Permanently protected: 3D e-chain® for 6-axis robots in automotive industry

Profile

• What was needed: twisterchain®, triflex® R, triflex® RS
• Requirements: The protective corrugated hoses provided by the factory were permanently torn or had worn through, leading to stoppages. The company sought out a solution that would provide safe and durable protection while being able to accommodate the complex movements across each axis.
• Industry: automotive industry
• Success for the customer: Across the various axes, the different e-chain® applications demonstrated their strengths perfectly. They guided the cables safely in complex motion sequences, reduced downtime and provided safety and stability.

Wandres GmbH specializes in developing and producing brushing and air cleaning systems. Removing dust, fibers, and minute particles from surfaces is crucial for many manufacturing processes, especially in the automotive industry. A Wandres robotic sword brush is used for a special cleaning process called 3D micro-cleaning before the final painting of an automobile.

In the Wandres technical center, a multi-axis robot runs endurance tests to check the cleaning quality and results of this robotic sword brush on various surface structures. This brush is particularly suitable for cleaning complex geometries that cannot be reached with alternative methods. The robot travels at approximately 300 to 400mm/s, and both cycle and continuous operation are possible.

The basis of the cleaning process is Wandres' patented special micro-moistening system, "Ingromat". This significantly minimizes electrostatic charges and safely removes adhering dust and particles.

The 6-axis robot using this brush was originally fitted with the factory-provided protective hoses to protect its cables. After about two and a half years, these hoses had permanently cracked or wore through, causing the entire test system to come to a standstill. The company needed a solution that would not only be secure but would also provide lasting protection.

For over 20 years, the Wandres surface cleaning specialist had been working with igus® products for cable guidance, which were in almost all Wandres cleaning systems. Thanks to this business relationship, all six axes of the cleaning robot were equipped with 3-dimensionally moving e-chains®.

An igus twisterchain® protects cables at the circular movement of the rotary axis. This spiral-shaped modular energy supply system is suitable for circular movements of up to 540° and can be completely pre-assembled on request. Hoses and cables are safely guided, abrasion is significantly reduced, smooth operation increases. 

On axes 2 to 6, the multi-dimensionally moving cable carriers reduce downtime and bring stability and safety for applications from large welding robots to small palletizing robots. Thanks to the round design, the energy supply system smoothly glides over the outer contour of the robot, without getting tilted or hooked.Axes 2 and 3 of the robot are equipped with the triflex R light variant, a functionally reliable solution for less complex movements. For axes 4 to 6, the compact triflex RS was used. With the universal module, the chain is guided parallel to the robot arm to save space.

Applications can be implemented in the tightest of installation spaces. Fiber-rods within the chain create a pre-tension to achieve complete or partial stiffening. Automatic retraction mechanisms avoid looping and cable stress at the robot head. The "trailer principle" enables the high tensile strength of the system. The individual elements are connected like a trailer coupling (ball and socket principle). This allows a high degree of movement in all directions. In addition, there is a defined freedom of movement in all directions, which also increases the service life of the chain, cables and hoses.

On axis 1 (the rotary axis), the twisterchain® energy supply system is used with a rotary movement of 180°.

The compact triflex RS set is used on axes 4 to 6. With this universal module, the energy chain is always guided parallel to the robot arm to saves space.

Energy supply system "triflex R" with integrated return spring. This always creates a targeted pretension to prevent cable stress.

Clean connection of robot brush to the energy supply. The bus cable (purple) is a special cable for dynamic use in e-chains.