Intelligent energy supply system saves installation time

Preassembled e-chain systems in application in machines for the timber and furniture

In today's world, the end customer demands a reduced energy requirement of his production systems. The manufacturer of these systems primarily wants to significantly reduce its assembly and throughput times, meet high quality standards, but still be able to react flexibly to customer requests. In this demanding environment, pre-assembled energy supply systems from igus demonstrate their technical and economic advantages and ensure permanently functionally reliable, robust material flow solutions in the wood and furniture industry.

Profile

What was needed: Energy chains of the E4/4 light system of the 14240 series as pre-assembled "readychain" systems
Requirements: fast installation of the cable carriers, long cycle times and tight bending radii require a durable guide and cable solution, solution must be able to cope with the dusty and dry ambient conditions and at the same time be as light as possible for energy-saving reasons
Industry: Wood and furniture processing industry
Success for the customer: pre-assembled readychain systems enable particularly short assembly, the electrical installation time has been almost halved; resilient chainflex cables defy the high dynamic loads and guarantee high system availability; Weight has been reduced due to the easy-running energy chains

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Problem

HOMAG Automation GmbH in Hemmoor is part of the globally active HOMAG Group, the market-leading supplier of production systems and machines for woodworking. Within this group, HOMAG has specialized in handling. Whenever wood-panel-shaped materials need to be transported, stacked, stored, turned or sorted, HOMAG machines can be used. This ranges from the smallest craft business to the internationally positioned high-tech company worldwide.
The number of portal systems ordered annually has increased rapidly. The good order situation is leading to major space problems in production. Therefore, we had to reduce the throughput times of the individual systems. The specialist must therefore save time in all areas, including energy supply systems, which must be able to be installed as easily and quickly as possible. However, HOMAG also places other demands on the energy supply systems due to the way the machines work: Long cycle times and narrow bending radii put considerable strain on the energy supply system and cables. The travel distances for the gantry and storage systems are between 4 and 60 m. Speeds of 60 to 290 m/min are driven with accelerations of up to 12 m/s². In addition, a cycle rate of max. 20 cycles/min is achieved for loading and stacking systems. The conditions of use on site are typical for woodworking – dry, dusty and usually warm.
But weight also plays a major role for HOMAG. Because another major challenge – in addition to the issue of downtimes – is rising energy prices. Plant engineering, which is planning to reduce the energy consumption of the systems by 20 or even 30%, therefore relies on lightweight construction, which must also be reflected in all machine components such as the energy supply systems.

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Solution

For more than twenty years, igus energy chains with the matching guide troughs have been used in the stacking and storage systems for loading and unstacking furniture parts. To be more precise, prefabricated complete systems are used here, the so-called "ReadyChain" systems. The chains are delivered complete with cables and plugs from igus and are ready for assembly immediately. It also includes bend-resistant" Chainflex" cablesto guarantee the increasing dynamic loads and high system availability. Part of the product range has been successfully converted to these pre-assembled energy supply systems for some time now.
The simple, prefabricated chain solutions also meet the machine manufacturer's goal of reducing throughput times. By using the solution, the electrical assembly time could be almost halved. Today, the highly qualified employees no longer spend time inserting cables into the energy chain but can be better deployed elsewhere.
The energy supply systems are also suitable for tough continuous use in the furniture industry and are characterized by low wear in their moving parts. With the latest drive and control technology, high cycle rates are realized. Specifically, energy supply systems from the igus system "E4/4 light", series 14240, were used for the horizontal driving axis and the vertical lifting axis. They combine two technical features: firstly, a reduced wall thickness of the side links and a lighter bridge, which means less weight and a better ratio of internal and external dimensions. Secondly, a form-fitting rear grip, which provides even more lateral stability.
And finally, the easy running igus energy supply systems also help to reduce the energy consumption of the entire system.

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By using the pre-assembled energy supply systems, we have almost halved the electrical installation time! Today, our highly qualified employees no longer spend time inserting cables into the energy chain, but are better deployed elsewhere.

Merten Hamann

Head of Purchasing at HOMAG Automation GmbH in Hemmoor

Pre-assembled energy supply systems from igus for the horizontal travel axis and the vertical lifting axis.

Functionally reliable "Chainflex" cables especially for use in highly dynamic use in energy chains.

"E4/4 light" energy chain, assembled with bend-resistant "Chainflex" cables, among other things.

Delivery of the pre-assembled energy supply systems to the customer. Ready for quick assembly.

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