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Transfersystem TS 5Preview

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Bosch Rexroth AG 1–13 842 540 380 (2008.09) TS 5

Table of Contents

TS 5 features

Workpiece pallets

Drive units

Curves/diverters/switches

Positioning and orientation

Transportation control

Identification systems

Technical data

Leg sets

Longitudinal conveyors

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from the obligation of own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.

1–2 Bosch Rexroth AG

TS 5 features

TS 5 3 842 540 380 (2008.09)

TS 5 – The roller conveyor in a class by itself

Driven by high-quality technology: the king shaftThe TS 5 transfer system with king shaft offers you considerable advantages compared to the normal chain drives: – Absolutely maintenance-free – Noise-free operation – High energy efficiency through

effective performance with low drive force requirements

– Friction can be adjusted from the outside without tools

New possibilities in all directionsAs opposed to a chain-driven conveyor system, TS 5 can be used without any limitations. Its drive concept gives you a great amount of planning freedom. You can, for example, branch the system off to the right or to the left. This is very economical because no additional drive modules are needed in many system layouts.

Flexible planning, simple set-up, quick commissioningAs a system supplier for all areas of automation, we offer you an extensive, industrially manufactured, modular product line-up.The new TS 5 transfer system is also based on a flexible system of modular components. As a Rexroth customer, this offers you many advantages, including the fact that you will be operating in a familiar environment right from the start of assembly – with everything proceeding quickly and smoothly.As the components for the TS 5 are included in our MTpro program, the parts list is generated automatically, which considerably simplifies the entire planning process.

A choice of transport typesDifferent products require different types of sections. Accordingly, you can choose whether to transport your goods on a workpiece pallet or directly on a continuous roller conveyor.

Unique selling points at a glance– Fast, cost-effective system planning

and expansion: The conveyor section design allows

branching in both directions. And because the assembly space required for the drive is lower than the conveyor height, you can choose to have the drive mounted on either side. As always, all components are available in the MTpro planning tool.

– Reliable construction and fast start-up: Industrially manufactured modular

system design with standardized components, resulting in short delivery times.

– High system up-time thanks to the maintenance-free king shaft drive concept. Advantages: No more need for lubrication and greasing.

– Robust design: Suitable for particularly harsh

production environments and heavy loads

– Everything from a single source: Easy ordering thanks to compatibility

with the entire assembly technology product range.

The TS 5 transfer system transports loads of up to 300 kg. Rexroth offers you a comprehensive system of conveyor modules: drive modules, workpiece pallets, roller sections, curves, diverters, positioning units and components for traffic control. Everything is set up modularly and preassembled and can be combined as needed using a single interface.

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Bosch Rexroth AG 2–1

Workpiece pallet selection F2 2-2

Base pallet F2 2-4

Carrying plates F2 2-6

Accessories F2 2-5

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Workpiece pallets

3 842 540 380 (2008.09) TS 5

Workpiece pallets


00132859

Workpiece pallets

TS 5 3 842 540 380 (2008.09)

Workpiece pallet selection

Application and functions

The workpiece pallet transports the workpiece in the transfer system as it goes through the processing stations.— Defined positioning of the supported

workpiece in the processing station is enabled through integrated positioning bushings.

— Integrated damping elements help to avoid noise and damage when workpiece pallets run into each other.

— Workpiece-related information can be transferred with the workpiece during processing using optional data tags. The information can then be evaluated locally and updated.

Versions

The workpiece pallet is a modular system consisting of a base pallet, carrying plate, and positioning bushings.— Workpiece pallet in 6 standard sizes.— Side rollers reduce friction, particularly

in curves, diverters, and switches.— Aluminum carrying plates in 2

thicknesses and with variable dimensions. The carrying plate may protrude over all sides of the base pallet.

Note: If the carrying plate is longer than the base pallet (lWT < lTP), the user should install a bumper to absorb shocks and reduce noise.

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lWT

1/31/3

bWT

h s

00132926

00132924

FGL

bWTb

WTlWT

lWT

Workpiece pallets

3 842 540 380 (2008.09) TS 5

Workpiece pallet selection

Size and load carrying capacity

Load carrying capacity F for a workpiece pallet results from — the thickness of the carrying plate— the surface of the base pallet

The point-by-point load carrying capacity of the transfer system is based on— the roller spacing (distances)— the load class of the conveyor unit

Permissible gravity center position

In order to be able to absorb acceleration forces without any problems when separating and changing the direction of the pallets (in curves, when changing to transverse conveyors), the location of the load center position on the workpiece pallet must be noted. We generally recommend:

1. Loading the workpiece pallet as close as possible to the center

2. Not exceeding a load center position at height hS of over 1/2 bWT (with bWT ≤ lWT)

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00132861

bWT

lWT

lWT bWT mWT1) Nr.

(mm) (mm) (kg)

455 455 7,4 3 842 545 254 650 455 10,3 3 842 545 255 650 650 15,7 3 842 545 256 845 650 20,1 3 842 545 257 845 845 27,2 3 842 545 258 1040 845 32,0 3 842 545 259

F2 10-6

Workpiece pallets

TS 5 3 842 540 380 (2008.09)

Base pallet

Application:The base pallet is the interface between the transfer system and the carrying plate with workpiece fixtures.The base pallet is designed to deal with the highest loads.

Version:— 6 standard sizes— Lateral guiding via rollers— Optimized contours for easier

movement through curves— Stop gate stop on interior and exterior

of the workpiece pallet surface— Integrated bumper (damping element)— Damping elements to cushion

inductive proximity switches— Installation option for mobile data tags

from the ID 15 and ID40 F Catalog identification systems

Material:PE UHMW

Delivery condition:Assembled, without carrying plate, F2 2-6

Optional accessories:— Positioning bushing kit, F2 2-5— Damping elements (spare part) F2 2-5

— Carrying plate

1) Empty weight/pallet weight

Base pallet

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00132863

No. 2 3 842 545 264

No. 2 3 842 545 265

Workpiece pallets

3 842 540 380 (2008.09) TS 5

Accessories

Positioning bushing kit

Application:— For fastening the carrying plate— For a defined workpiece pallet entry in

the positioning unit— Scope of delivery: 2 positioning

bushings, 2 screws to fasten the carrying plate

Material:Hardened steel

Positioning bushing kit

00132862

Damping elements

Application:Damping elements are integrated in the workpiece pallet at the factory. They help to avoid noise and damage when workpiece pallets run into each other.

Material:PUR

Damping elements (spare part)


00132864

bWT-4 lWT-4

bWT lWT dPl * mPl Nr. dPl * mPl Nr. (mm) (mm) (mm) (mm) (kg) (mm) (mm) (kg) 455 455 12,7 0,6 6,9 3 842 545 081 19,05 0,6 10,4 3 842 545 266 455 650 12,7 0,8 9,9 3 842 545 084 19,05 0,8 14,9 3 842 545 267 650 650 12,7 0,8 14,3 3 842 545 087 19,05 0,8 21,4 3 842 545 268 650 845 12,7 1,0 18,6 3 842 545 090 19,05 1,0 27,9 3 842 545 269 845 845 12,7 1,0 24,2 3 842 545 093 19,05 1,0 36,3 3 842 545 270 845 1040 12,7 1,2 29,8 3 842 545 096 19,05 1,2 44,7 3 842 545 271

F2 10-7

Workpiece pallets

TS 5 3 842 540 380 (2008.09)

Carrying plates (standard sizes)

Application:— For combination with a base pallet to

form a WT 5 workpiece pallet— For machining for mounting of

attachments by the user

Version:— 6 standard sizes in 2 thicknesses— Carrying plate, ready to assemble with

mounting bores

Note:For mounting the carrying plate on the base pallet: 2x positioning bushing kit 3 842 545 264.

dPl Plate thickness * Evenness mPl Plate weight

Carrying plates (standard sizes)

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00132872

bWT-4

lWT-4

bWT lWT dPl * Nr. dPl * Nr. (mm) (mm) (mm) (mm) (mm) (mm) 455 ≤ lTP ≤ 650 455 ≤ bWT ≤ 650 12,7 0,6 3 842 998 562 19,05 0,6 3 842 998 563 650 ≤ lTP ≤ 845 455 ≤ bWT ≤ 650 12,7 0,8 3 842 998 564 19,05 0,8 3 842 998 565 650 ≤ lTP ≤ 845 650 ≤ bWT ≤ 845 12,7 0,8 3 842 998 566 19,05 0,8 3 842 998 567 845 ≤ lTP ≤ 1040 650 ≤ bWT ≤ 845 12,7 1,0 3 842 998 568 19,05 1,0 3 842 998 569 845 ≤ lTP ≤ 1040 845 ≤ bWT ≤ 1040 12,7 1,0 3 842 998 570 19,05 1,0 3 842 998 5711040 ≤ lTP ≤ 1250 845 ≤ bWT ≤ 1040 12,7 1,2 3 842 998 572 19,05 1,2 3 842 998 573

F2 10-8

Workpiece pallets

3 842 540 380 (2008.09) TS 5

Carrying plates (special sizes)

Application:— For combination with a base pallet to

form a WT 5 workpiece pallet— For machining for mounting of

attachments by the user

Version:— Variable sizes in 2 thicknesses— Carrying plate, ready to assemble with

mounting bores

Note: The carrying plate may protrude over all sides of the base pallet.Install dampers if carrying plate protrudes. For mounting the carrying plate on the base pallet: 2x positioning bushing kit 3 842 545 264.

dPl Plate thickness * Evenness mPl Plate weight

Carrying plates


Workpiece pallets

TS 5 3 842 540 380 (2008.09)

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Design F2 3-2

Drive units F2 3-4

00132866.eps

Drive unit

3 842 540 380 (2008.09) TS 5

Drive unit


Drive unit

TS 5 3 842 540 380 (2008.09)

Ready-for-operation module to drive conveyor units, curves, diverters, and switches in 3 system widths and 2 load classes. Version with dumbbell rollers (standard) or full rollers. The rollers in the conveyor section are driven by a king shaft in the respective drive unit. The king shaft (driving medium) is located behind a protective cover below the transport level; the workpiece pallet can pass over the king shaft.The length of the driven conveyor section depends on the roller spacing. A drive torque of 60 Nm is enough to drive a 20 m section with curves and diverters (all rollers blocked so that the friction clutches of the rollers slide).Curves, diverters, and switches include 2 conveyor sections.

Required accessories:— Leg sets SZ 5/... F2 6-2— Connection kit F2 4-10

Drive units

Design

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00132902

A

B

p

p

Drive unit

3 842 540 380 (2008.09) TS 5

Drive layout

When laying out the system, make sure that there is enough driving power for the entire conveyor section.

The rollers are driven by a king shaft in the respective drive unit. A friction clutch on each roller prevents blocking of the drive.The maximum transferable overall drive force thus results from the force briefly before an individual clutch slides, multiplied by the total number of rollers in the section.

Example layout:

Drive torque 60 Nm, each roller requires 0.3 Nm with a sliding clutch. Each curve requires 15 Nm, each diverter or switch 15 Nm. Recommended maximum section length: 20 m.Note: Install the motor as close as possible to the center of the section.

Example A:Section with roller division p = 130 mm and a curveQuestion: If one drive unit is used, how long may the straight section be?

Calculation:60 Nm – 15 Nm (for curve) = 45 Nm remaining for the straight section45 Nm ÷ 0.3 Nm = 150 (driven rollers)

150 x 130 mm = 19500 mm straight section.

Example B:20 m section, p = 130, includes 1 diverter, 1 switch, 1 curve (b = 650 mm)Question: Will one drive unit be sufficient?

Calculation:60 Nm – 15 Nm (curve) – 15 Nm (diverter) – 15 Nm (switch) = 15 Nm remaining for the straight section

20000 mm – 1149 mm (curve) – 1560 mm (diverter) – 1560 mm (switch) = 15731 mm straight section

15731 mm ÷ 130 mm = 121 rollers121 x 0.3 Nm = 36.3 NmTwo drives are needed in order to attain the torque to be transferred.


00132870

AS 5/H

AS 5/XH

b

lb

l

45x90

45x180

F2 10-9

b1) l2) vN3) GM4) U, f, MOD5) AT6) LG7) BG8) Nr.

(mm) (mm) (m/min) F2 10-21 455 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 3 842 998 533 (AS 5/H) 650 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 3 842 998 532 (AS 5/XH) 845 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 b = … mm U = … V f = … Hz AT = … LG = … BG = …

Drive unit

TS 5 3 842 540 380 (2008.09)

AS 5/H, AS 5/XH drive units

Application:— Driving ST 5/... conveyor units,

CU 5/… curves, DI 5/… diverters, and JU 5/… switches

Version:— Dumbbell rollers— Suitable for reversible operation— Motor connection with cable/plug

(AT=S) or terminal box (AT=K)

Delivery condition:— Ready-to-install, gear motor enclosed

separately.

AS 5/H, AS 5/XH drive units

1) b = track width in direction of transport2) l = length3) vN = nominal speed; vN = 0; without gear motor4) GM = gear motor; 0: Without (SW27 interface) 1: With gear motor SW27 2: Without (interface to SEW connection, round shaft ø 20)

5) MOD (only with frequency converter) = Standard I/O module Application ProfiBus CAN/system bus6) AT = motor connection with cable/plug (AT=S) or terminal box (AT=K)

7) LG = lateral guide material 1: Steel 2: Polymer 3: Aluminum8) BG = bevel wheel material 1: Polymer 2: Sintered metal

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kg/cm

00132871

AS 5/H-FR

AS 5/XH-FR

45x90

45x180

lb

lb

F2 10-10

b1) l2) vN3) GM4) U, f, MOD5) AT6) LG7) BG8) Nr.

(mm) (mm) (m/min) F2 10-21 455 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 3 842 998 535 (AS 5/H-FR) 650 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 3 842 998 534 (AS 5/XH-FR) 845 390 0; 2; 4; 6; 9; 12; 15; 18; 2-7; 7-18 0; 1; 2 K; S 1; 2; 3 1; 2 b = … mm U = … V f = … Hz AT = … LG = … BG = …

Drive unit

3 842 540 380 (2008.09) TS 5

AS 5/H-FR, AS 5/XH-FR drive units

AS 5/H-FR, AS 5/XH-FR drive units

Application:— Driving ST 5/...-FR conveyor units,

CU 5/…-FR curves, DI 5/…-FR diverters, and JU 5/…-FR switches

Version:— Full rollers— Suitable for reversible operation— Motor connection with cable/plug

(AT=S) or terminal box (AT=K)

Delivery condition:— Ready-to-install, gear motor enclosed

separately.

1) b = track width in direction of transport2) l = length3) vN = nominal speed; vN = 0; without gear motor4) GM = gear motor; 0: Without (SW27 interface) 1: With gear motor SW27 2: Without (interface to SEW connection, round shaft ø 20)

5) MOD (only with frequency converter) = Standard I/O module Application ProfiBus CAN/system bus6) AT = motor connection with cable/plug (AT=S) or terminal box (AT=K)

7) LG = lateral guide material 1: Steel 2: Polymer 3: Aluminum8) BG = bevel wheel material 1: Polymer 2: Sintered metal


Drive unit

TS 5 3 842 540 380 (2008.09)

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Protective covers for ST 5/H, ST 5/XH F2 4-3

Protective covers for ST 5/H-FR, ST 5/XH-FR F2 4-5

Connection kits F2 4-6

Conveyor units ST 5/H, ST 5/XH F2 4-2

Conveyor units ST 5/H-FR, ST 5/XH-FR F2 4-4

Longitudinal conveyor

3 842 540 380 (2008.09) TS 5



b1) l2) lV3) p4) N5) lWT6) LG7) BG8) No. (mm) (mm) (mm) (mm) 455; 650; 845 390-4160 130 3; 4; 5 ... 32 455 1; 2; 3 1; 2 3 842 998 520 (ST 5/H)455; 650; 845 585-4095 195 3; 4; 5 ... 21 650 1; 2; 3 1; 2 3 842 998 521 (ST 5/XH)455; 650; 845 780-4160 260 3; 4; 5 ... 16 845 1; 2; 3 1; 2 b = … mm455; 650; 845 975-3900 325 3; 4; 5 ... 12 1040 1; 2; 3 1; 2 l = … mm p = … mm LG = … BG = …

00132868

ST 5/H

b

l

l

b

ST 5/XH

p

p

45x90

45x180

F2 10-11


TS 5 3 842 540 380 (2008.09)

ST 5/H, ST 5/XH conveyor units

Application:The conveyor unit is a ready-for-operation module for linear transport of workpiece pallets.

Version:— Support profile made of anodized

aluminum— Permissible section load: ST 5/H: 200 kg/m ST 5/XH: 300 kg/m— Lateral guide profile made of steel,

polymer, or aluminum in anodized aluminum support, can be easily exchanged in case of wear

— Drive via king shaft with bevel wheels

Delivery condition:— Ready-to-install

ST 5/H, ST 5/XH conveyor units

1) b = track width in direction of transport2) l = length is rounded down to the roller division, l = p×N3) lV = preferred size4) p = roller spacing (division)5) N = number of rollers, multiplier for length (l = p×N), pricing factor in the price list.

6) lWT = workpiece pallet length (in direction of transport)7) LG = lateral guide material 1: Steel 2: Polymer 3: Aluminum8) BG = bevel wheel material 1: Polymer 2: Sintered metal

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00132875

A B

D

b1) p2) Nr. Nr. Nr. p1/p22) Nr. (mm) (mm) A3) B4) C5) (mm) D6)

455 130 3 842 545 404 3 842 545 679 3 842 545 689 130/130 3 842 545 404 455 195 3 842 545 609 3 842 545 680 3 842 545 690 130/195 3 842 545 616 650 130 3 842 545 405 3 842 545 681 3 842 545 691 130/130 3 842 545 405 650 195 3 842 545 360 3 842 545 682 3 842 545 692 130/195 3 842 545 619 650 260 3 842 545 612 3 842 545 683 3 842 545 693 130/260 3 842 545 360 845 130 3 842 545 361 3 842 545 684 3 842 545 694 130/130 3 842 545 361 845 195 3 842 545 362 3 842 545 685 3 842 545 695 130/195 3 842 545 628 845 260 3 842 545 363 3 842 545 686 3 842 545 696 130/260 3 842 545 362 845 325 3 842 545 403 3 842 545 687 3 842 545 697 130/325 1040 130 3 842 545 364 - - 130/130 3 842 545 364 1040 195 3 842 545 365 - - 130/195 3 842 545 638 1040 260 3 842 545 366 3 842 545 688 3 842 545 698 130/260 3 842 545 365

F2 10-13


3 842 540 380 (2008.09) TS 5

Protective covers for ST 5/H, ST 5/XH

Application:The protective covers are included as a selection parameter for the scope of delivery for curves, diverters, and switches. They can be ordered separately for conveyor units.The protective covers are clipped between the rollers using spring elements.

Versions:— Protective covers for various widths

and roller spacings.— Special protective covers for section

center, ends, and transitions.

Material: Steel, galvanized

Protective covers for section center/end/transitions

1) b = track width in direction of transport2) p = roller spacing (division)3) A = section center protective cover4) B = section end protective covers, left drive side5) C = section end protective covers, right drive side6) D = section transition protective covers


00132869

ST 5/H-FR

b

l

p

l

b

ST 5/XH-FR

p

ST 5/H

45x90

45x180

b1) l2) lV3) p4) N5) lWT6) LG7) BG8) No. (mm) (mm) (mm) (mm) 455; 650; 845 390-4160 130 3; 4; 5 ... 32 455 1; 2; 3 1; 2 3 842 998 522 (ST 5/H-FR)455; 650; 845 585-4095 195 3; 4; 5 ... 21 650 1; 2; 3 1; 2 3 842 998 523 (ST 5/XH-FR)455; 650; 845 780-4160 260 3; 4; 5 ... 16 845 1; 2; 3 1; 2 b = … mm455; 650; 845 975-3900 325 3; 4; 5 ... 12 1040 1; 2; 3 1; 2 l = … mm p = … mm LG = … BG = …

F2 10-12


TS 5 3 842 540 380 (2008.09)

ST 5/H-FR, ST 5/XH-FR conveyor units

Application:The conveyor unit is a ready-for-operation module particularly suitable for linear transport of workpieces without workpiece pallets.Note:The usability of ...-FR conveyor units with WT is limited.

Version: — Support profile made of anodized

aluminum— Permissible section load: ST 5/H: 200 kg/m ST 5/XH: 300 kg/m— Lateral guide profile made of steel,

polymer, or aluminum in anodized aluminum support, can be easily exchanged in case of wear

— Drive via king shaft with bevel wheels

Delivery condition:— Ready-to-install

ST 5/H-FR, ST 5/XH-FR conveyor units

1) b = track width in direction of transport2) l = length is rounded down to the roller division, l = p×N3) lV = preferred size4) p = roller spacing (division)5) N = number of rollers, multiplier for length (l = p×N), pricing factor in the price list.


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00132904

A B

C

D

b1) p2) Nr. Nr. Nr. p1/p22) Nr. (mm) (mm) A3) B4) C5) (mm) D6)

455 130 3 842 545 406 3 842 545 659 3 842 545 669 130/130 3 842 545 406 455 195 3 842 545 610 3 842 545 660 3 842 545 670 130/195 3 842 545 614 650 130 3 842 545 407 3 842 545 661 3 842 545 671 130/130 3 842 545 407 650 195 3 842 545 408 3 842 545 662 3 842 545 672 130/195 3 842 545 620 650 260 3 842 545 613 3 842 545 663 3 842 545 673 130/260 3 842 545 408 845 130 3 842 545 409 3 842 545 664 3 842 545 674 130/130 3 842 545 409 845 195 3 842 545 410 3 842 545 665 3 842 545 675 130/195 3 842 545 626 845 260 3 842 545 411 3 842 545 666 3 842 545 676 130/260 3 842 545 410 845 325 3 842 545 415 3 842 545 667 3 842 545 677 130/325 1040 130 3 842 545 412 - - 130/130 3 842 545 412 1040 195 3 842 545 413 - - 130/195 3 842 545 639 1040 260 3 842 545 414 3 842 545 668 3 842 545 678 130/260 3 842 545 413

F2 10-13


3 842 540 380 (2008.09) TS 5

Protective covers for ST 5/H-FR, ST 5/XH-FR

Application:The protective covers are included as a selection parameter for the scope of delivery for curves, diverters, and switches. They can be ordered separately for conveyor units.The protective covers are clipped between the rollers using spring elements.




Material: Steel, galvanized

Protective covers for section center/end/transitions

1) b = track width in direction of transport2) p = roller spacing (division)3) A = section center protective cover4) B = section end protective covers, left drive side5) C = section end protective covers, right drive side6) D = section transition protective covers


D

CB

A

00132879

00132957

B

00132909

A

Nr. 10 3 842 545 699

Nr. 10 3 842 528 746


TS 5 3 842 540 380 (2008.09)

Connection kits

Application:To connect two TS 5 modules, you will need:— 4 profile connectors for section

profiles (A)— 2 profile connectors for lateral

guides (B)— 2 intermediate plates (C)— 1 coupling (D)

The coupling is used to connect the king shafts. A cross plate in the coupling compensates for alignment errors and concentricity tolerances.

Application:The profile ends are connected to each other using profile connectors.

Material:Steel, galvanized

Scope of delivery:Profile connector, screws

Profile connector for lateral guide

Profile connector for section profile

Profile connector for section profile/lateral guide

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00132910

C

00132911

D Nr. 10 3 842 545 160

p (mm) 130 195 260 325

130 3 842 545 215 3 842 545 354 3 842 545 216 3 842 545 355

195 3 842 545 216

260 3 842 545 217

325 3 842 545 218


3 842 540 380 (2008.09) TS 5

Connection kits

Application:Rollers are separated by intermediate plates with division p.


Intermediate plates

Intermediate plates for section transitions (same or different division)

Application:For connecting the king shaft. Compensates for alignment errors and concentricity tolerances.

Material:Steel, galvanizedBrass

Scope of delivery:Coupling, screws

Coupling

Coupling



TS 5 3 842 540 380 (2008.09)

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Switches F2 5-6

Curves F2 5-2

Diverters F2 5-4

Connection kits F2 5-8


3 842 540 380 (2008.09) TS 5



l

00132876

b

45x9045x180

l1

CU 5/H

CU 5/XH

b1) lWT2) l3) l14) CD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 921,5 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 525 (CU 5/H) 650 650; 845 1149 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 526 (CU 5/XH) 845 845; 1040 1376,5 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm CD = … DSM = DST = … LG = … BG = … PS = …


TS 5 3 842 540 380 (2008.09)

CU 5/H, CU 5/XH curves

Application:The curve is a ready-for-operation module for branching, linear transport of workpiece pallets. Left and right curves can be driven on the inside or outside.


aluminum— Exchangeable guide profile made of

steel, polymer, or aluminum— Drive via king shaft with bevel wheels

Delivery condition:Ready-to-install


1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = curve length (length of main section)4) l1 = secondary section length5) CD = curve direction 1: Left 2: Right

8) LG = lateral guide material 1: Steel 2: Polymer 3: Aluminum9) BG = bevel wheel material 1: Polymer 2: Sintered metal10) PS = protective cover 0: Without protective cover 1: With protective cover

6) DSM = king shaft installation on main section 1: Left in direction of travel 2: Right in direction of travel7) DST = king shaft installation on secondary section 1: Left in direction of travel 2: Right in direction of travel

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CD=2DSM=1DST=2

CD=1DSM=1DST=1

CD=2DSM=2DST=2

CD=1DSM=2DST=1

CD=2DSM=1DST=1

CD=1DSM=1DST=2

CD=2DSM=2DST=1

CD=1DSM=2DST=2

00132880


3 842 540 380 (2008.09) TS 5


Order examples:


l

00132877

b

45x9045x180l1l1

l1

DI 5/H

DI 5/XH

b1) lWT2) l3) l14) DD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 1300 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 528 (DI 5/H) 650 650; 845 1560 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 529 (DI 5/XH) 845 845 1820 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm DD = … DSM = DST = … LG = … BG = … PS = …


TS 5 3 842 540 380 (2008.09)

DI 5/H, DI 5/XH diverters

Application:The diverter is a ready-for-operation module for branching, linear transport of workpiece pallets. The drive side can be selected for the main and secondary section.The diverter is controlled as an active element via a pneumatic cylinder (p = 6 bar).






1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = diverter length (length of main section)4) l1 = secondary section length5) DD = diverter direction 1: Left 2: Right



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DD=2DSM=1DST=2

DD=1DSM=1DST=1

DD=2DSM=2DST=2

DD=1DSM=2DST=1

DD=2DSM=1DST=1

DD=1DSM=1DST=2

DD=2DSM=2DST=1

DD=1DSM=2DST=2

00132881


3 842 540 380 (2008.09) TS 5


Order examples:


l

00132878

b

45x9045x180l1l1

l1

JU 5/H

JU 5/XH

b1) lWT2) l3) l14) JD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 1300 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 530 (JU 5/H) 650 650; 845 1560 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 531 (JU 5/XH) 845 845 1820 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm JD = … DSM = DST = … LG = … BG = … PS = …


TS 5 3 842 540 380 (2008.09)

JU 5/H, JU 5/XH switches

Application:The switch is a ready-for-operation module for branching, linear transport of workpiece pallets. The drive side can be selected for the main and secondary section.The switch is a passive element without any control. The workpiece pallet moves the diverter arm into the respective position.






1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = switch length (length of main section)4) l1 = secondary section length5) JD = switch direction 1: Left 2: Right



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JD=2DSM=1DST=1

JD=1DSM=1DST=2

JD=2DSM=2DST=1

JD=1DSM=2DST=2

JD=2DSM=1DST=2

JD=1DSM=1DST=1

JD=2DSM=2DST=2

JD=1DSM=2DST=1

00132882


3 842 540 380 (2008.09) TS 5


Order examples:


D

CB

A

00132879

00132957

B

00132909

A

Nr. 10 3 842 545 699

Nr. 10 3 842 528 746


TS 5 3 842 540 380 (2008.09)

Connection kits

Application:To connect two TS 5 modules, you will need:— 4 profile connectors for section

profiles (A)— 2 profile connectors for lateral

guides (B)— 2 intermediate plates (C)— 1 coupling (D)

The coupling is used to connect the king shafts. A cross plate in the coupling compensates for alignment errors and concentricity tolerances.

Application:The profile ends are connected to each other using profile connectors.


Scope of delivery:Profile connector, screws

Profile connector for lateral guide

Profile connector for section profile

Profile connector for section profile/lateral guide

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00132910

C

00132911

D

Nr. 10 3 842 545 160

p (mm) 130 195 260 325

130 3 842 545 215 3 842 545 354 3 842 545 216 3 842 545 355

195 3 842 545 216

260 3 842 545 217

325 3 842 545 218


3 842 540 380 (2008.09) TS 5

Connection kits

Application:Rollers are separated by intermediate plates with division p.


Intermediate plates

Intermediate plates for section transitions (same or different division)

Application:For connecting the king shaft. Compensates for alignment errors and concentricity tolerances.

Material:Steel, galvanizedBrass

Scope of delivery:Coupling, screws

Coupling

Coupling



TS 5 3 842 540 380 (2008.09)

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Design F2 6-2

Legsets F2 6-4

00108434.eps

Foundationbracket F2 6-6

Legsets

3842540380(2008.09) TS5

Legsets


max. 250max. 2000

00132920

Legsets

TS5 3842540380(2008.09)

Design

Legsetssupporttheconveyorsection.Werecommendprovidingaseparatelegsetforeverymodule(conveyorunit,curve,diverter,switch)inordertocompensateforheighttolerancesatthetransitions.Amax.legdistanceof2000mmmustbemaintained.

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00132906

100

CU 5/HCU 5/XH

00132907

DI 5/H, DI 5/XHJU 5/H, JU 5/XH

100

Legsets

3842540380(2008.09) TS5

Design

Sincecurves,diverters,andswitchesareonlysupportedby2legs,thesecondarysectionmustbeimmediatelysupportedafterthetransition,seeFigures.

Optional accessories:Legsetscanbeanchoredtothefloorusingfoundationbrackets3 842 146 815 andanchorbolts3 842 526 560 F26-6


00132896

b

b+80

h sz<

350

b hSZ No. (mm) (mm) 455;650;845 200–2000 3 842 998 506 b=…mm hSZ =…mm

00132923

b

b+80

h sz>

350

00132925

45

25

95

Legsets

TS5 3842540380(2008.09)

SZ5legset

Application:—Legsetforgeneralapplications

Version: –Extrudedaluminumprofiles–Height-adjustablebases–Suitablefortheconstructionofhigh-

loadconveyorsectionsinconjunctionwithST5/...conveyorunits

Scope of delivery:Incl.height-adjustablebases,incl.fasteningmaterialtomountthelegsetontoaconveyorsection,driveunit,curve,diverter,orswitch.

Delivery condition:Notassembled

SZ5legset

b=trackwidthindirectionoftransporthSZ=legsetheight

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b hSZ No. (mm) (mm) 455;650;845 360–2000 3 842 998 507 b=…mm hSZ =…mm

00132897

b

b+230

b+140

h sz

155

Legsets

3842540380(2008.09) TS5

b=trackwidthindirectionoftransporthSZ=legsetheight

Application:—Legsetformulti-levelsections

Version: –Extrudedaluminumprofiles–Height-adjustablebases–Suitablefortheconstructionofhigh-

loadconveyorsectionsinconjunctionwithST5/...conveyorunits

Scope of delivery:Incl.height-adjustablebases,incl.fasteningmaterialtomountthelegsetontoaconveyorsection,driveunit,curve,diverter,orswitch.

Delivery condition:Notassembled

SZ5/Ulegset

SZ5/Ulegset


8

SW13C

M8D

20

25,5

21

BA

76

10 -

2373

90

42

160

00132905

No. B 1 3 842 526 560

No. C 100 3 842 345 081*)

D 100 3 842 528 718*)

No.

A 20 3 842 146 815

Legsets

TS5 3842540380(2008.09)

Foundationbracket,anchorbolt

Application:Framesarefastenedtothefloorwiththefoundationbracket.Theholefortheanchorboltcanbeboredwithoutremovingthefoundationbracket.

Material:—A:Sheetsteel,galvanized

andblackchrome-plated

Foundationbracket

Anchorbolt

T-headboltandnut

*) Partnumber.Articlecanonlybeorderedinthequantityspecifiedasapackingunit( ).

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Design F2 7-2

Positioning unit F2 7-3

00108286.eps


3 842 540 380 (2008.09) TS 5




TS 5 3 842 540 380 (2008.09)

Design

In order to process workpieces and maintain production tolerances, workpiece pallets must be stopped and positioned in the processing station.

In doing so, the workpiece pallets can be exactly positioned by up to ±0.3 mm and the system can absorb vertical process forces of up to 1000 N.

Applications:– For a manual workplace with low

demands on positioning accuracy and if there are no forces on the workpiece pallet, a VE 5 stop gate F2 8-3 alone may be sufficient.

– For exact positioning and to lift the workpiece pallet from the conveyor medium: PE 5 F2 7-3.

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b l No. (mm) (mm) 455 455 3 842 998 512 455 650 b = … mm 650 650 l = … m 650 845 845 845 845 1040

00132916


3 842 540 380 (2008.09) TS 5

PE 5 positioning unit

b = track width in direction of transportl = workpiece pallet length

PE 5 positioning unit

Application:Positioning a workpiece pallet in a manual or automated processing station with high demands on positioning accuracy (±0.3 mm).

Version:– Can be used with all WT 5 workpiece

pallets up to 845 x 1040 mm– Lift over conveyor medium

approx. 4 mm– Positioning accuracy: ±0.3 mm– Permissible vertical process force with

center load: Up to 1000 N* incl. WT 5*) Permissible vertical process load if

assembled in the section. Higher process forces possible with direct support (on request).

Scope of delivery:Incl. fastening material for mounting of the PE 5 in conveyor sections.

Delivery condition:Assembled

Required accessories:VE 5/... stop gate F2 8-3



TS 5 3 842 540 380 (2008.09)

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Design F2 8-2

Stop gates F2 8-3

Switch bracket F2 8-5

Proximity switch F2 8-6

00108295.eps


3 842 540 380 (2008.09) TS 5




TS 5 3 842 540 380 (2008.09)


The transportation control components are used to control the flow of workpiece pallets in the transfer system. Transportation control includes:

– Stopping and separating workpiece pallets F2 8-3

– Querying the position of a workpiece pallet. A suitable bracket for the switch or identification system is required for this F2 8-5; 9-2

– Controlling operation sequences

Stop gates

VE 5/… and VE 6/… stop gates are used to separate and stop workpiece pallets, e.g. in an automated station.They are pneumatically operated. If no pressure is applied, the stop gate is moved into the locked position via a spring, thus substantially improving production reliability.

Stop gates are available with and without shock absorbers.

Switch bracket

Switch brackets are used to fasten switches that transfer information on whether a workpiece pallet has been stopped by the stop gate or if it has passed it.

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00132917

00132918

No. 3 842 998 518

No. 3 842 998 517

WT vN1)

(kg) (m/min) 250 2 250 4 250 6 250 9

WT vN1)

(kg) (m/min) 12 – 300 6 12 – 300 9 12 – 260 12 12 – 160 18


3 842 540 380 (2008.09) TS 5

Stop gates

VE 5/200 stop gate

Application:Stopping of one or more accumulating workpiece pallets at the defined workpiece pallet stop surfaces.

Version:– Pneumatic stop gate. If no pressure is

applied, the stop gate is moved into the locked position via a spring and stops the workpiece pallet.

Delivery condition:Assembled.

VE 5/D-300 stop gate

Application:Damped stopping of one or more accumulating workpiece pallets at the defined workpiece pallet stop surfaces.




Scope of delivery: Incl. fastening material for assembly on the conveyor section, pneumatic connection (Steckfix, ø 4 mm).

Optional accessories: – Proximity switch for position

inquiry F2 8-5


Optional accessories: Proximity switch for– Stop gate position inquiry (engaged/

not engaged)– Damper position inquiry (extended/

retracted)

VE 5/200 stop gate


Permissible impact force per WT


1) Permissible conveyor speed



00132919

No. 3 842 998 516

WT vN1)

(kg) (m/min) 1000 6 1000 9 900 12 700 18


TS 5 3 842 540 380 (2008.09)

Stop gates


Application:Damped stopping of one or more accumulating workpiece pallets at the defined workpiece pallet stop surfaces.





Optional accessories: Proximity switch for inquiry of– Stop gate position inquiry (engaged/

not engaged)– Damper position inquiry (extended/

retracted)




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No. 3 842 537 289

00132898

b No. (mm)

455 3 842 545 132 650 3 842 545 134 845 3 842 545 134

00125175.eps


3 842 540 380 (2008.09) TS 5

Switch bracket

SH 2/U-H switch bracket

Application:For fastening an M12x1 proximity switch for workpiece pallet position inquiry from below.Especially sturdy metal version.

Version:– Die-cast aluminum– Bearing load up to 100 kg– Centering lugs for pre-positioning and

fast assembly in the profile groove– Integrated stop for 12 mm sensor

Mounting location:On the assembly kit for the switch bracket.

Assembly kit for SH 2/U-H switch bracket

Application:Holding plate to bring the switch bracket into the correct inquiry position.

Version:Centering lugs for pre-positioning and fast assembly

Mounting location:On section profile.

Scope of delivery:Incl. fastening material for assembly.

Required accessories:– Assembly kit for SH 2/U-H switch

bracket– M12x1 proximity switch with switch

distance SN ≥ 7 mm, F2 8-6

Required accessories:– SH 2/U-H switch bracket– M12x1 proximity switch with switch

distance SN ≥ 7 mm, F2 8-6

Scope of delivery:Incl. fastening material for assembly.

Delivery condition:Not assembled.

SH 2/U-H switch bracket

SH 2/U-H kit

b = track width in direction of transport


00125216.eps

E2

00127928.eps

1/BN

I L+

L-

4/BK

3/BU

1

4

2

3

M12 x1

6

No.

3 842 537 995


TS 5 3 842 540 380 (2008.09)

Proximity switch

M12×1 proximity switch

Application:Recognition of the position of a workpiece pallet

Version:– NO PNP according to IEC/EN 60947-

5-2-2004, connection via V1 plug (M12)

– Can be used for all applications in the TS range

– Resistant to media such as test oil and test petrol

– Optical LED function display– Gold-plated contacts– Short installation lengths of 50 mm– Metal thread M12x1– Switch distance SN = 7 mm– Operating voltage: 0 to 30 V– Switching frequency: 300 Hz– Operating current: 150 mA– Idle current: Max. 15 mA– Protection class: IP 67– Ambient temperature: –25 to 70°C

Required accessories:– SH 2/U-H switch bracket – Holding plate for switch bracket F2 8-5

M12×1 proximity switch

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No.DE/EN/FR 3 842 536 509

Identificationsystems

3842540380(2008.09) TS5


Identificationanddatatagsystemsareusedtocontrolnumerousproductionandtransportsystemsintheassemblytechnologysector.

Datarelatedtoobjectsisthebasisfor–targetedcontrolofprocessesand

processingsteps–Infeedingoroutfeedingworkpiece

palletsaccordingtotypeorvariantwhenmanufacturingproductvariantsonflexibleassemblysystems.

Identificationsystemscatalog

YoucanfindourcurrentrangeofidentificationanddatatagsystemsintheIdentificationsystemscatalog.

Required accessories: –Assemblykitforidentificationsystem

read/writeheads9-2


00132900

00132901

b No. (mm)

455 3 842 545 140 650 3 842 545 142 845 3 842 545 142

b No. (mm)

455 3 842 545 136 650 3 842 545 136 845 3 842 545 136


TS5 3842540380(2008.09)

Assembly kit for ID 15 identification system

Application:Forfasteningaread/writeheadfortheID15identificationsystem

Version:–Centeringlugsforpre-positioningand

fastassembly

Mounting location:Onsectionprofile.

Assembly kit for ID 40 identification system

Application:Forfasteningaread/writeheadfortheID40identificationsystem

Version:–Centeringlugsforpre-positioningand

fastassembly

Mounting location:Onsectionprofile.

AssemblykitforID15identificationsystem

AssemblykitforID40identificationsystem

Scope of delivery:Incl.fasteningmaterialforassemblyofthebracket.

Delivery condition:Notassembled.

Required accessories:ID15read/writehead,9-1

Scope of delivery:Incl.fasteningmaterialforassemblyofthebracket.

Delivery condition:Notassembled.

Required accessories:ID40read/writehead,9-1

b=trackwidthindirectionoftransport

b=trackwidthindirectionoftransport

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Metric/English conversion chart F2 10-20

System specifications F2 10-2

Dimensioned drawings F2 10-6

Motor data F2 10-17

Technical data

3 842 540 380 (2008.09) TS 5

Technical data


Technical data

TS 5 3 842 540 380 (2008.09)

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 work stations on an assembly line.

Planning

Transfer system planning, setup, initial start-up and maintenance should only be done by trained personnel. Rexroth offers training courses for this.

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 guarantee special functional safety or if installing them at a later point would require too much effort. The notes on the required flow control valves and check valves in the pneumatic switching plan (listed in the assembly and operation instructions) must be followed.

Notes

ExamplesInstallation references, pneumatic switching plans and typical function processes are described in the catalogs and assembly instructions. These must be followed when setting up and initially operating the system.

CE identification, responsibilityComponents that fall under the EC machinery guideline are delivered with the corresponding manufacturer’s declaration. Overall responsibility forsystem safety (declaration of conformity, CE identification) lies with the system builder. The references in the assembly instructions and in the Instructions for Employees on Safety – 3 842 527 147 must be followed.

Ambient conditions

Environmental conditions – climaticThe 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 loadStorage temperature -25°C to +70°CRelative humidity 5 to 85%, non-condensingAir pressure > 84 kPa appropriate height < 1400 m

above sea level. Load values are reduced by 15%

when the system is set up at a location that is over 1400 m above sea level.

Environmental conditions – biologicalAvoid molds, fungi, rodents, and other vermin.

Environmental conditions – physicalDo 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.

Environmental conditions – chemicalDo not set up near industrial systems with chemical emissions.

Materials usedThe 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.

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Technical data

3 842 540 380 (2008.09) TS 5

Media resistanceResistant 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.

Suitability for electrostatically sensitive areasAlmost all of the components and parts in Rexroth transfer systems are ESD-compatible or available in ESD-compatible design. They can thus principally be used in EPA (ESD protected areas). We do, however, recommend that you contact your Rexroth representative.

ContaminationWear 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 shortened.

Functional safetyResistance to media and contamination does not mean that functional safety 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 transferable by friction if they are carried over onto systems with rollers.

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

Environmental sustainability, recyclingThe materials used are environmentally sustainable and may be recycled or reused (if components are converted or replaced). Recyclability is ensured by the selection of material and the possibility to take the components apart.

Pneumatic connection dataOiled or non-oiled, filtered, dry compressed air.Operating pressure 6 bar.Performance data is for an operating pressure of 6 bar.

Maintenance The TS components require very little maintenance. Maintenance instructions are included in the operating manual.


l wt

1 / 3

bwt1/3

h s

00127903.eps

Technical data

TS 5 3 842 540 380 (2008.09)

System specifications

Load specificationsPermitted loads apply for conveyor sections only under the condition that workpiece pallets with the maximum permitted weight have accumulated.Higher loads are permitted if accumulation can be safely avoided. Accumulation operation is not permitted on curves, diverters, switches, or the positioning unit.

Wear and conveyor speedNominal data for the permitted workpiece pallet weight describe operation with standard speeds and normal operating conditions.Wear on the workpiece pallet wear pads and the conveyor medium will not influence system function throughout the service life.

Wear and higher/lower loadsHigher loads may lead to more wear and thus require, among other measures, shorter maintenance intervals. A linear decrease in wear can be calculated for lower loads (half load = half the wear = twice the service life).

Loading the workpiece pallet, gravity center positionConcentric load with a low center of gravity is generally preferable. Incorrect load distribution with a high and/or eccentric gravity center on the workpiece pallet may have a negative influence on running and safety. Pay attention when arranging workpiece supports and workpieces on the pallet that the center of gravity of the loaded workpiece pallet is within the area 1/3 of the length or width from the center of the workpiece pallet. The maximum height of the center of gravity over the conveying level should not exceed 1/2 of the workpiece pallet length or width.

Wear Wear is caused by the basic principle of this system and cannot be avoided. Constructive measures and selection of the proper materials will help functional safety last for the lifetime of the system. However, wear depends on the operating, maintenance, and ambient conditions of the system and the location (resistance, contamination).

Measures to reduce wearThe following measures reduce wear and the friction caused by it:– Switch off conveyor sections when

the system is not running, e.g. during breaks, over night, on the weekend.

– Only select speeds that correspond to the particular function.

– Minimize the weight of the workpiece pallet – do not overload with material in workpiece supports.

– Avoid unnecessary accumulation sections, e.g. by reducing the number of workpiece pallets.

– Switch off accumulation sections carrying heavy workpiece pallets if transport is not necessary.

– Especially important: Avoid contamination by abrasive media or reduce contamination with regular cleaning.

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Technical data

3 842 540 380 (2008.09) TS 5

Loading the workpiece pallet,combination of empty and loadedworkpiece palletsWhen setting up and testing the modular units, the workpieces pallets should not all have the same weight on the sections, i.e. full and empty pallets should all come through the circuit. Extreme differences in weight may require special measures to avoid functional disruptions. This applies, e.g. to the permitted accumulation length before stop gates and for the function of dampers and damped stop gates.Function is usually not limited if the weight ratio is 2:1 between heavy workpiece pallets (loaded with a workpiece) and light workpiece pallets (empty).

Loading the workpiece pallet,minimum weightThe minimum weight of the workpiece pallet is generally not relevant. In special cases, depending on the marginal conditions, an application-specific minimum weight may be required for safe and continuous transport. This can occur, for example, if switching elements have to be manually operated (e.g. on a rocker), or if a lighter workpiece pallet does not run smoothly when changing directions. In such unusual cases, additional weight should be added when designing the workpiece pallet.

OverloadingOverloading the conveyor sections may damage the conveying medium and cause the motor and gears to fail.When overloading of pneumatic components occurs, function cannot be guaranteed.

Transportation speed,influence on wearWear on the conveying medium, slide rails, workpiece pallet wear pads and the like is proportional to the conveying speed. This means that, in comparison to the standard speed of 12 m/min., when running at 18 m/min. the wear limit is already reached at 12/18 or 2/3 of the running time.

Transportation speed, dynamic influencesWhen the conveying speed increases, bumps when changing directions and the rebound force on the stop gates also increase. This may require longer settling periods or shock absorbers before the next movement.


b =

bW

T

l = lWT 37

b 1

==

l1

= =

00132883

BDE

C

A

bWT lWT mWT FG b1

l1 Nr. (mm) (mm) (kg) (kg) (mm) (mm)

455 455 7,4 150 195 195 3 842 545 254 455 650 10,3 215 195 325 3 842 545 255 650 650 15,7 215 325 325 3 842 545 256 650 845 20,1 260 325 520 3 842 545 257 845 845 27,2 260 520 520 3 842 545 258 845 1040 32,0 260 520 715 3 842 545 259

Technical data

TS 5 3 842 540 380 (2008.09)

Dimensioned drawings

WT 5 workpiece pallet

A Exciter element B Recess for ID 40 data tagC Stop-gate recessD Bore for positioning bushing E Guide rollers

mWT = Workpiece pallet weight FG = Permissible workpiece pallet loading weight on the conveyor medium.

2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


l = lWT-4

b =

bW

T-4

V

5,8

4

23,5

H7

11

11

00132884

b 1

==

l1

= =

bWT lWT v mPl b1 l1 Nr. v mPl b1 l1 Nr. (mm) (mm) (mm) (kg) (mm) (mm) (mm) (kg) (mm) (mm) 455 455 12,7 6,9 195 195 3 842 545 081 19,05 10,4 195 195 3 842 545 266 455 650 12,7 9,9 195 325 3 842 545 084 19,05 14,9 195 325 3 842 545 267 650 650 12,7 14,3 325 325 3 842 545 087 19,05 21,4 325 325 3 842 545 268 650 845 12,7 18,6 325 520 3 842 545 090 19,05 27,9 325 520 3 842 545 269 845 845 12,7 24,2 520 520 3 842 545 093 19,05 36,3 520 520 3 842 545 270 845 1040 12,7 29,8 520 715 3 842 545 096 19,05 44,7 520 715 3 842 545 271

Technical data

3 842 540 380 (2008.09) TS 5


WT 5: Carrying plate standard dimensions

mPl = Plate weight


l = lWT -4 mm

b =

bW

-4 m

m

V

11 5,8

4

23,5

H7

11

00132885

l1

= =

b 1

==

bWT lWT v b1 l1 Nr. v b1 l1 Nr. (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) 455 ≤ lTP ≤ 650 455 ≤ bWT ≤ 650 12,7 ? ? 3 842 998 562 19,05 ? ? 3 842 998 563 650 ≤ lTP ≤ 845 455 ≤ bWT ≤ 650 12,7 ? ? 3 842 998 564 19,05 ? ? 3 842 998 565 650 ≤ lTP ≤ 845 650 ≤ bWT ≤ 845 12,7 ? ? 3 842 998 566 19,05 ? ? 3 842 998 567 845 ≤ lTP ≤ 1040 650 ≤ bWT ≤ 845 12,7 ? ? 3 842 998 568 19,05 ? ? 3 842 998 569 845 ≤ lTP ≤ 1040 845 ≤ bWT ≤ 1040 12,7 ? ? 3 842 998 570 19,05 ? ? 3 842 998 571 1040 ≤ lTP ≤ 1250 845 ≤ bWT ≤ 1040 12,7 ? ? 3 842 998 572 19,05 ? ? 3 842 998 573

Technical data

TS 5 3 842 540 380 (2008.09)

WT 5: Carrying plate special dimensions

2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


b+3

b-10

b+80

50

3 842 998 5333 842 998 532

00132886

b-10

b+80

390

b22

928

9

b+3390

318

199

160

33,5

AS 5/XH

AS 5/H

Technical data

3 842 540 380 (2008.09) TS 5


AS 5/H, AS 5/XH drive module

Variables:GM = gear motor; 0: Without (SW27 interface) 1: With gear motor SW27 2: Without (interface to SEW connection, round shaft ø 20)

b = section width in direction of transportLG = lateral guide material 1: Steel 2: Polymer 3: Aluminum

BG = bevel wheel material 1: Polymer 2: Sintered metalMotor data, connection either with cable/plug (AT=S) or terminal box (AT=K) F2 10-21


b+3

00132887

390

b22

928

9

b+3390

318

199

AS 5/XH-FR

AS 5/H-FR

b-10

b+80

50

b-10

b+80

33,5

50

3 842 998 5353 842 998 534

160

Technical data

TS 5 3 842 540 380 (2008.09)

AS 5/H-FR, AS 5/XH-FR drive module

Variables:GM = gear motor; 0: Without (SW27 interface) 1: With gear motor SW27 2: Without (interface to SEW connection, round shaft ø 20)

b = section width in direction of transportLG = lateral guide material 1: Steel 2: Polymer 3: Aluminum

BG = bevel wheel material 1: Polymer 2: Sintered metalMotor data, connection either with cable/plug (AT=S) or terminal box (AT=K) F2 10-21

2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


00132888

b

60

p = = = = = = = =p2

l

b28

9

bl

199

b+80

50

p2

ST 5/XH

ST 5/H

b1) l2) lV3) p4) N5) lWT6) LG7) BG8) Nr.

(mm) (mm) (mm) (mm) 455; 650; 845 390-4160 130 3; 4; 5 ... 32 455 1; 2; 3 1; 2 3 842 998 520 (ST 5/H)455; 650; 845 585-4095 195 3; 4; 5 ... 21 650 1; 2; 3 1; 2 3 842 998 521 (ST 5/XH)455; 650; 845 780-4160 260 3; 4; 5 ... 16 845 1; 2; 3 1; 2 b = … mm455; 650; 845 975-3900 325 3; 4; 5 ... 12 1040 1; 2; 3 1; 2 l = … mm p = … mm LG = … BG = …

Technical data

3 842 540 380 (2008.09) TS 5


ST 5/H, ST 5/XH conveyor unit

1) b = track width in direction of transport2) l = length is rounded down acc. to the roller division, l = p×N

4) p = roller spacing (division)5) N = number of rollers, multiplier for length (l = p×N), pricing factor in the price list.



00132889

b

60

p = = = = = = = =p2

l

b28

9

bl

199

b+8

050

p2

ST 5/XH-FR

ST 5/H-FR

b1) l2) lV3) p4) N5) lWT6) LG7) BG8) Nr.

(mm) (mm) (mm) (mm) 455; 650; 845 390-4160 130 3; 4; 5 ... 32 455 1; 2; 3 1; 2 3 842 998 522 (ST 5/H-FR)455; 650; 845 585-4095 195 3; 4; 5 ... 21 650 1; 2; 3 1; 2 3 842 998 523 (ST 5/XH-FR)455; 650; 845 780-4160 260 3; 4; 5 ... 16 845 1; 2; 3 1; 2 b = … mm455; 650; 845 975-3900 325 3; 4; 5 ... 12 1040 1; 2; 3 1; 2 l = … mm p = … mm LG = … BG = …

Technical data

TS 5 3 842 540 380 (2008.09)

ST 5/H-FR, ST 5/XH-FR conveyor unit

1) b = track width in direction of transport2) l = length is rounded down acc. to the roller division, l = p×N3) lV = preferred size4) p = roller spacing (division)5) N = number of rollers, multiplier for length (l = p×N), pricing factor in the price list.


2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


00132890

l = b

WT

1,5

Technical data

3 842 540 380 (2008.09) TS 5


Conveyor unit/curve protective covers

The protective covers are included as a selection parameter for the scope of delivery for curves, diverters, and switches. They can be ordered separately for conveyor units F2 4-5




Material:Steel, galvanized.


l150

50

l

b

b+129,5

00132893

289

199

CU 5/XH

CU 5/H

b1) lWT2) l3) l14) CD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 921,5 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 525 (CU 5/H) 650 650; 845 1149 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 526 (CU 5/XH) 845 845; 1040 1376,5 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm CD = … DSM = DST = … LG = … BG = … PS = …

Technical data

TS 5 3 842 540 380 (2008.09)


CU 5/H, CU 5/XH curve

1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = curve length (length of main section)4) l1 = secondary section length5) CD = curve direction 1: Left 2: Right



2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


DI 5/H

199

289

DI 5/XH

l

l1

b50

b+129,5

00132894

b50

b+80

b1) lWT2) l3) l14) DD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 1300 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 528 (DI 5/H) 650 650; 845 1560 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 529 (DI 5/XH) 845 845 1820 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm DD = … DSM = DST = … LG = … BG = … PS = …

Technical data

3 842 540 380 (2008.09) TS 5

DI 5/H, DI 5/XH diverter

1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = diverter length (length of main section)4) l1 = secondary section length5) DD = diverter direction 1: Left 2: Right




JU 5/H

199

289

JU 5/XH

l

l1

bXX

b+129,5

00132895

b50

b+80

b1) lWT2) l3) l14) JD5) DSM6) DST7) LG8) BG9) PS10) Nr.

(mm) (mm) (mm) 455 455; 650 1300 382,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 530 (JU 5/H) 650 650; 845 1560 415 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 3 842 998 531 (JU 5/XH) 845 845 1820 447,5 1; 2 1; 2 1; 2 1; 2; 3 1; 2 0; 1 b = … mm JD = … DSM = DST = … LG = … BG = … PS = …

Technical data

TS 5 3 842 540 380 (2008.09)


JU 5/H, JU 5/XH switch

1) b = track width in direction of transport2) lWT = workpiece pallet length (in direction of transport)3) l = switch length (length of main section)4) l1 = secondary section length5) JD = switch direction 1: Left 2: Right



2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


200 V/50 Hz 208 V/60 Hz 220 V/50 Hz 220 V/60 Hz 240 V/50 Hz 230 V/60 Hz 380 V/50 Hz 240 V/60 Hz 400 V/50 Hz 260 V/60 Hz 415 V/50 Hz 380 V/60 Hz 500 V/50 Hz 400 V/60 Hz 440 V/60 Hz 460 V/60 Hz 480 V/60 Hz 575 V/60 Hz2)

01) /50 Hz 01) /60 Hz

00116778.eps

l = 400 mm

Technical data

3 842 540 380 (2008.09) TS 5

Connection conditions

Motor data

Electrical connection conditions for the drive motors:Connection to a 3-phase five-wire system (L1, L2, L3, N, PE). The motors are equipped with protective temperature switches which are to be connected to an overload switch-off and to be wired by the system installer according to the technical functions for operation during system set-up.

Standard connection voltages for three-phase motors:Indicate the voltage/frequency combination in the ordering information for components that are operated with three-phase motors.

Voltage/frequency combinations:

1) Without motor, with gears (if technically practical)2) Motor design according to cURus

(UL Recognition Mark USA + Canada)

Motor connection with cable/plug (AT=S) and 3A metal industrial plug-in connector


∆ Y ∆ Y Y 200 V 220 V 380 V 500 V 240 V 400 V 415 V 208 V 380 V 260 V 440 V 575 V 220 V 400 V 460 V 230 V 480 V 240 V (50 Hz) (60 Hz) IN [A] IN [A] IN [A] IN [A] IN [A] cos ϕ1) P [W]2) P [W]3)

003 ---- ---- 0.05 0.03 ---- 0.46 10 ---- 524 0.8 0.5 0.7 0.4 0.3 0.76 90 105 624 1.4 0.8 1.2 0.7 0.6 0.7 180 220 634 2.0 1.2 1.7 1.0 0.8 0.6 250 290 714 1.6 0.9 1.4 0.8 0.7 0.7 250 290 716 1.4 0.8 1.2 0.7 0.6 0.73 180 210 734 2.4 1.4 2.1 1.2 1.0 0.69 370 420 734a 2.6 1.5 2.3 1.3 1.0 0.72 455 520 738 1.4 0.8 1.2 0.7 0.6 0.51 120 140 744 3.5 2.0 3.0 1.7 1.4 0.67 550 630 814 3.2 1.8 2.8 1.6 1.3 0.74 550 630 824 4.4 2.5 3.8 2.2 1.8 0.71 750 860

Technical data

TS 5 3 842 540 380 (2008.09)

Voltage/current consumption

Motor data

Circuit type

Voltage at 50 Hz

Voltage at 60 Hz

Current consumption at rated power

Motor type

1) Power factor2) Power output at 50 Hz3) Power output at 60 HzThe data are typical values. Subject to changes. See motor type plate for binding data.

2

1

3

4

5

6

7

8

9

10

11

12

13

14

15

16


41 2

533

1

4

5

2

00126849.eps

1L1 U1

U1

X1–1 X1–1

2L2 V1

V1

3L3 W1

W1

4TW1 TW1

5TW2 TW2

PEPE PE

PE

3~

1 1

2 2

3 3

4 5

5 6

27 x 1,5 mm

PE PE

M

TW1

TW2

U1 1 1 L1

V1 2 2 L2

W1 3 3 L3

TW1 5 4 Thermo

TW2 6 5 Thermo

PE PE PE

Technical data

3 842 540 380 (2008.09) TS 5

Motor data

Motor connection with cable/plug (AT=S)

Connection terminals, motor 3~ Wire no. Pin no. Code

Connection list

Plug Socket

Cable according to VDE 0282 part 810, e.g.:– Lapp Öl-Flex 7* x 1.5 mm2

– HO7RN-F 7* x 1.5 mm2

– YSLY-JZ 7* x 1.5 mm2

* Wire no. 4 is cut off.


Measurement multiply by to get:

Linear millimeters (mm)incheskilometers (km)miles

0.0393725.40.62141.6093

inchesmillimeters (mm)mileskilometers (km)

Area millimeters2 (mm2)inches2

0.00155645.16

inches2

millimeters2 (mm2)

Volume centimeters3 (cm3)inches3

1 cm3 = 1 milliliter (ml)1000 ml = 1 liter

0.0610216,387

inches3

centimeters3 (cm3)

Acceleration meter/second2 (m/s2)inch/second2

39.370.0254

inch/second2inch/second2

meter/second2 (m/s2)

Velocity meter/secondfeet/second

3,2810.3048

feet/secondmeter/second

Mass kilogram (kg)pounds

2.20460.4536

poundskilogram (kg)

Force kilograms-f (kgf)Newtons (N)pounds-f

9,8070.101944,448

Newtons (N)kilograms-f (kgf)Newtons (N)

Pressure NewtonsbarPSI

0.224814.569

pounds-fPSIbar

Torque Newton meters (Nm)pound-inches

8,8510.11298

pound-inchesNewton meters (Nm)

Moment of inertia centimeters4 (cm4)inches4

0.0240341,623

inches4inches4

centimeters4 (cm4)

Power kilowatts (kW)horsepower (HP)

1.34746

horsepower (HP)kilowatts (kW)

Energy Joules (J)foot/pounds (ft/lbs)

0.73761.3558

feet/pounds (ft/lbs)Joules (J)

Tap Tap Drill size

M4 M4 × 0.7 3.3 mm

M5 M5 × 0.8 4.2 mm

M6 M6 × 1 5.0 mm

M8 M8 × 1.25 6.8 mm

M12 M12 × 1.75 10.2 mm

M16 M16 × 2 14.0 mm

Degrees Celsius5 × (degrees Fahrenheit – 32)

9

Degrees Fahrenheit9 × (degrees Celsius) + 32

5

Metric/English conversion chart

Metric tap/drill specifications Temperature

Technical data

TS 5 3 842 540 380 (2008.09)

BallRailSystems RollerRailSystems LinearBushingsandShafts

LinearMotionandAssemblyTechnologies

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Bosch Rexroth AG Linear Motion and Assembly Technologies Postfach 30 02 0770442 Stuttgart, GermanyTel. +49 711 811-30698Fax +49 711 811-30364www.boschrexroth.com/brl

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© Bosch Rexroth AG 2008Printed in Germany3 842 540 380 (2008.09) EN • BRL/MKT2

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