Bosch Rexroth’s addition to its comprehensive VarioFlow conveyor system is designed for the smooth transport of fast-moving consumer goods (FMCG), pharmaceuticals and healthcare products.
Its modular belt chain features a fine-meshed surface that is almost completely closed and flat, which enables the mass transport of unstable or bulk film-packed products, like small sealed-edge bags, as well as larger items, such as packs of paper towels or toilet paper. The system is versatile enough to handle products that are inherently stable, even allowing for sideways protrusion in horizontal sections.
Customization and Modularity
The belt conveyor has standard modular belt widths of 406 mm and 608 mm, with scalable cross connectors that enable system integrators to customize belt widths using identical components. The basic elements of this modular system include the base unit for the drive, a return unit, section profile and both vertical and horizontal curves. This design allows for conveyor lengths of up to 30 meters and speeds of up to 40 m/min, all powered by a single drive.
The VarioFlow plus and VarioFlow belt share identical system components such as product guides, leg sets and drive kits. This modularity aims to streamline inventory management and simplify maintenance.
Streamlined Configuration with MTpro Software Tool
The company’s free and intuitive software, MTpro, supports users throughout the entire process—from selection and configuration to the ordering of Rexroth products. The Layout Designer within the software tool enables users to create complex constructions and system layouts. Additionally, the integrated evaluation function facilitates a thorough design check, eliminating the need for third-party assessments and further reducing engineering times.
Machine Design wanted to learn more about the particulars, so we reached out to Krupa Ravichandraan, sales product manager, VarioFlow plus & ACTIVE Shuttle, and TJ Tatum, digital sales specialist, Bosch Rexroth.
Editor’s Note: Questions and answers may have been edited for style and clarity.
Machine Design: What are the implications of the conveyor’s speed capabilities on production throughput, particularly for bulk and oversized medical device packaging?
Ravichandraan Krupa: VarioFlow Belt can currently run at a maximum speed of 40m/min., which empowers medical device manufacturers to achieve a high throughput especially for transportation of oversized and bulk materials.
Due to the flat modular plastic chain design with interlocking belt modules, medical device packages will be transported safely without any damages, which reduces number of rejected products and thus increases production quality throughput. This belt design allows transportation of flexible packages with uneven surfaces and packages with small attachments or protrusion without any hazard of catchpoints and damages, thus reducing equipment downtime and product waste.
Due to the chain, drive unit and slide rail design, a single drive unit can pull a maximum of up to 30 m or around 100 ft. of chain which means customers will have [a fewer] number of motors per mile of conveyor, which is a huge cost saving when miles of conveyors are used in a factory floor to transport packages. This also translates to less inventory of motors in stock, less maintenance, and more energy savings.
The load capacity is 8.8 lb./in. across the width of the conveyor. Bulk or mass flow of products is possible on the 420 mm (16 in.) and 622 mm (24 in.) wide conveyor systems. Flat chain design allows for large and wide products to overhang from the conveyor without the need for wider chains and larger motors. Custom width options are also available.
The VarioFlow Plus conveyor can run at a maximum speed of up to 120 m/min. (390 ft./min.) for special applications and up to 60 m/min. (200 ft./min.) for standard applications. One of the fastest conveyors in the market to reliably transport delicate products safely without any damage.
MD: Can you elaborate on the features of the MTPro software and how it aids in the configuration and engineering of the VarioFlow belt conveyors?
RK: The software allows the usage of macros to draw conveyors quickly, a stretch command to see three orthogonal levels, the ability to create leg sets and add lateral guides, and a chain tension calculator for system layout.
MD: How does the integration of smart design features in the VarioFlow system facilitate quicker assembly and installation?
RK: The VarioFlow Belt conveyor design features modular framing construction that allows for easy and quick assembly. Width of the conveyor can be modified by changing the cross-connectors connecting the two side frames of the conveyor and by adding or removing support profile in between. The modular belt chain is made of small belt modules that are interlocked through a single pin that makes it easy to assemble chain or modify the chain width. With little training, VarioFlow Belt conveyor can be built from zero to completion in a matter of hours for a relatively small conveyor system.
Disassembly of chain is easy, as well. There is no need for any special equipment to disconnect/remove the chain. When the conveyor is stopped and safe to work, lift the chain slightly and use a screwdriver to remove the pin connecting the chains modules to disconnect the chain for any maintenance activities. It is equally convenient to disassemble modular conveyor framing to change conveyor width to retrofit if needed.
Drive and return kits are configurable with stainless steel side frame designed to support the gearmotor kit. Rexroth supplied gearmotors allow for easy change in orientation of motor in the field, if necessary, without having to modify gearbox oil or entering a new part number for new orientation.
Leg sets are made of MGE profiles with aluminum or stainless-steel construction. This allows for quick and easy assembly and elevation changes. The framing has t-slots to attach guide rails mounts, sensors, stops and other accessories easily.
MD: What feedback have you received from engineers and system integrators regarding the usability of MTPro, and how have those insights influenced recent updates or improvements?
TJ Tatum: Overall, the feedback has been incredibly positive. MTPro has helped reduced design time, quickly generate a bill of materials and provide a CAD output.
The MTPro macro “handle” features allow users to quickly draw a system. Leg sets and guide rails can be easily added with a simple click of a button.
MD: Can you discuss any case studies or applications where the VarioFlow conveyor has significantly improved operational efficiency in medical device manufacturing?
RK: There was this application where VarioFlow was used to transport medical device optical products. Due to an NDA, we cannot share the name of the customer or the product. The customer was using manual loading, manual unloading, offline inspection stations and inefficient conveyors taking up majority of the floor space before they approached Rexroth.
Rexroth reviewed the requirements and developed an efficient solution, which allowed optimal flow of materials across the workstations, reduced the number of motors required, optimized floor space for workers by using overhead conveyors and created space for worker connectivity.
VarioFlow Plus conveyor design allowed a smooth flow of products with less friction, minimized catchpoints, and thus reduced downtime due to unplanned interruptions in material flow.
The conveyor has been running for more than a decade with the original conveyor frame even today. All that the customer had to replace was the chain links, slide rails, etc. as necessary.
