Modern production automation: stepper motors and variable speeds

Transfer System This Makes Efficient System Layouts Possible

2025-11-14 From David Schmidt, Product Manager Transfer Systems Bosch Rexroth AG | Translated by AI 4 min Reading Time

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Stepper motors instead of pneumatics, parameterization instead of programming, variable speeds instead of fixed cycle times: This is how the central requirements of modern production automation can be met.

Transfer system TS 1 48V from Bosch Rexroth: Fully electric, segment-wise controllable conveyor modules with stepper motors work continuously up to 24 m/min and can be parameterized via IO-Link for flexible, precise assembly lines.(Image: Bosch Rexroth AG) — Transfer system TS 1 48V from Bosch Rexroth: Fully electric, segment-wise controllable conveyor modules with stepper motors work continuously up to 24 m/min and can be parameterized via IO-Link for flexible, precise assembly lines.
(Image: Bosch Rexroth AG)

The introduction of assembly line production by Henry Ford in 1914 established a rigid, synchronized cycle in the production process. Ford's Model T could thus be manufactured much more efficiently. The highly standardized but inflexible principle shaped industrial production for decades.

Today, the requirements for material flow management have changed fundamentally. Shorter product life cycles and the trend towards smaller batch sizes demand highly flexible assembly lines. These must be able to process different products and require precise coordination between automatic and manual stations with variable cycle times. In addition, the efficient use of space and the reduction of energy consumption are becoming increasingly important as key cost drivers.

Gallery

The transfer modules are driven by compact stepper motors based on 48-volt technology. These are significantly more compact than conventional geared motors, which further reduces the space required.(Image: Bosch Rexroth AG)

The TS 1 is specially designed for transporting small, lightweight products and assemblies weighing up to 3 kg and is also suitable for use in clean and dry rooms and electrostatically sensitive areas.(Image: Bosch Rexroth AG)

Each transfer component of the TS 1 48V is controlled via its own interface module, which communicates with the higher-level system controller (PLC) via an IO-Link master(Image: Bosch Rexroth)

Precise Handling of Compact And Lightweight Products

This is accompanied by a paradigm shift: the focus is no longer on a constant conveyor speed across all stations, but rather the assembly process determines the speeds between the individual stations. Requirements such as these can be implemented with the TS 1 transfer system from Bosch Rexroth. Whether medical technology, automotive, consumer goods or microelectronics: the TS 1 is specially designed for transporting small, lightweight products and assemblies weighing up to 6.6 lb. With positioning accuracies of up to ±0.0006 in and the ability to be used in clean rooms, dry rooms or electrostatically sensitive areas, it offers ideal conditions for lean, efficient and precise assembly lines.

48V Conveyor Technology: Flexible Material Flow for Maximum Efficiency

The new generation of the TS 1 transfer system relies on an all-electric drive concept and dispenses with pneumatics in order to meet the requirements of state-of-the-art assembly lines. The focus is on 48-volt technology, on the basis of which the transfer modules are driven by stepper motors. These are significantly more compact than conventional geared motors, which further reduces the already small footprint of the TS 1. Each module can be controlled individually, with infinitely variable conveyor speeds of up to 79 ft/min. The individual control enables the simple integration of cycle time-independent sections and simplifies the synchronization of additional stations—for maximum efficiency in the material flow.

Bosch Rexroth has replaced the pneumatic actuators in the units for transverse transport (so-called stroke transverse units) with stepper motors. The switch to all-electric actuators offers significant advantages: Valves and hoses are no longer required, which reduces installation and maintenance costs. The system is more energy-efficient, as losses due to compression and leakage are eliminated. This reduces operating costs and increases system availability. In addition, travel paths, strokes and speeds can be parameterized individually and precisely. This enables optimum adaptation to the respective process.

Smart Solution: Parameterizing Instead of Programming

Modern production systems require solutions that enable fast and simple process adaptations without complex programming. Each transfer component of the TS 1 48V is controlled via its own interface module. These interface modules communicate with the higher-level system controller (PLC) via an IO-Link master. As a fieldbus-independent point-to-point standard, IO-Link integrates seamlessly into almost all common control environments and fieldbus systems.

Farewell to the one-size-fits-all approach

With its TS 1 48V transfer system, Bosch Rexroth relies on stepper motors and IO-Link, replacing pneumatics and simplifying integration. This reduces energy and maintenance costs and enables smooth material handling despite high transport speeds—important for sensitive workpieces. The segmented control allows asynchronous operation and makes it easier to change variants using a parameter set. Compatibility scores points for existing systems: modules can be retrofitted step by step without breaking up layouts. Clean parameter management with diagnostics, safety and versioning remains crucial. Conclusion: Less air, more electrons—this is how the material flow gains flexibility, efficiency and process stability.

A commentary by Ute Drescher

This considerably simplifies the system architecture and reduces the integration effort. Motion profiles are stored as individual parameter sets directly in the interface modules. The system controller only needs to call up the appropriate parameter set. Complex PLC programming is no longer necessary. Adaptations to product variants and process sequences can be implemented quickly.

The use of stepper motors in this architecture opens up additional functional possibilities that go beyond the pure conveying function. Thanks to the precise controllability of the motors, belt sections can realize gentle approach and stop ramps. This sensitive movement control is of crucial importance when transporting sensitive workpieces, such as electronic components, or handling liquid-filled containers. It minimizes the risk of damage and rejects and contributes significantly to the quality assurance of the end product. The exact reproducibility of the movement profiles via IO-Link guarantees maximum process stability.

Tailor-Made Solutions for Greenfield And Brownfield Sites

The new TS-1-48V modules are a future-proof addition to the TS-1 portfolio to continuously optimize assembly processes. Thanks to the precise controllability of the conveyor segments, the material flow can be optimally adapted to individual cycle and transport times, which leads to a significant increase in efficiency throughout the entire assembly line. A decisive advantage is the full compatibility of the 48V modules with the existing TS-1 modular system. This considerably expands the range of applications: the modules are not only suitable for designing and implementing new greenfield conveyor lines, but also offer excellent opportunities for increasing flexibility and productivity in brownfield scenarios. By selectively replacing or adding TS-1-48V modules to defined sections of the line, existing TS 1 lines can be modernized and optimized with minimal investment without affecting the overall structure of the system. This enables companies to gradually switch to a more efficient and adaptable production environment.

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Date: 08.12.2025

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