TS 1 Modular Conveyors for Flexible Manufacturing

Transcription

1 TS 1 Modular Conveyors for Flexible Manufacturing Version 3.0 Handle pallet payloads up to 3.0 kg (6.6 lbs.)

2 1-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction TS 1 Modular Conveyors 1 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.

3 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 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

4 1-2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction Table of Contents 1 Section 1: Introduction System overview 1-8 Customer support services 1-9 Application photos 1-10 How to use this catalog Section 2: Workpiece pallets and components 2-2 Assembled workpiece pallets 2-3 Dimensional Data - WT1/K 2-4 Dimensional Data - WT1/S 2-5 Dimensional Data - WT1/P Section 3: Belt drive components 3-1 UM1 Belt return units AS1 Belt drive units 3-4 ST1 Conveyor sections and cross links 3-5 Connection links 3-5 SP1 Conveyor section profiles 3-6 FP1 Belt guide profile 3-6 GT1 Transport belt 3-7 Belt welding kit Leg sets 3-10 Foundation brackets Section 4: Transverse conveyors BS1 Transverse conveyors BS1/T Transverse conveyors BS1/M Mid-mount transverse conveyor Section 5: Curve units 5-1 KE1/90-0 Curve KE1/180-0 Curve KU1/90 Curve KU1/180 Curve KU1/360 Curve 5-10 Accumulation Control, KU1/... Curves Section 6: Lift-transfer units HQ1/U Lift-transfer unit EQ1/TR Tandem lift-transfer unit EQ1/T Tandem lift-transverse conveyor EQ1/TE Lift-transverse conveyor

5 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 1-3 Introduction Section 7: Positioning units 7-1 PE1, PE1/P Positioning unit HP1 Lift-position unit 1 Section 8: Stop gates 8-1 VE1 Stop gates 8-2 VE1/D Cushioned stop gate 8-3 VE1/DB Cushioned lift-position stop gate 8-4 VE1/DA Cushioned transfer stop 8-5 AL1 Stop rail Section 9: Proximity switches and brackets 9-2 SH1/U Vertical sensing switch brackets 9-3 SH1/S Horizontal sensing switch brackets 9-4 SH1/M Horizontal sensing bracket for curves 9-5 Proximity switches Section 10: Technical data 10-1 Pallet loading 10-2 Pneumatic summary 10-2 Lift-transfer unit pneumatic diagrams 10-3 Positioning unit pneumatic diagrams 10-3 Stop gate pneumatic diagrams 10-3 CE Declaration 10-4 Conversion charts. Section 11: Part Number Index 11-1 Part Number Index

6 1-4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction TS 1 - The choice for small products, or small spaces 1 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. Positioning. Pallets can be positioned at workstations to ± 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. 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. Stopping. Pallets can be stopped on the leading or trailing edge regardless 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. SECTION 3 Drive Belts Modularity also simplifies system design and assembly. As a result, you can be more responsive to changing market demands. Installation and maintenance are also simple further 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: The workpiece pallet can be accessed from all sides allowing maximum flexibility in automated or manual workstation placement around the conveyor. SECTION 5 Curve Units

7 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 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. 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. 1 SECTION 7 Lift-Position and Positioning Units SECTION 8 Stop Gates SECTION 4 Transverse Conveyors SECTION 3 Drives SECTION 9 Proximity Switches and Brackets SECTION 3 Conveyor Section Components SECTION 3 Return Units SECTION 6 Lift-Transfer Units SECTION 3 Leg Sets SECTION 2 Workpiece Pallets

8 1 6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction Numerous configuration possibilities Choose the TS 1 configuration that best suits your application or facility 1 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. Rectangular Return Transverse Conveyor Lift-Transfer Units Drive 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. Parallel Return Drive Return Curve Track Roller Drive A parallel configuration, while similar to a rectangular system, uses tandem lift transfer units or curve units to connect the conveyor sections. Serpentine Drive Return Return Drive Transverse Conveyor Curve 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. 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.

9 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 1 7 Introduction A A A Operation 1 A A Operation 2 A A A A Further tailor your system to match specific assembly requirements 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. 1 Cycle-independent stations can be used to balance assembly operations with differing cycle times. Cycle-independent stations are constructed using standardized modules and therefore are easily added to the main conveyor. A Applications for TS 1 A A Station A A A A 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. A 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 Automotive components Ink-jet Cartridges Hard drives Small subassemblies Electronics Medical Devices A B A B Station A A B Station B A B Different products can also be processed simultaneously.

10 1 8 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction Complete support: before, during and after installation 1 Every assembly project has its challenges. But you don t 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 you ve taken the first step by requesting this catalog, we ll help you with all the rest from 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. They ll carefully review your requirements cycle time, payload, floor space, process flow and devise the best conveyor layout to meet them. If you d 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, we ll respond quickly with a detailed quotation and answer any questions you may have. And we ll 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 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. After-sale service assures your continued success 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. We re 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.

11 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 1 9 Introduction Documentation that answers (and anticipates) your questions Of course, you don t want to call Rexroth every time you have a question. Fortunately, our approach to documentation ensures that you won t have to. Product catalogs (like this one) make planning and ordering easy, with detailed specifications and dimensions, 3-D illustrations and part numbers. When your system arrives, everything you need to know for set-up and operation comes with it. And if you d like to know which spare parts to keep on hand, we ll 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. You ll find your local authorized integrator there, too, at: Visit today, and see why it pays to specify Rexroth. 1 Application Photos

12 1 10 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Introduction Getting started using this catalog 1 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: 10-digit part number Name of the module Quantity Other ordering parameters as needed Rexroth Terms and Definitions 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: Additional info: (None required.) 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 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. If you need application assistance, have any questions about ordering, or want to identify the integrator nearest you, call us, toll-free: In Canada Nominal Height: Distance from floor to top of transport media. Transport Level Transport Level: Nominal Height WT B L B WT L WT B Q B L = Workpiece pallet = Nominal width = Nominal length = Workpiece pallet width = Workpiece pallet length = Lift transfer unit width = Lift transfer unit length Main Conveyor Section L Workpiece Pallet B Q 150 = Load Carrying capacity in Kg = Pallet Flow B WT B WT B L Lift Transfer Unit T-Slot: The longitudinal slot in the extruded aluminum profiles of the conveyor L WT WT B WT T-Bolt and T-Nut: Hardware used to secure components and accessories to the T-slots of a profile L L WT B Transverse Conveyor T-Slot Line Flow Profile T-Bolt T-Nut Figure 1

13 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 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. Workpiece pallets are ordered fully assembled in nylon, nylon with steel support plate, or aluminum with positioning bushings. 2 WT1/K Assembled Plastic Workpiece Pallets 2-2 to 2-3 WT1/S Assembled Steel Workpiece Pallets 2-2 to 2-4 WT1/P Assembled Aluminum Workpiece Pallets with Bushings 2-2 to 2-5

14 2-2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Workpiece Pallets Assembled Workpiece Pallets Exciter Block Model WT1/K, WT1/S, WT1/P Accumulation Bumpers 2 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 Model Pallet Material Size Weight kg Max. Total Weight kg. Part Number WT1/K PA66 80 x 80 mm 120 x 120 mm 160 x 160 mm WT1/S PA66 frame with Steel Mounting Plate 80 x 80 mm 120 x 120 mm 160 x 160 mm WT1/P Aluminum frame, UHMW-PE Wear Strips, (4) Bushings 80 x 80 mm 120 x 120 mm 160 x 160 mm Exciter Block, lot size Accumulation Bumpers (use with WT1/K or WT1/S pallets), lot size

15 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 2-3 Workpiece Pallets Dimensional data for WT1/K Ø8 H7 Measurement Contact Locating Groove, 2X 0.3 A H B 42 WT1/K F ± 0.2 4x Ø F ± 0.2 B 42 Pallet Size (b) F H K WT1/K N/A B ±0.1 B SW B 2 ± 0.1 Ø8 H7 Measurement Contact NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

16 2 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Workpiece Pallets Dimensional data for WT1/S Ø8 H7 Measurement Contact B 28 Locating Groove, 2X B 42 WT1/S 2 F ± 0.1 4x Ø 4.3 ± 0.05 B F ± 0.1 B 42 B 1 Pallet Size (b) E F G H K WT1/S N/A ± B B 2 ± 0.1 Ø8 H7 Measurement Contact SW NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

17 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 2 5 Workpiece Pallets Dimensional data for WT1/P Measurement Contact Ø 8h7 5.5 C 5.5 A B 2 10 C B 16.5 A 4x12 4x Ø6 F Measurement Contact Ø 8h7 Pallet Size (b) A B C WT1/P 80 x x x E ± 0.03 F G Pallet WT1/P Size (b) 80 x x x 160 D E F G D NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

18 3-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Belt Drive Components Section 3- Belt Drive Components 3 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. Belt Drive components in this section can be configured into any of the basic line layouts below. 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 Return Drive Return Drive Return Drive Drive Return Drive Return In-Line Parallel Rectangular UM1 Belt Returns 3-1 AS1 Belt Drives 3-2 to 3-3 ST1 Conveyor Sections and Cross Links 3-4 SP1 Connection Links and Conveyor Section Profile 3-5 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 Foundation Brackets 3-10

19 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 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. Return Unit Width (B)* * Return unit width must match workpiece pallet. Your Choices are: 80, 120, 160 Part Number Your selection: 3 Dimensional data for UM1 B+1 B+25 AS1-UM1 Connection Kit 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. AS 1 UM 1 Ordering Information for AS1-UM1 Connection Kit Description Part Number AS1-UM1 Connection Kit

20 3 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 3 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 L R Transport direction 270 Outboard Mounted Motor orientation 180 Transport direction 0 90 Ordering Information for Belt Drive Unit AS1 In addition to part number, please specify: Your choices are: AS1 Drive Unit Your selection: Drive Unit width (B) Nominal speed* Motor voltage/frequency Motor Orientation Motor Position 80, 120, 160 9, 12, 15, 18 See Table 3-1 0, 90, 180, 270 L, R mm m/min. V Hz * Full load conveyor speeds vary depending on motor frequency. See Table 3-1 To omit motor, specify 000V 00Hz.

21 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 3 3 Belt Drive Components Technical data for AS1 Nominal conveyor speed = See table 3-1 Permissible loading weight = 80 kg Maximum conveyor unit length = 12 m (39 ft.) Motor RPM at 50 Hz = 1400 Motor RPM at 60 Hz = 1700 Motor, electrical specifications = See table 3-1 Max. Length = 12.0 meters F F Max. Load = 80.0 kg F Electrical data for AS1 Nom. M/min Actual Speed 50 Hz N/A 60 Hz HP / / Full Load 380/ / Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table / / Dimensional data for AS1 130 B+25 B

22 3 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Belt Drive Components Conveyor Section QV 1 Cross Connector 500 Model ST1 3 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 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) /... * To order conveyor sections 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: /2000. Dimensional data for ST1 B+15 B 30 Length QV1 cross connectors (not included see below) must be used every 500 mm to maintain proper belt section width and alignment. FP b-30 Cross Connectors 9 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 Ordering Information for Cross Connectors QV1 Description Part Number Cross Connector, B = Cross Connector, B = Cross Connector, B =

23 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 3 5 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 Material: Zinc chromated steel 8 M6 10Nm Ordering Information for Connection Links Description Part Number Connection Link, one Conveyor Section Profile Model SP1 Ø 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 T- nuts eliminating the need for additional machining Profile is available cut-to-order up to 6100 mm long, or as full uncut lengths. 8 Ordering Information for Conveyor Section Profile SP1 Description Part Number Single uncut stick, L=6100 mm Cut-to-length, specify length 100 mm to 6000 mm* /...mm * To order conveyor section profiles 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: /2051.

24 3 6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Belt Drive Components Belt Guide Profile Model FP 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 Cut-to-length, specify length 50 mm to 2000 mm* /...mm * To order belt guide profiles 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: /1027. Transport Belt Model GT 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* * 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 meters of belt, your part number should look like this: Qty. = 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 Required belt length ((2 x L S + 918) x 0.988) + 40 [ mm] ((2 x L + 918) x 0.985) + 40 [ mm] Conveyor Section Length, L S mm S [mm]

25 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 3 7 Belt Drive Components Belt Welding Kit 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. To cut welding time in half, a second heating press is recommended for welding two adjacent belts at the same time. Tensioning Device 3 NOTE: This kit is for flat belts only and not intended for use on toothed or round transport belts. Belt Heating Press, 110VAC, 60Hz Belt Grinder Ordering Information for Belt Welding Kit Description Belt Welding Kit for belts up to 17,300 mm long. Includes: tensioning device, belt grinder, heating press, adhesive, brush, and thermometer. Belt Heating Press, 110VAC, 60Hz Part Number R Belt Ginder, 110VAC, 60Hz R

26 3 8 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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 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/L SZ1 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: Part Number Your selection: Width (B) 80, 120, 160 mm Height (H) H = < 200 > 1200 mm Ordering Information for Leg Sets SZ1/D Specify part number, then select from the options below. Your Choices are: Part Number Your selection: Width, (B) 80, 120, 160 mm Line Spacing, (A) 60, 135 mm Height, (H) H = < 200 > 1200 mm

27 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 3 9 Belt Drive Components Dimensional data for SZ1/L SZ 1/L 62.5 B SZ H 3 45 B SZ = B WT+15 Dimensional data for SZ1 SZ B A H SZ 45 B = 2 x(b +15)+a SZ WT

28 3 10 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. Cover Cap 43 19mm T-Bolt Kit 10 3 The die-cast aluminum bracket has a natural aluminum finish and includes two 19 mm T- bolt 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. SW13 SW (5/16") mm Anchor Bolt 8 (5/16") Ordering Information for Foundation Brackets Description 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 Part Number Recommended foundation bracket placement 2 m typ. 2 m typ. 2 m typ. Foundation Bracket Return End Drive End

29 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 4 1 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. 4 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

30 4 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 4 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. Primary Pallet Flow Outboard Mounted Motor Orientation Pallet Flow Motor Position L M Transverse conveyors are fully assembled and include all required mounting hardware. 0 R Ordering Information for Transverse Conveyor BS1 Specify part number, then select from the options below. Your Choices are: Part Number Your selection: Width (B) Belt Type Length (L) 80, 120, 160 Non-Antistatic (N) Antistatic (A) 250 to 5000 (in 5 mm increments) mm mm Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Motor Voltage/frequency See Table 4-1 m/min V Hz Motor Orientation 0, 180, 270 Motor Position 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.

31 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 4 3 Transverse Conveyors Technical Data for BS1 Nominal belt speed = see Table 4-1 Load Capacity = 30 kg (15 kg reverse) Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 4-1 Electrical data for BS1 Nom. M/min Actual Speed 50 Hz Hz N/A Dimensional data for BS1 HP 208/60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A B + 28 B + 1 B 45 B + 28 B L 110 B + 1

32 4 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 4 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. In normal operation the load capacity for transverse conveyors is 30 kg. In addition positioning and control modules can be mounted on the module. Primary Pallet Flow Outboard Mounted Motor Orientation Pallet Flow Motor Position L M 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. Ordering Information for Transverse Conveyor BS1/T Specify part number, then select from the options below. Width (B) Belt Type Length (L) 0 Your Choices are: 80, 120, 160 Non-Antistatic (N) Antistatic (A) 320 to 5000 (in 5 mm increments) Part Number Your selection: R mm mm Nominal belt speed (m/min)* 6, 9, 12, 15, 18 m/min Motor Voltage/frequency See Table 4-2 V Hz Motor Orientation 0, 180, 270 Motor Position 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. 270 motor orientation only available when Length (L) > 400 mm

33 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 4 5 Transverse Conveyors Technical Data for BS1/T Nominal belt speed = see Table 4-2 Load Capacity = 30 kg (15 kg reverse) Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 4-2 Electrical data for BS1/T Nom. M/min Actual Speed 50 Hz Hz N/A HP 208/60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A 4 Dimensional data for BS1/T L 110 B B 40 B + 28 B + 125

34 4-6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 4 Mounting the drive in the center of the conveyor s 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. 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 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. Primary Pallet Flow Outboard Mounted Motor Orientation Pallet Flow Motor Position Ordering Information for Transverse Conveyor BS1/M Specify part number, then select from the options below. Width (B) Transverse Conveyor Length (L) Section 1 Length (L 1 ) 0 * 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. 270 motor orientation only available when Length (L) > 400 mm 90 Your Choices are: 80, 120, 160 Motor Voltage/frequency See Table 4-3 Motor Position Belt Type 280 to 5000 (in 5 mm increments) 80 to 2450 (in 5 mm increments) Nominal belt speed (m/min)* 6, 9, 12, 15, 18 L, M**, R Non-Antistatic (N) Antistatic (A) L M R Part Number Your selection: mm mm mm m/min V Hz Motor Orientation 0, 90, 180, 270

35 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 4-7 Transverse Conveyors Technical data for BS1/M Nominal belt speed = see Table 4-3 Load Capacity = 30 kg (15 kg reverse) Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 4-3 Electrical data for BS1/M Nom. M/min Actual Speed 50 Hz Hz N/A HP 208/60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A 4 Dimensional data for BS1/M B L2 110 L1 L B B + 1 B 45

36 5-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Curve Units Section 5- Curve Units 5 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. 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/ Curve 5-1 KE1/ Curve 5-2 KU1/90 90 Curve 5-4 KU1/ Curve 5-6 KU1/2X180 2X180 Curve 5-8

37 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 5 1 Curve Units 90 Curve 5 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. Dimensional data for KE1/0-90 Ordering Information for Curve Unit KE1/0-90 Specify part number, then select from the options below. Nominal Line Width (B) Direction of Rotation Mounting Type AS1 AS1 A Your Choices are: Pallet Flow C 80, 120, 160 L, R UM1 BS1 BS1/T Pallet Flow B BS1/T Pallet Flow D BS1 or UM1 BS1/T Pallet Flow Part Number Your selection: (specify A, B, C, or D) BS/UM b +55 b Right Rotation 90 Left Rotation b + 1 b +55 b

38 5 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Curve Units 180 Curve 5 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. 5 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 Specify part number, then select from the options below. Your Choices are: Nominal Line Width (B) 80, 120, 160 Line Spacing "A" 60, 135 Part Number Your selection: mm mm Direction of Rotation Mounting Type AS1 AS1 A Pallet Flow C L, R UM1 BS1 BS1/T Pallet Flow B BS1/T Pallet Flow D BS1 or UM1 BS1/T Pallet Flow (specify A, B, C, or D)

39 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 5 3 Curve Units Dimensional data for KE1/ b BS / UM Right Rotation Left Rotation b b + 1 a+15 (b + 1) a 2 x (b + 1) + a + 50 b BS / UM Right Rotation Left Rotation b + 1 a+15 b (b + 1) a 2 x (b + 1) + a

40 5 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 5 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 (L 2) 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. The KU1/90 is shipped partially assembled. The curve, L1 conveyor section, and L 2 conveyor section are shipped as separate units. 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. Ordering Information for Curve Unit KU1/90 Specify part number, then select from the options below. Width (B) Your Choices are: 80, 120, 160 Motor Voltage/frequency See Table 5-1 Direction of Rotation Motor Mounting Position** Belt Type KU1/90 L 1 = 0mm, L 2 = 0mm 0 or Section 1 Length (L 1 ) (in 5 mm increments) Section 2 Length (L 2 ) 0 or (in 5 mm increments) Nominal belt speed (m/min)* 6, 9, 12, 15, 18 L, R I = Inboard A = Outboard Non-Antistatic (N) Antistatic (A) KU1/90 L1 = 0mm, L2 = 2000mm Part Number Your selection: mm mm mm m/min V Hz * 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 L 1 or L 2 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 R R

41 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 5 5 Curve Units Technical data for KU1/90 Nominal belt speed = see Table 5-1 Load capacity = 30 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 5-1 Electrical data for KU1/90 Nom. M/min Actual Speed 50 Hz Hz N/A HP Dimensional data for KU1/90 208/60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A 5 L 1 L 2 I = Inboard E G L = Left Rotation F R = Right Rotation 14 B 110 A = Outboard B (mm) E F G

42 5 6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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. 5 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. The KU1/180 is shipped partially assembled. The curve, L 1 conveyor section, and L2 conveyor section are shipped as separate units. 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. KU1/180 L 1 = 0mm, L 2 = 0mm Ordering Information for Curve Unit KU1/180 Specify part number, then select from the options below. Width (B) Your Choices are: 80, 120, or Section 1 Length (L 1 ) (in 5 mm increments) Section 2 Length (L 2 ) 0 or (in 5 mm increments) Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Motor Voltage/frequency See Table 5-2 Direction of Rotation Belt Type L, R Non-Antistatic (N) Antistatic (A) KU1/180 L1 = 2000mm, L2 = 1000mm * 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 L 1 or L 2 only when length is 150mm or greater. Ordering Information for KU1/180 Mounting Kit Part Number Your selection: mm mm mm m/min V Hz Motor Mounting Position** A = Outboard A (outboard) 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 R R

43 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 5 7 Curve Units Technical data for KU1/180 Nominal belt speed = see Table 5-2 Load capacity = 30 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 5-2 Electrical data for KU1/180 Nom. M/min Actual Speed 50 Hz Hz N/A HP Dimensional data for KU1/ /60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A 5 L 1 G F 135 L 2 L = Left Rotation B 7 A = Outboard R = Right Rotation B (mm) F G

44 5 8 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Curve Units 2x180 Curve 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. 5 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 (L 1) 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 (L 1) is available with either a standard (N) or anti-static (A) belt. The turntable is made from polyurethane. Ordering Information for Curve Unit KU1/2x180 Specify part number, then select from the options below. Width (B) Length (L 1 ) Number of Drives (AE) Your Choices are: 80, 120, (in 5 mm increments) 1, 2 Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Part Number Your selection: mm mm m/min The KU1/2x180 is shipped fully assembled. All required mounting hardware is included. Motor Voltage/frequency See Table 5-3 Direction of Rotation L, R V Hz Motor Position** A = Outboard A (outboard) Belt Type 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).

45 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 5 9 Curve Units Technical data for KU1/2x180 Nominal belt speed = see Table 5-3 Load capacity 1 drive = 24 kg Load capacity 2 drives = 30 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 5-3 Electrical data for KU1/2x180 Nom. M/min Actual Speed 50 Hz Hz N/A HP 208/60 240/60 N/A Full Load 380/50 415/50 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 N/A 5 Dimensional data for KU1/2x180 L F 135 L = Left Rotation G L 1 A = Outboard R = Right Rotation B (mm) F G

46 5 10 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 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. b wt +10 WI /M VE 1 5 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

47 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 6 1 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, 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 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. 6 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

48 6 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Lift Transfer Units Lift-Transfer Unit 3 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 6 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. For pass through applications, the HQ1/U is lowered 8.6 mm below the transport surface. The HQ1/U is completely reversible enabling pallet diversion in two directions from a single transfer point. The HQ1/U can be mounted to a BS1 transverse conveyor as well as the standard ST1 conveyor section. 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. Ordering Information for Lift-Transfer Unit HQ1/U Specify part number, then select from the options below. Lift Transfer size- B Q x B L Your Choices are: 80 x 80 mm 120 x 120 mm 160 x 160 mm Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Motor Voltage/frequency See Table 6-1 Part Number Your selection: mm m/min V Hz * Full load conveyor speeds vary depending on motor frequency. See Table 6-1

49 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 6 3 Lift Transfer Units Technical data for HQ1/U Nominal belt speed = see Table 6-1 Load Capacity = 3 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 6-1 Air pressure = 4-8 bar Cylinder diameter = 25 mm Cylinder stroke = 13 mm Air fittings = 4 mm (5/32") push-lock Electrical data for HQ1/U Nom. M/min Actual Speed 50 Hz N/A 60 Hz HP 208/60 240/60 Full Load 380/50 N/A 415/50 N/A 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 Dimensional data for HQ1/U B L BQ B L +15 B L B Q BQ =Raised Position =Transport Surface 2.2 Center, Rest Position 8.6 Pass-through Position B Q

50 6 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Lift Transfer Units Tandem Lift-Transfer Unit 3 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. 6 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- B Q x B L Line Spacing (A) Your Choices are: 80 x 80 mm 120 x 120 mm 160 x 160 mm 60, or 135 mm Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Motor Voltage/frequency See Table 6-2 Part Number Your selection: mm mm m/min V Hz * Full load conveyor speeds vary depending on motor frequency. See Table 6-2

51 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 6 5 Lift Transfer Units Technical data for EQ1/TR Nominal belt speed = see Table 6-2 Load Capacity = 3 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 6-2 Air pressure = 4-8 bar Cylinder diameter = 25 mm Cylinder stroke = 13 mm Air fittings = 4 mm (5/16") push-lock Electrical data for EQ1/TR Nom. M/min Actual Speed 50 Hz N/A 60 Hz HP 208/60 240/60 Full Load 380/50 N/A 415/50 N/A 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 Dimensional data for EQ1/TR 6 B L +A+15 B L +1 5 B L B L -30 A BQ BQ+1 BQ =Raised Position =Transport Surface 2.2 Center, Rest Position 8.6 Pass-through Position

52 6 6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Lift Transfer Units Tandem Lift-Transverse Conveyor 30 3 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. 6 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 The BS1/T is used to power the two slave driven lift transfer units. Each Lift- Transfer 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. Outboard Mounted Motor Orientation 180 Primary Pallet Flow 270 Pallet Flow Ordering Information for Lift-Transfer Unit EQ1/T Specify part number, then select from the options below. 0 Tandem Lift Transfer size- B L x B Q Belt Type Length (L) Your Choices are: 80 x x x 160 Motor Voltage/frequency See Table 6-3 Motor Orientation Motor Position Non-Antistatic (N) Antistatic (A) 320 to 5000 (in 5 mm increments) Nominal belt speed (m/min)* 6, 9, 12, 15, 18 0, 180, 270 L, M**, R Motor Position * Full load conveyor speeds vary depending on motor frequency. See Table 6-3 ** Mid-mount only available on 160 mm wide modules M L Part Number Your selection: R mm mm m/min V Hz

53 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 6 7 Lift Transfer Units Technical data for EQ1/T Nominal belt speed = see Table 6-3 Load Capacity Transverse conveyor = 30 kg (15 kg reverse) Lift-transfer unit = 3 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 6-3 Air pressure = 4-8 bar Cylinder diameter = 25 mm Cylinder stroke = 13 mm Air fittings = 4 mm (5/32 ) push-lock Electrical data for EQ1/T Nom. M/min Actual Speed 50 Hz N/A 60 Hz HP 208/60 240/60 Full Load 380/50 N/A 415/50 N/A 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 6 Dimensional data for EQ1/T B L L B L +15 BQ BQ+55 B L B L +4.4=Raised Position =Transport Surface 2.2 Center, Rest Position 8.6 Pass-through Position

54 6 8 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Lift Transfer Units Lift-Transverse Conveyor 30 3 Model EQ1/TE 6 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 180 Primary Pallet Flow Pallet Flow Ordering Information for Lift-Transfer Unit EQ1/TE Specify part number, then select from the options below. Tandem Lift Transfer size- B L x B Q Lift Transfer Position Belt Type Length (L) Your Choices are: 80 x x x 160 Drive end Return end R Motor and Lift-transfer Position (D) (R) Non-Antistatic (N) Antistatic (A) 320 to 4900 (in 5 mm increments) M L Your selection: D R Part Number mm mm Nominal belt speed (m/min)* 6, 9, 12, 15, 18 Motor Voltage/frequency See Table 6-4 m/min V Hz Motor Orientation Motor Position 0, 180, 270 L, M**, R * Full load conveyor speeds vary depending on motor frequency. See Table 6-4 ** Mid-mount only available on 160 mm wide modules

55 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 6 9 Lift Transfer Units Technical data for EQ1/TE Nominal belt speed = see Table 6-4 Load Capacity Transverse conveyor = 30 kg (15 kg reverse) Lift-transfer unit = 3 kg Motor 50 Hz = 1400 Motor 60 Hz = 1700 Motor electrical specifications = see Table 6-4 Air pressure = 4-8 bar Cylinder diameter = 25 mm Cylinder stroke = 13 mm Air fittings = 4 mm (5/32 ) push-lock Electrical data for EQ1/TE Nom. M/min Actual Speed 50 Hz N/A 60 Hz HP 208/60 240/60 Full Load 380/50 N/A 415/50 N/A 480/60 Note: Electrical Data for reference only. Refer to motor data plate for actual ratings. Table /60 6 Dimensional data for EQ1/TE 110 L B L + 15 B L BQ BQ =Raised Position =Transport Surface 2.2 Center, Rest Position 8.6 Pass-through Position 105

56 7-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 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, PSI (4-8 bar) connected through 4 mm pushlock plastic tubing is required on all positioning units. Pneumatic diagrams for these units are shown on page PE1/P Positioning Unit 7-1 HP1 Lift-Position Unit 7-2 to 7-3

57 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 7-1 Positioning Units Positioning Unit 10 Model PE1/P The PE1/P positioning unit provides repeatability up to mm (.001 ) with a WT1/S steel workpiece pallet and mm (.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) Specify part number, then select from the options below. Positioning Unit Width (B) Your choices are: 80, 120, 160 Part Number Your selection: 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. The positioning units mount directly to the T- slots in the bottom of the conveyor profile or to the table top of an automatic workstation. 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. 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. Dimensional data for PE1/P Ordering Information for Positioning Unit PE1/P (For use with WT1/P pallets) Specify part number, then select from the options below. Positioning Unit Width (B) 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 = 100 N Applied Force Permitted Turning = 10 Nm Moment Stroke = 6.5 mm Cylinder Diameter = 25 mm Air pressure = 4-8 bar Air fittings = 4 mm Your choices are: 80, 120, 160 Part Number Your selection: Station mount dimensions* 52.5 ± ± ±0.2 B = Tap M6 Dowel Hole ± ±0.2 (B=80) 32.5 ±0.2 (B=120) 52.5 ±0.3 (B=160) 7 8 End View B S Top View B +15 B 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.

58 7 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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). 7 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. 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 Specify part number, then select from the options below. Workpiece Pallet Size, B Optional Hold Down Plate, Qty 2 Your Choices are: 80 x 80, 120 x 120, 160 x 160 Part Number Your selection: The HP1 is shipped with all required mounting hardware including pneumatic fittings positioning pins, flow control valves and protective cover. Dimensional data for optional hold down plate

59 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 7 3 Positioning Units Technical data for HP1 Load Capacity = 80 kg Positioning Accuracy = ±0.025 mm both x and y axis Max Allowable Applied Force = 400 N Permitted turning moment = 15 Nm Air pressure = 4-8 bar Stroke Down = 8 mm fixed Stroke Up = 0-50 mm adjustable Cylinder diameter = 50 mm Air fittings = 4 mm Dimensional data for HP1 Station Mount Dimensions* 175 B 42 L1 2X ø6 (H7) 128 B 42 L2 7 Stroke ( 8 to 50) B 32 B + 13 B 15 4X M6 R7.5 C D E A A B C D E *Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.

60 8-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 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, 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 VE1 Standard Stop Gate Page 8-1 VE1/D, VE1/DA1B Cushioned Stop Gates Page 8-2 to 8-3 VE1/DA Transfer Stop Page 8-4 AL1 Stop Rail Page 8-5 WI1/M Rocker Stop Page 8-6

61 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 8 1 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. The VE1 is delivered completely assembled and includes a 4 mm quick connect fitting and all required mounting hardware. Ordering Information for Stop Gate, VE1 Description Stop Gate Part Number Queue load, VE1 Description VE1 Queue Load (kg) Nominal Line Speed (m/min) Dimensional data for VE1 8 A Leading Edge B Trailing Edge 4-6 Bar Mount VE1 Stop gates to the inner left-a or the inner right-b side of the conveyor section.

62 8 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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 Queue load, VE1/D Description VE1/D Queue Load (kg) Nominal Line Speed (m/min) Dimensional data for VE1/D ±0.1 Stroke

63 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 8 3 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. 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. Product Bulletin Ordering Information for Cushioned Stop Gate, VE1/DA1B Description Part Number Cushioned Stop Gate Kit for use with HP Dimensional data for VE1/DA1B Mounting Location, HP1 4.5 WT 1/P DA 1/B 31 8 M

64 8 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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 Description Part Number Transfer Damper All required mounting hardware is included. Queue load, VE1/DA Description VE1S/DA Queue Load (kg) Nominal Line Speed (m/min) Dimensional data for DA1 8 AL1 Stop Rail mounting 62 7 VE1/DA WT EQ 1/TR 73 7 Stroke AL Mounting location, AL1 33 M4 4.5 M5

65 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 8 5 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. All hardware required to mount the AL1 to the conveyor line is included. Ordering Information for Stop Rail, AL1 Description Stop Rail Part Number Dimensional Data for AL

66 8 6 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Stop gates TS1 Mini Rocker Stop Model WI/M 44 mm 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. Pneumatic Cylinder Switch 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. Dimensional data for WI/M 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. 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 bwt +10 VE (91) WI/M Ordering Information for Mini-Rocker Stop, WI/M Description Part Number WI/M Rocker Module (Fastening Hardware Included) Pneumatic Cylinder Switch

67 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 9 1 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 9

68 9 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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) Vertical Sensing Bracket (ESD safe) Dimensional data SH1/U

69 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 9 3 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. The polyamide bracket is shipped with all required mounting hardware. Ordering Information for Horizontal Sensing Bracket SH1/S Description Part Number Horizontal Sensing Bracket Dimensional data SH1/S Exciter Block See Page 2-2

70 9 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Proximity Switches and Brackets Horizontal Sensing Switch Brackets Model SH1/M 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. A A A B 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. Ordering Information for Horizontal Sensing Bracket SH1/K Description Part Number A Prox Switch Holder Top B Prox Switch Holder Base The polyamide brackets are shipped with all required mounting hardware. Dimensional data for SH1/M (for mounting to an AL1 stop rail) Dimensional data for SH1/M (for mounting to KU1, KE1 or PE1/P) SH 1/M WT 1 SH 1/M WT 1 9 AL1 7 ST KU1 ST

71 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 9 5 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. The quick disconnect switch and plug provides fast assembly and service. All required hardware is included. A. B. 6.5mm x 60mm shielded VDC, normally open, quick disconnect 50 mm 60 mm 6.5mm x 50mm unshielded VDC, normally open, quick disconnect C. 90 Quick Disconnect Plug with 5m of 3-conductor cable Ordering Information for Proximity Switches Sensing Description Application 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 Vertical or Horizontal Horizontal For Use With SH1/U, SH1/S, SH1/M SH1/M, SH1/S Sensing Range 3.0mm 4.0mm Part Number

72 10-0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /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 (L WT or B WT ) of the workpiece pallet. Maximum permissible loading for the load bearing edge is shown in Figure 10-1 Workpiece Pallet load-bearing edge L WT or B WT Maximum Load in kg* LWT BWT Maximum permissible workpiece pallet payload (includes pallet, fixturing, workpiece and coding system) depends on the supported length of the pallet as shown in Figure Never exceed the maximum load per pallet or per drive unit. The load is maximum when pallets are in queue as shown in Figure * Maximum load is the combined weight of all pallet components, fixture, and parts. Figure 10-1 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. Figure 10-2 Conveyor section Supported length Conveying media 10 Conveying direction Workpiece pallets should be conveyed toward a drive unit. Reversible operation is only possible when explicitly stated. Transportation direction MAXIMUM LOAD F F F F F F F NOTE: Drive capacity must be greater then the maximum load between the drive and return unit Figure 10-3

73 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 10 1 Technical Data Section 10- TS 1 System Specifications Application 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. 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. CE identification, responsibility Components that fall under the EC machinery guideline are delivered with the corresponding manufacturer s 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. 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 +40 C -5 to +60 C with 20% less load Storage temperature -25 C to +70 C 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. Materials used The materials used in the components are primarily: 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

74 10 2 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Technical Data 10 Functional reliability Resistance to media and contamination does not mean that functional reliability is guaranteed in every case. 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 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. 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. Maintenance 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. 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 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. Load specifications 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.

75 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 10 3 Technical Data Pneumatic Summary NOTE: Non-oiled DRY air, PSI (4-8 bar) connected through 4 mm push-lock plastic tubing is required on all TS 1 pneumatic components. Module HQ1/U EQ1/TR EQ1/T EQ1/TE PE1/ HP1 VE1 VE1/D DA1 Bore (mm) Stroke (mm) Volume (cc) per stroke Tube Size Port mm 4mm 4mm 4mm 4mm 4mm 4mm 4mm 4mm M5 M5 M5 M5 M5 M5 M5 M5 M5 Module Tube Size (mm) Port Flow rate Pneumatic Cylinder Switch 4 barbed hose connector 40l/min 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 ø4 mm Not Included ø4 mm Not Included ø4 mm 10 Pneumatic diagram for EQ1/TR For single Acting Lift Applications only Pneumatic diagram for EQ1/TR For Double Acting Lift and Lower Applications only ø4 mm Not Included 4 2 ø4 mm Not Included ø4 mm

76 10 4 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Technical Data Positioning Unit Pneumatic Diagrams Pneumatic diagram for PE1/P, HP ø4 mm ø4 mm 1 2 Not Included Stop Gate Pneumatic Diagrams Pneumatic diagram, VE1, VE1/D, and DA1 Pneumatic diagram, Pneumatic Cylinder Switch VE 1 10 ø4 mm P ø4 mm 2 R 1 3 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.

77 /08 TS1 Assembly Conveyors Linear Motion and Assembly Technologies 10 5 Technical Data Conversion Factors Metric/English Conversion Chart Measurement Multiply by to get: Linear Area Volume Acceleration Velocity Mass Force Pressure Torque Moment of Inertia Power Energy millimeters (mm) inches kilometers (km) miles millimeters 2 (mm 2 ) inches 2 centimeters 3 (cm 3 ) 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) inches millimeters (mm) miles kilometers (km) inches 2 millimeters 2 (mm 2 ) inches 3 centimeters 3 (cm 3 ) inches 3 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) 10 Metric Tap/Drill Specifications Tap Tap Drill Size M4 M4 x mm M5 M5 x mm M6 M6 x mm M8 M8 x mm M12 M12 x mm M16 M16 x mm Temperature Degrees Celsius Degrees Fahrenheit 5 x (degrees F - 32) 9 (9 x degrees C)

78 11 0 Linear Motion and Assembly Technologies TS1 Assembly Conveyors /08 Part Number Index Section 11- Part Number Index Part Number Page Part Number Page Part Number Page R

79 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 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: mm Maximum Product Weight: 10kg. VarioFlow : Model VF90 Product Width: 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 plant like machine bases, guarding and workstations can 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: or call, (in USA)