Igus introduces Quick-install hose packages for the robot industry

The "Triflex R" robot accessory package from the German energy chain expert, igus GmbH, Cologne, includes well over 200 components. From large welding to small palletizing robots, every application is covered.

Corrugated hoses can kink and tear. That is why igus developed the 3D energy chain "Triflex R" for robot producers and users. It is available in three designs. The first is a closed version to protect the cables on rough applications, such as welding spatters, chips, and dirt. The second is the "Easy" version in which the cables are simply pressed into the chain by hand, finally an easy to handle and install "Light" version is available.

Guiding the cables around difficult geometries.

The multi-dimensional, movable robot chain can have its length adjusted at any time thanks to its modular construction. It can be either shortened or lengthened at any place. It achieves its high tensile strength using the “ball and socket” joint. The individual elements are not connected to each other using extra steel cables similar, but with a simple connection like a trailer tow bar. This ball and socket design ensures mobility in every direction. It is possible to turn about +/- 10° per link in the chain. This makes it much easier to guide the cables around difficult geometries.

No tangles, no stress with cables

In addition, there is a defined freedom of movement in all three dimensions. The bending radius is the same in every direction, which also reduces stress on the chain itself, as well as the cables, and hoses. In addition, the use of spring-rod modules generates a directed pre-tension. This makes it possible to create a system where the chain is suspended and doesn’t get caught up in the working area. igus also offers a "Triflex RS" set specially for robot applications with limited installation space. This version guides the energy chain parallel to the robot arm to save space. It can be mounted directly on all attachment points on the robot. Finally, protectors, quick attachment systems, and attachment modules for nearly any robot complete the wide product range.

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No tangles, no cable stress: "Triflex R" hose package from igus GmbH, Cologne, Germany for all applications in the robot industry.

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Extremely fast exchanges of cables: "Triflex R" energy chain, shown here in the "Easy" version. The cables are simply pressed into the chain by hand and are always accessible from the outside. This reduces maintenance and overhaul work and reduces the downtime of the robot.

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New bolt connection ("C version"). Here the links of the chain are connected using a spherical plain bearing for form fitting power transmission.

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Also new: additional connections ("B version") for up to four times as much radius stability. The ball and socket connection was altered for this design.

Cables are easily accessible

igus presented two central innovations for its "Easy" version at the "Automatica" Exhibition. The "Easy" version allows the cables and hoses – which are simply pressed into the energy chain – to be easily visible and accessible from the outside. This makes it possible to very quickly replace individual cables or the entire hose/cable package if service is needed. This solution shortens the time needed for maintenance and overhauls and thus reduces the downtime for the robot.

New: 50 percent higher tensile strength

Firstly, the "Easy Triflex R" is now available in size 125 with a pinned connection (the so-called "C version"). This permits simple installation and removal of the links in the chain. The connection of the links of the chain is made using a spherical plain bearing – spherical cap and locking pin – which ensures form fitting power transmission. The linear tensile force absorption has been increased to 4,000 N. The energychain can now compensate for even greater torsion forces.

New: four times as stable

Secondly, the "Easy Triflex R" is now available with a further improved attachment system (the so-called "B version"). This provides up to four times as much radius stability so that even higher forces can be absorbed for complicated and restricted movements of the robot arm while still protecting the cables. The ball and socket connection was altered in the design for extremely rough applications with high accelerations and very high speeds. The quadruple increase in the bending radius stability has been demonstrated in numerous company tests at the igus-Technicum Center in Cologne.

About igus India:

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® PillowBlock Bearings, DryLin® linear bearings & guide systems enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Igus “Guidelok” Offers Total chip protection for machine tools

Metal chips are a problem for long travels and for when energy chains need to be used for gliding applications. Now the designers from igus have developed a horizontal upper run guiding system called “Guidelok”. This new energy chain solution is ideal for longer travels up to 50 m and unsupported travel in the machining industry.

The new system carries the upper run of the energy chain on a swivelling roller bracket which moves away from the moving radius guaranteeing an unhindered ride. Guided in a lightweight aluminium trough, the energy chain passes through the roller brackets first. The roller bracket then moves out again behind the radius. Afterwards the upper energy chain run is supported on the roller brackets. Due to this construction no debris can settle between the sliding surfaces of the upper run and lower run of the energy chain.

With less material and energy, almost no wear.

Along with the main benefit of protecting cables and hoses against chips and debris, this design offers a number of other advantages. The enormous improvement of the free-supporting length allows users to choose a smaller energy chain for the given length, saving material and overall costs. Secondly – by using a smaller and unsupported energy chain the required drive force reduces. Thirdly upper run and lower run of the new “Guidelok” are separated from each other. This minimizes friction and wear, which increases the lifetime once again.

 Picture PM2209-01: igus GmbH, Cologne

New energy chain “Guidelok” for chip areas -from igus Gmbh, Cologne. Up to 50 m long unsupported travels are now possible. So no debris and chips can settle between upper run and lower run of the chain.

 Picture PM2209-02: igus GmbH, Cologne

The energy chain passes the swivelling roller brackets (left), moves in and behind the radius then out again (middle). Then the upper run sets down again, and is supported by the brackets (right).

Already in service

Just introduced, the new energy chain system is already used successfully in an industrial application at a German manufacturer of machine tools. A heavy steel chain has just been exchanged with “Guidelok”. Changing the existing system for a gliding energy chain solution was out of the question. Metal chips of a 1 Euro coin size would have settled in the inner radius between upper run and lower run, which could have caused damage. In contrast the new system for long unsupported lengths is ideal for such applications.

The “Guidelok” energy guiding is - designed modular and with few parts, and is optional with or without side troughs - available ex works straight away. The company from Cologne is showing the product at http://www.igus.in/wpck/default.aspx?Pagename=overview_guidelok_hor&C=IN&L=en ; among other things, a movie illustrating the new principle of design. The manufacturer igus can deliver within 24 hrs or at the same day. The program includes more than 70,000 energychain, cable, plug and connector components as well as other accessories.

About igus India:

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal®, DryLin® linear bearings & guide systems enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

The igus bearings have three times higher lifetime

The polymer specialist from igus, presented last year with the material “iglidur Q2” a high load plainbearing which is more durable by a factor of 2 to 5 in harsh environmental conditions than the other 40 plain bearing materials of the company. Based on this material, the limits of performance of injection-moulded plastic bearings could be once again altered with a clever multi-component system: in comparison with iglidur Q2, the new iglidur Q2E (=enclosed) reaches in igus internal pan tests a higher lifetime by a factor of 3 at a radial load at 180 MPa. For this reason a two-component bearing of 30 mm length and 25 mm diameter can take loads of about 13.7 tons. This is equivalent to the weight of two full-grown bull elephants.

It all comes down to the mixture

The bearings consist of a hard polymer shell and a tribo-optimized core made of iglidur Q2 that is also stable in shape and wear-resistant even under high loads. Similar to an exoskeleton, the shell provides the bearing with high stability and makes for an increased lifetime. In addition to that there is the corrosion and maintenance freedom that can increase the productivity in many applications, especially compared to metallic solutions, because downtimes for service or repair can be renounced. iglidur Q2E is initially available for shaft diameters of 20, 25, 30 and 40 mm.

Even more selection for standards

The plain bearing program of the standard high-load material iglidur Q2 has been increased. Available are now iglidur Q2 bearings for shaft diameters up to 75 mm with and without collar. Especially in the field of agricultural engineering, commercial vehicles, construction machines as well as jig manufacturing and mechanical engineering, iglidur Q2 and Q2E plain bearings prove robustness.

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The new two-component polymer bearing Q2E is suitable for high-load panning applications in harsh environments.

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iglidur Q2E can’t only move elephants. It is also suitable for many applications, where high loads, dirt and humidity are involved.

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The standard high-load material iglidur Q2 has been enlarged about other sizes. It is now available for shaft diameters up to 75 mm with and without collar.

About igus India:

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® PillowBlock Bearings, DryLin® linear bearings & guide systems enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Igus Introduces Custom-made lubrication-free piston rings

Polymer bearing expert igus, has been producing customer-specific piston rings, tailor-made in terms of geometry and material, for about ten years. Now, the company is supplying piston rings in a wide standard catalogue range. The clip-type guide rings are used in valves, actuators and lifting components in armatures, the food and drinks industry, chemical and medical technology, to name but a few. The igus piston rings are lubrication free, wear-resistant, have a defined clearance and are dimensionally stable even with edge loads. This makes the “iglidur” piston rings suitable for linear and/or rotary, lifting or pivoting movements.

Clip rather than fiddle

One major advantage – in addition to being lubrication free – is they are fast fitting. The ready-to-fit piston rings are fitted in only one movement, into an undercut machined in a bore or in a groove of a shaft. The “iglidur” piston rings are positioned, clipped and then snap in places. They are increasingly replacing PTFE tapes that have to be punched or cut from raw material in a time-consuming process, then inserted manually in a groove before the piston is then slipped into the bore of the assembly. Moreover, the straightforward handling of the piston rings reduces potential sources of faults – there is no more deformation, and fitting errors are almost eliminated.

Photo 01: igus 

Position, clip, finished: Maintenance-free “iglidur” polymer piston rings from igus GmbH, Cologne, are fitted in one movement. Ready-to-fit, they are increasingly replacing PTFE tape that requires a complex manufacturing process.

Polymer piston rings made of the tribo-optimised universal material “iglidur J” are now available ex stock in 13 dimensions for shaft diameters from 10 to 70 mm. From now, they can be delivered in specific materials and dimensions within 10 days. All “iglidur” materials and standard bearing dimensions are available on the basis of the company’s plain bearing catalogue range. Popular piston ring materials (besides “iglidur J”) are the FDA-approved material “iglidur A180”, “iglidur X” for use in chemicals and high temperatures, the low-cost material “iglidur J4” and “iglidur J350” for applications at over 90°C.

can be delivered in specific materials and dimensions within 10 days. Customers can choose from the whole “iglidur” catalogue range.

Photo 02: igus 

Lubrication-free polymer piston rings made of the universal material “iglidur J” are now available ex stock in 13 dimensions for diameters from 10 to 70 mm. 

About igus India:

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® PillowBlock Bearings, DryLin® linear bearings & guide systems enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

igus introduces the new generation of micro-chains

igus has given its micro-chains for tight design spaces a makeover and come up with a new modular system: clever design tricks such as the double stop system or the “brake” make the E2 micro versions even sturdier and quieter than their predecessors. With the e-chain E2.15 an increase in possible additional load of 100 per cent was achieved. With a self-supporting length of the upper run of up to 1.25 m, new application options are now possible in the tightest of spaces.

The micro-chains from igus are made up of very small one or two-part e-chains. Their low weight makes them extremely suitable for highly dynamic applications such as automatic doors, measuring machines, handling, pick-and-place robots or adjusting units.

                    

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Every E2 micro-chain is delivered with a plastic opening tool. The wings are hinged at the side and open all bridges in seconds for even faster installation.

With the series E2.10 and E2.15 the tribo-polymer company from Cologne has developed a new generation of micro-chains. The new energy chains are much sturdier than their same-size predecessors. The high stability is due in part to the clever design – a double stop system helps the E2.15 series to achieve an increase in possible additional load of up to 100 per cent. And with a maximum self-supported length of 1.25 m, 25 per cent more than with the predecessor chain, new application possibilities are possible even where space is extremely tight. New in the modular system are the micro-separating bridges, the catches of which guarantee a firm hold even with side fixtures. In addition, the round contours of the bridges ensure a particularly smooth interior that goes easy on the cables. A built-in “brake” dampens stop noises and guarantees smooth running.

Opening tool for assembly in seconds

The E2 micro system includes connection elements in different versions – rigid, one-sided and two-sided pendulum bearings. This means the E2 micro can be mounted in any direction on the chain and attached to the machine – including on the front when the quick flange clipped in at the side is used. This allows the E2 micro to be used for all applications – horizontally, vertically downwards or upwards, circular or even lateral.

A further aspect of the new E2 micro is its fast and easy installation. There is an entering diagonal worked into the bolts of the sides to make assembly easier. Every E2 chain is delivered with a plastic opening tool to make installation even faster. The tool can be hinged open at the side and has wings which open all the bridges in seconds.

Modular system also for the smallest e-chains

The new e-chains differ from their one-part predecessors in terms of design too, the E2 micro system is available in the igus-specific modular range in three variants: Alongside a completely closed version, the E2 micro can be opened with two different bridge versions in the outer or inner radius. At the moment, all versions with an inner width of 20 mm for the heights 10 mm and 15 mm are available. Gradually, after the Hanover Fair, both series will be manufactured in seven further widths each.

                                

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The new generation of igus micro-chains is even sturdier than its same-size predecessors: With the e-chain E2.15 a few design features achieved an increase in possible additional load of 100 per cent.

About igus India;

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® spherical bearings, DryLin® linear bearings & guide systems enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

New twistable fibre optic cable makes safe data transfer possible for robots

Bus system problems often occur during twisting applications in energy chains, particularly with shielded data cables if the shields get damaged or open up. This is not the case with glass fibre optic cables: These do not have a mechanically vulnerable shield braid, and they are insensitive to EMC whilst transferring high-speed bus signals up to a length of 400 m. Following comprehensive tests, the Cologne-based company igus GmbH has now developed a new twistable fibre optic cable for all 3D movements in energy chains, to keep bus systems working reliably. The twistable TPE fibre optic cable "Chainflex CF Robot-LWL" makes high data rates possible and can be routed directly alongside high-capacity electrical power cables. The special design uses twist-optimised compensating elements, and the mechanically strong fibre optic cable is absolutely robust even with rotary angles of +180° eg on a robot arm.

One million cycles, 360° torsion angle

The new fibre optic cable has been running on a test set-up 1 m long in the igus technical centre for more than 1 million double cycles. There is no change to the excellent data transfer rates even at a torsion angle of 360°. The fibre optic cable has a 2-fibre optic core, is resistant to oil, bio-oil and UV light and remains flexible in the cold. The FOC wires with high-tensile aramid fibres and dampers are stranded firmly around a GRP core. The pressure-extruded outer sheath is made of a halogen-free TPE mixture. Highly dynamic in continuous movement, the cable can be used for indoor and outdoor applications at temperatures from -20 to +60°C.

The "Chainflex CF Robot-LWL" has a fibre diameter of 50/125 µm and is suitable for almost all high-speed buses provided that suitable converters are used. This covers a wide range of uses in Flex Cable Applications, such as in energy chains on robots and machine handling where vision technology plays an exciting role. This helps to meet the requirements on moving quality control monitoring, which are becoming ever more demanding. The new fibre optic cable is a solution suitable for industrial applications for image transmission for GigE, FireWire IEEE1394a/b and USB. 

Image: "Chainflex CF Robot-LWL" for energy chains – new 2-fibre gradient fibre optic cable for all torsion applications.

Igus launches “guidefast” for a lateral mounting to standard carriers of industry and hall cranes

The energy supply specialist igus GmbH Cologne, introduces a guiding trough for energy chains, that is easy and simple to install. “guidefast” has been developed especially for a lateral mounting to standard carriers of industry and hall cranes. The modular design and a reduced number of components significantly reduce the installation time: Up to 80 % compared with standard energy supply solutions for hall cranes. The cheap guiding trough is available in different materials and sizes.

Brackets, trough, clips - ready

The elaborate concept simplifies the work of the installer with every step: Special brackets that are mounted via screw/thread or welding bolts allow simple vertical fine-adjustment. Furthermore, the static cables can be directly fixed to the integrated strain relief of the bracket – this considerably simplifies electrification and additional installation as, for example, cable clips or hose clamps, become needless. To connect guiding troughs with a standard trough length of 2 m easily and without shearing edges, special clips are available. Every 500 mm the trough elements dispose of a cable supply as well as prefabricated bore patterns for the connecting elements of the energy chain. The energy chain is directly inserted into the guiding trough including cables. Through the cable supply, the installer can flexibly connect consumers or feeds wherever the situation of installation requires it. The prefabricated bore patterns accelerate installation, because time consuming measuring, drilling or cutting is unnecessary. All savings sum up to 80 % less installation time. For this reason, “guidefast” does not only contribute to reduce costs, above all, it also allows faster commissioning. Customers, that like to save additional installation time, can order pre-harnessed and ready-made “readychain” energy chains from igus. At www.igus.eu/guidefast-video , igus branch manager Christian Strauch demonstrates the fast and simple installation of the new system.

Complete construction kit – thoroughly tested

Like any other igus products, “guidefast” has been thoroughly tested in the company’s own 1.030 m² test laboratory. In long-term tests the guiding trough has proven its strength and resistance against vibration also under harsh environmental conditions. “guidefast” is part of the complete package for crane applications and consists of trough, the E2/000 energy chain and “chainflex” cables. The trough is available in different designs such as galvanised steel, stainless steel or black powdered steel versions. An aluminium version is planned.

Picture PM2512-01: igus

The new guiding trough construction kit for hall cranes from igus: fast and simple to install with a few movements. To make the crane operate faster, the number of components and cycles are reduced to a minimum: bracket, trough, clips – nothing more is required to reduce installation time.

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Especially to install at hall cranes: brackets are directly mounted to the crane carrier via welding bolt or screw / thread. The trough is available in steel, stainless steel and as black powdered version; an aluminium version is in preparation. On demand an individually pre-harnessed “readychain” is available as part of the complete package.