TSplus Carousel Configuration Basic Equipment Guide
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 2 Table of Contents Important Safety Infomation....................................... 3 Introduction................................................................ 4 Leveling and aligning.......................................... 22 Fitting the flat-top GT2 chain............................. 23 Checking the Motor Rotation............................. 27 Extending and breaking the chain......................
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Important Safety Information! IMPORTANT: This manual must be reviewed with all equipment operators as part of your operator training program! SAFETY FIRST! Important safety information is contained throughout this manual to alert you to potentially dangerous situations and help prevent accidental injury and property damage.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Introduction Like all Bosch Rexroth flexible assembly systems, TSplus is constructed solely from standardized modules that are precisely matched to each other. One important benefit of this modular design is that you can interlink manual and automatic work stations freely, making TSplus suitable for virtually any assembly task.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Application and Function The flat-top chain version of the Bosch Rexroth TSplus conveyor uses dual strands of sideflexing flat-top chain as its transport medium. The low coefficient of friction with the workpiece pallets allows pallets to be stopped on the conveyor while the chain continies to move beneath them. It is thus possible to queue workpiece pallets as work processes are performed either manually or automatically.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 6 Design and Detailed Description The TSplus basic carousel conveyor configuration consists of the following modules: 10 9 1. Carousel Drive module (AS2/CAR) 2. Leg Sets (SZ2/E) 3. Conveyor Profile 4. Connection links 5. Cross Connector (QV2) 6. Foundation brackets and floor anchors 7. Flat-top chain (GT2/C) 8.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Technical Data for AS2/CAR Nominal conveyor speed = See Below Table Permissible loading weight = 175 kg to 815 kg Maximum conveyor unit length = 30.5 m (100 ft.) Motor electrical specifications = See Below Table eters 0.5 m Max. =3 ength L Electrical data for Carousel Drives Units AS2/CAR Nom. M/min Actual Speed RPM HP 6 9 12 18 5.1 9.4 11.8 18.8 1140 1725 1725 1725 1 1.5 1.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide 8 Bosch Rexroth Corporation Carousel Drive Module AS2/CAR The TSplus flat-top chain (FTC) carousel drive module AS2/CAR (Fig. 1) is delivered completely assembled and ready to be mounted to ST2/C-100 and KU2/O-90/180 conveyor chain sections. 6 13 13 19 14 12 8 9 11 17 10 15 3 18 4 8 7 12 1 2 12 13 8 4 3 5 16 15 18 13 8 1 2 Fig. 1 The AS2/CAR carousel drive module consists of the following main components: 1. 2. 3. 4.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) 29 R980 500 Rexroth 388 4/10Corporation Bosch Drive Module AS2/CAR (Fig 3a) Carousel Drive Module AS2/CAR In the TSplus AS2/CAR carousel flat top chain (FTC) drive, the Gear Reducer (1) is powered by an AC Motor (2) which rotates clockwise solid Drive Shaft (16). Attached via a Drive Chain Sprocket (8) to the Carousel Drive Module AS2/CAR (Fig.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation TSplus Conveyor Chain Section The chain conveyor section acts as the bearing surface for the chain, as well as a guide for the workpiece pallets from station to station. Additionally, the chain section as a whole functions as a frame to which other modules and components are mounted, such as stop gates and proximity switches, as well as support and connection elements.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) TSplus Conveyor Chain Section Three basic types of TSplus conveyor sections are available (Fig. 6), depending on the configuration of your system: • Straight sections • 90° curve sections • 180° curve sections Straight sections can be ordered in lengths from 200 mm to 6000 mm. Curve sections come pre-assembled and their dimensions vary according to the dimensions of the workpiece pallet used in the system.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation Links Connection Links The conveyor section is extended with the help of connection links, with one per conveyor rail for each conveyor-section joint. The connection link consists of the following parts (Fig. 7): 1. Connecting link with four M8 threaded holes 2. M8 hex bolts with lockwashers and backing washers (Qty. 4) 1 2 Fig.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Chains Flat-Top Chain The flat-top chain conveys the workpiece pallet from station to station. The TSplus flat-top chain (Fig. 9) is a wear-resistant, side-flexing #40 chain which has a low-friction, plasticcapped conveying surface. The lack of significant friction allows pallets to be stopped anywhere along the conveyor for processing or assembling operations while the conveyor chain continues to move. Fig.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide 14 Bosch Rexroth Corporation Assembly NOTE: The assembly instructions that follow describe the installation of a basic, single-level TSplus transport system. The assembly of other configurations is similar.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Leg Set Assembly 1. Use cross links (2) to join the pre-assembled vertical posts (1). Position the cross links so that the milled slots are on the underside of the cross links, as shown in Fig. 12. NOTE: If assembling the leg sets on a table or other horizontal work surface, place shims (approx. 7.5 mm thick) beneath the cross links so that the cross link T-slots line up with the vertical post T-slots. 2.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation Fitting Leg Sets to the Carousel Drive Module NOTE: For reasons of safety, as well as to avoid damage to the equipment, all steps in the assembly of the conveyor section should be performed by at least two technicians. Always lift heavy parts with the appropriate tools or assistance. Assembly sequence: 1. Carefully place the conveyor drive module where you expect the drive to be located (See Fig. 16 on Page 17). Fig.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Fitting Leg Sets to the Carousel Drive Module (cont.) 4. Attach a pre-assembled leg set to the module strut profiles (Fig. 15). Torque the bolts on the connection links to 18lb.ft. (25 Nm) using a metric 13mm torque wrench. 5. Carefully lower drive module onto the floor so that the leveling foot just touches the floor. Make sure that the floor area is clean.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation Fitting Leg Sets to the Carousel Drive Module (cont.) 8. Lower the assembly to the floor and relax the lifting strap(s) sling(s). For safety reasons, keep the hoist and lifting strap(s) sling(s) attached. 9. Check and make Profile sure the drive/conveyor section assembly is leveled and square. Conveyor 10. Continue by mounting additional leg sets, conveyor sections and curves (See Fig. 18 on page 19).
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Extend the Conveyor: Straight Sections 1. Pre-install the mounting hardware into the 4-hole connection links. Slide the connection links into the T-slots of each conveyor section, spanning the joint evenly. 2. Slide the next conveyor section onto the leg set and connection links and support the other end with an additional leg set (Fig. 18). Conveyor Profiles 3.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation Extend the Conveyor: Curve Sections (cont.) NOTE: Curve sections are delivered pre-assembled, complete with cross links for proper spacing, as well as guide blocks and guide rails for smooth pallet transfer around curves. The cross links on the pre-assembled curve sections should not be removed or loosened. Attach the first 90/180 curve section to the straight sections at the end farthest from the drive module.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Fitting the Cross Links To ensure proper spacing where there are no leg sets, fit cross links at 2 meter intervals along the conveyor section (Fig. 20). Do not fit cross links where leg sets are already present. 2m Fig. 20 Cross Link R980 500 388 (6.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide 22 Bosch Rexroth Corporation Leveling and Aligning the Conveyor Align the conveyor Level the conveyor Check to see whether the leg sets supporting the straight sections of the conveyor are exactly in line. The conveyor should be checked from side to side and end to end to make sure that it is level along its entire length. Adjust the leveling feet as needed to make sure it is level.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Fitting the Flat-top Chain Flat-top chain is #40 type with extended link pins. It is delivered in 6 and 12 meter rolls. Each roll includes one master link with a white cap for easy visual identification. Additional master links, white and black chain caps for flat-top chain may be ordered separately. 1. First, remove the side guards (Fig. 23) on the carousel drive module using a metric hex wrench. 2. Removing the drive chain.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation Fitting the Flat-top Chain (cont.) 4. To Install the transport flat top chain, you must first remove the guide block (Fig. 26) on each side using a metric hex wrench. 5. Before start installing the chain. IMPORTANT! Carefully support the chain roll to avoid contact with the floor and to prevent kinking the chain. Support a roll of transport chain as shown in the assembly tip on (Fig. 27). Fig.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Fitting the Flat-top Chain (cont.) 7. Now start installing the chain from below. Feed the chain under the idler wheel and then over the idler sprockets onto the out-feed conveyor sections (Fig. 29). 8. Continue feeding the chain onto and around the conveyor sections, joining new lengths as necessary. The white chain cap can be used to mark the master link locations. (See Page 28 extending and breaking the chain). 9.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 26 Fitting the Flat-top Chain (cont.) 11. Feed the chain onto the drive sprockets simultaneously; then, turn the drive sprocket by hand. Lower the chain around the idler wheel so that the ends of the respective chains can be joined together. 12. Gauge and mark the chain below the idler wheel so that the chain loop will just clear the idler wheel after it is joined (Fig. 32).
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Checking the Motor Rotation CAUTION! LOCK OUT all power supplies before beginning the next step (page 4). 16. Wire the motor and verify correct motor rotation before connecting the chain (See page 29). Use a qualified technician who is familiar with the control system during the initial step. Although subsequent step is pictured with the guards removed for ease in viewing, the guards must be installed before the drive is operated. 17.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 28 Extending and Breaking Chain The steps below describe how to add or remove the flat-top chain using the special tools shown on this page. These procedures are used both during initial set-up of the conveyor, and as part of the regular maintenance of the conveyor system. CAP CAUTION! 1. 2. 3. Snap off several plastic chain caps to provide room for the tool. MASTER LINK WITH TAB DOWN 12.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Initial Start-Up WARNING! Before starting up the conveyor for the first time, re-check all mounting hardware for tightness. NOTE: The customer assumes responsibility for the control system, and must provide an EMERGENCY-OFF SWITCH in the TSplus conveyor. U2 V2 W2 U3 U1 V3 V1 W3 W1 Connect the Motor Wiring IMPORTANT! All electrical wiring must be connected by a qualified electrician.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 30 Maintenance WARNING! LOCK OUT all power supplies before beginning maintenance work of any type. The gearbox and motor used in the TSplus conveyor are maintenance-free. The following cleaning and adjustment procedures, however, will help keep your conveyor in almost new condition if performed on a regular basis. 1.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide R980 500 388 (6.2010) Repair Replacing Side Guide Profiles 4. All FP2 side guide profiles should be checked for wear regularly and replaced if needed. WARNING! Lock out power before proceeding! NOTE: Replacing the FP2 side guide profile does not require removal of the transport chain. Use a flat-blade screwdriver and pryoff the old guide profile. Cut a new guide profile the same length as the aluminum conveyor section.
R980 500 388 (6.2010) TSplus Carousel Basic Equipment Guide Bosch Rexroth Corporation 32 Repair Replacing the drive sprocket and drive shaft WARNING! Lock out power before proceeding! NOTE: Before replacing the drive sprocket and drive shaft, you must first perform the following steps. 1. Remove the top and inside covers from the drive module (See Fig. 13 on Page 16). 2. Remove the drive chain (See Fig. 24 on Page 23). 3. Disconnect the transport chain.
Bosch Rexroth Corporation TSplus Carousel Basic Equipment Guide Repair Replacing motor and gear reducer WARNING! Lock out power before proceeding! NOTE: Before replacing a motor and gear reducer, you must first perform the following steps. 1. Remove the top and inside covers from the drive module (See Fig. 13 on Page 16). 2. Remove the drive chain (See Fig. 24 on Page 23). Replacing motor 3. Disconnect electrical wiring to the motor. 4.
Bosch Rexroth Corporation Linear Motion and Assembly Technologies 14001 South Lakes Drive Charlotte, NC 28273 Telephone 704-583-4338 Facsimile 704-583-0523 www.boschrexroth-us.com R980 500 388 (6.
