
achieve a repeatability factor of 0.125
mm. The power and free roller design
allows accumulation with minimum
queuing pressure.
Workpiece Pallet Size Range:
443 x 443 mm to 1243 x 1243 mm in
200 mm increments
Workpiece Pallet Load Capacity:
Up to 250 kg (550 lbs)
Transport Media:
Roller Chain
Transport Rate:
6, 9, 12 or 15 m/min

VarioFlow is a
single strand
conveyor system
designed for the
specific needs of
the packaging,
material handling
and assembly industries in two system
widths, 65mm and 90mm. Extremely
stable chain design allows VarioFlow to
achieve chain tensile forces (pulling
strength) of 1250 N in both widths.
Transport speeds include nine fixed and
two variable speed drives.
VarioFlow: Model VF65
Product Width: 15-175 mm
Maximum Product Weight: 10kg.
VarioFlow: Model VF90
Product Width: 35-200 mm
Maximum Product Weight: 20kg.
Transport Rate:
Fixed or variable up to 60 m/min.

Bosch Rexroth integrators solve tough assembly problems


From lean manufacturing cells to fully automated systems, no one helps you get
more out of your assembly operation than a Bosch Rexroth Integrator.
Our integrators are experts at integrating modular conveyors from Bosch Rexroth
into flexible, productive systems, tailored to your needs. Count on them for:
diverse application experience;
certified expertise with Bosch Rexroth conveyors, framing and guarding.
standard-setting quality in people and components.
When you have an assembly challenge, your conveniently-located Bosch Rexroth
Integrator can provide a turnkey automation solution along with the training and
support to assure its success.

Call the Bosch Rexroth team for framing application assistance


Practically anything for your plantlike machine bases, guarding and
workstationscan be made faster and more economically with aluminum structural
framing from Bosch Rexroth. Our authorized distributors make it happen in a hurry with:
local inventory of kits and components
shipment of bulk material within 24 hours
expert application advice and certified service
Modular framing from Bosch Rexroth is strong, easy to assemble and
competitively priced. It comes in more than 100 profiles with hundreds of
connectors and accessories, all precision-engineered.

To identify the right authorized integrator or distributor for your project,


and for the latest product updates,
visit our website at: www.boschrexroth-us.com
or call, 1-800-322-6724 (in USA)

Bosch Rexroth Corporation


Linear Motion and
Assembly Technologies
816 E. Third Street
Buchanan, MI 49107
Telephone (269) 695-0151
Facsimile (269) 695-5363
www.boschrexroth-us.com

Bosch Rexroth Corporation


Corporate Headquarters
5150 Prairie Stone Parkway
Hoffman Estates, IL 60192-3707
Telephone (847) 645-3600
Facsimile (847) 645-6201
Bosch Rexroth Corporation
Industrial Hydraulics
2315 City Line Road
Bethlehem, PA 18017-2131
Telephone (610) 694-8300
Facsimile (610) 694-8467
Bosch Rexroth Corporation
Electric Drives and Controls
5150 Prairie Stone Parkway
Hoffman Estates, IL 60192-3707
Telephone (847) 645-3600
Facsimile (847) 645-6201
Bosch Rexroth Corporation
Pneumatics
1953 Mercer Road
Lexington, KY 40511-1021
Telephone (859) 254-8031
Facsimile (859) 281-3491
Bosch Rexroth Corporation
Mobile Hydraulics
1700 Old Mansfield Road
Wooster, OH 44691-0394
Telephone (330) 263-3300
Facsimile (330) 263-3333

Printed in the United States


8981 500 282 01/08