Machine. Tools. .com. Special igus products for. , ReadyChain, Chainflex Cables, Energy Chain Systems

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1 Special igus products for Machine Tools Energy Chain Systems.com, ReadyChain, Chainflex Cables, iglide, igubal, DryLin, PRT plastics for longer life ECS-B8

2 Contents 7000 rotations Triflex R, multi-axis cable carriers, page 12 Twisterband, rotating cable carriers, page 14 Oil resistant Chainflex continuous-flex cables, page 15 Reduce processed costs ReadyCable harnessed cables, page 16 ReadyChain harnessed cable carriers, page 17 2

3 How igus products can improve your machine tools Save assembly time E4-1 Energy Chain cable carriers, page 8 Chip resistant up to 1,562 F RX Energy Tubes, page 4 Guidelok, upper run guidance, page 6 Energy Tubes, page 10 Lubrication-free DryLin linear guides, page 18 iglide PRT slewing rings, page 19 DryLin W linear guides, page 20 iglide plain bearings, page 21 igubal spherical bearings, page 21 3

4 Chip protection Full chip protection without undercuts, projecting edges or gaps Round contour ensures all debris falls off Large interior cross section with 2.87 in. (73 mm) max. inner height Fastened with flange mounting brackets (strain relief optional) Fully enclosed pin/bore connection and stop dogs Easy open lids on the outer radius with locking mechanism 4 Interior separators and shelves to organize cables Mounting bracket with optional strain relief

5 RX40 Our most chip-repellent carrier to date Chips and dirt can significantly affect the service life of cables and hoses. The RX Energy Tube is an enclosed plastic cable carrier that is extremely easy to open. The Energy Tube repels chips, is almost air-tight, and can be opened easily at any point. Complete chip protection Smooth rounded contour prevents chip accumulation Large interior cross-section with 2.87 (73 mm) maximum inner height Covered pin/bore connection and stop dogs Reverse bending radius (RBR) is a standard option Special design 1,562 F HT material (optional): resistant to hot chips up to 1,562 F time (s) igus product competitor RX40 underwater It takes more than 30 seconds for the RX40 Energy Tube to fill up with water chips (g) igus product competitor Open trough design for safe guidance so chips can fall through Chip protection Only 0.2 g of chips were found inside the RX Energy Tube after 80,000 cycles An RX Energy Tube is used in a CNC precision turning-and-milling center Special HT material protects up to 1,562 F 5

6 Chip protection Upper run guide makes long, self-supporting lengths possible in chip areas Chips will not get stuck between the upper and lower runs For long travels on machine tools, metallic chips are a problem if the Energy Chain glides on itself. igus Guidelok is a cost-effective solution. Long, self-supporting lengths are possible Lower push/pull forces needed thanks to the smaller, self-supporting Energy Chain. Rollers deliver greater energy efficiency Modular system with minimal parts (also available without lower trough) Video: 6

7 Guidelok Design principle The Guidelok design allows support rollers to be used in the space where the radius of the chain needs to pass. As the Energy Chain is guided through the trough channel, it pushes back the spring-loaded roller support, Guidelok slimline F vertical guidance up to 22.9 ft/s and 32.8 ft/s 2 which snaps back out again after the Energy Chain radius has passed, total length field length = 6.56 ft. (2 m) allowing the upper run to rest on the roller support. unsupported travels up to 164 ft. (50 m) possible 7

8 System E4-1 System E4-1: One Energy Chain for virtually any application Crossbars every link for particularly demanding applications Series Inner height Inner width Outer width Outer height Bending radius hi Bi Ba ha R in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) E (21) (30-120) (44-134) 1.10 (28) (38-200) E (28) (40-300) (60-320) 1.65 (42) (55-250) E (32) (50-400) (73-423) 2.13 (54) (63-300) E (42) (50-400) (76-426) 2.52 (64) (75-350) E (56) (50-600) (84-634) 3.31 (84) ( ) E (80) (50-600) ( ) 4.25 (108) ( ) Crossbars every 2 nd link for almost all applications Series Inner height Inner width Outer width Outer height Bending radius hi Bi Ba ha R in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) H (32) (50-400) (73-423) 2.13 (54) (63-300) H (42) (50-400) (76-426) 2.52 (64) (75-350) H (56) (50-600) (84-634) 3.31 (84) ( ) H (80) (50-600) ( ) 4.25 (108) ( ) Energy Tubes fully enclosed, for complete cable protection Series Inner height Inner width Outer width Outer height Bending radius hi Bi Ba ha R in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) R (28) (50-300) (70-320) 1.65 (42) (75-250) R (32) (50-300) (73-323) 2.13 (54) ( ) R (42) (50-300) (76-326) 2.52 (64) ( ) R (56) (75-462) ( ) 3.31 (84) ( ) R (80) ( ) ( ) 4.25 (108) ( ) 8 The E4-1 system combines all the benefits of its three predecessors in the E4 range. E4-1 cable carriers offer greater stability with the same or smaller dimensions while almost all the accessories and mounting brackets are the same. With igus E4-1 cable carriers, the service life of your application can be increased and costs significantly reduced. Rugged, low noise and modular High load capacity, thanks to the special tongueand-groove design Ideal for side-mounted applications Large unsupported lengths possible Noise dampening pads available as additional noise-reducing option Outer and inner links can be opened for fast assembly

9 UniversalComponents & accessories Interior Separations Standard separator, wide foot Separator for QuickLock crossbar Separator, narrow foot Asymmetrical separator Notch separator for the new notch crossbar Full-width shelf, lockable Interior separations Mounting Brackets KMA with attachment capability on all sides Mounting brackets with strain relief Mounting brackets with profile rail KMA, pivoting KMA, locking Steel mounting bracket Mounting brackets Chainfix and Strain Relief Improved housing foot clamp for easy fit into profile rail Integration with igus KMA mounting brackets possible Clip-on tiewrap plates for opening crossbars Tiewrap plates with clip-on connection for the profile rail Chainfix clip Modular snap-on for the profile rail Chainfix Nugget Chainfix and strain relief Guide Troughs Aluminum Super Trough Basic Aluminum Super Trough Heavy-Duty Fixed end module, aluminum Super Trough Steel guide troughs Fixed end module, steel guide trough For support of the lower run Support Tray tool kit Guide troughs 9

10 Chip protection Energy tubes: protection from dirt and debris E4 Series: Fully enclosed Energy Tubes for long travels and harsh environments E2 Series R100, Series R and E4 Energy Tubes Since igus introduced the first openable Energy Tubes in the mid-1980s, many additions and improvements have been introduced into the product line. igus Energy Tubes work in hot chip areas, in areas subject to dirt and dust generated by woodworking, steel mills, pulp and paper mills, textile machinery, agricultural applications, coal plants and many other hostile environments. Energy Tubes made from igumid HT material: repels hot chips up to 1,562 F Hinged, snap-open, removable lids along the inner and outer radius Reduced assembly times 10 Application 4 years on: Energy Tubes offer superior protection in harsh, contaminated environments. The double stop-dog design delivers a longer service life.

11 Tubes Application examples High temperature Energy Tube guides and protects cables in a hot chip area E2 Energy Tube R100: Cost-effective, fully enclosed Energy Tube, inner heights from.82 to 1.97 (20.8 to 50 mm) Chip-repellent series R188 in a sidemounted application E2 Energy Tube R: Single lids, smaller pitch for an even smoother operation, inner heights from.98 to 1.77 An Energy Tube at work on a machine tool E4 Energy Tube: Fully enclosed Energy Tubes, inner heights from 1.10 to

12 Triflex R Triflex R multi-axis cable carriers Multi-axis three-dimensional cable carriers for robot applications Three options: TRC, TRE (easy to fill) and TRL (light version) Triflex R light: if-design award 2007 Triflex R was specially developed for 6-axis robotic systems in harsh industrial environments. Triflex R moves multi-dimensionally through all axes and can twist up to 380 per yard, enabling easy movement through complex configurations. Features include: Multi-dimensional movement High tensile strength thanks to ball-and-socket joint Easy assembly, installation and maintenance Small bending radii Optional fiber rod for spring loading The Triflex R product family now comprises more than 100 components meeting application requirements ranging from small palletizing robots to large welding robots. Typical industries and applications Robotics/automation Machine tools Handling machines - 6-axis Packaging machines General mechanical engineering, etc. 12

13 Multi-axisApplication examples RS Assembly Triflex RS is a very compact universal assembly that is mounted to installation points on a robot. Thanks to the low profile and the Triflex R guide parallel to the robotic arm, applications with extremely limited installation space are possible. Triflex RS has an integrated spring mechanism, which allows energy supply to the robot head without stressing the cables. The Triflex RS offers all the advantages of Triflex R accessories, such as the FlexBar, universal assembly kit and fiber-rod module, all in one system. All the features of Triflex R cable carriers are also included in the universal Triflex RS module. One package for all applications, ready to install Integrated fiber rods to retrack cables First choice for robotic applications with limited installation space Saves space with it slow profile and close routing on the robot arm Excellent service life Universal applications Triflex RS with additional mounting option for terminal boxes Triflex R in the working chamber of a machine tool 3D + torsion Movement range: ( mm) (according to size) Mounting brackets for safe fastening Glide lead-through for close and parallel guidance on the robotic arm Limit stop dog for defined movements Integrated spring prevents loop formations Single module, space saving and quick to mount on a robot Triflex R on a lathe spindle 13

14 Twisterband Twisterband: Compact, modular, cost-effective Rotary movements in minimal space 8 times around its own axis With compact igus Twisterband, complex and expensive rotary solutions are no longer necessary. Twisterband offers with low wear and low maintenance for confined spaces. 4 sizes available Rotary movements possible up to 3000 when installed vertically and more than 7000 when installed horizontally Rotary speeds up to 360 /s possible Compact, modular and lightweight Ribbons can be shortened easily Safe cable guidance in the smallest of spaces 14 New! igus E-Spool - The alternative to cable drums

15 Chainflex igus Chainflex cables for machine tools CF5 & CF6 - PVC control cables IGUS CHAINFLEX CF5 IGUS CHAINFLEX CF6 CF5 and CF6 PVC control cable for high load requirements, PVC outer jacket, resistant to oil, flame retardant CF112 & CF113 - PUR data cables IGUS CHAINFLEX CF112 IGUS CHAINFLEX CF113 CF112 & CF113 PUR-data cable for high load requirements, PUR outer jacket, twisted pair, resistant to oil and cooling agents, abrasion resistant, free of PVC and halogen, flame retardant CF270-UL-D - PUR servo cable IGUS CHAINFLEX CF270.UL.D CF270-UL-D PUR servo cable for medium load requirements, PUR outer jacket, shielded, resistant to oil and cooling agents, abrasion resistant, flame retardant, free of PVC and halogen CF BUS - TPE bus cable IGUS CHAINFLEX CFBUS CF BUS TPE bus cable for maximum loads requirements, TPE outer jacket, shielded, (bio-)/oil resistant, flame retardant CF300 & CF310 - TPE motor cable IGUS CHAINFLEX CF300 IGUS CHAINFLEX CF310 CF300 and CF310 motor cable for maximum load requirements, TPE outer jacket, shielded, (bio-)/oil resistant, flame retardant, UL-approval 15

16 ReadyCable Harnessed cables meet the specifications of the following manufacturers... Allen Bradley Danaher Motion ReadyCable : Harnessed drive technology ReadyCable igus offers more than 818 harnessed cables for drive systems according to Allen Bradley, Danaher Motion, Fanuc, Heidenhain, Lenze, Rexroth and Siemens. Servo, power and signal/encoder cables No cutting charges, no minimum order quantity, no packaging costs Cable length according to your requirements Smallest bending radius from 7.5 x d Reduce storage costs and increase cash flow Fanuc Let igus do the work for you! Heidenhain Lenze Rexroth s Obtain a quote for your application within 24 hours (Monday - Friday) Visit Siemens s...and many others upon request! 16

17 ReadyChain Fully harnessed systems: Reduce your inventory and procurement costs, and improve your delivery lead times to customers Mass production Completely harnessed Energy Chain Systems - delivered ready to install 700 systems per week produced in 10 ReadyChain factories worldwide ReadyChain specialists take care of your project Ask for fully harnessed igus ReadyChains to increase your cash-flow immediately. Increase production throughput Improve delivery lead times to customers Reduce inventory and procurement costs Enjoy the benefits of a complete system guarantee Use your manufacturing floor space more efficiently Improve your speed to market High voltage testing ensures quality 17

18 DryLin Slides Reduce engineering/manufacturing time and costs DryLin linear slide tables are the latest evolution of over 40-years of testing and developing of plastic bearing materials. After noticing that many of our customers were fabricating their own linear systems with belts or lead screws using parts from multiple suppliers, we designed our own. Positioned milling heads with DryLin HTS Save on engineering costs Eliminate catalog or internet research time Eliminate assembly drawings or work instructions Eliminate checking specifications for lead screws, shafting, blocks, acme nuts and bearings Eliminate waiting for quotes/samples/phone calls from multiple suppliers Eliminate designing your own parts Spend more time on other aspects of your design project Leadscrew table used for fine adjustment on aluminum cut-off saw SLW/SAW: Great blend of performance and value Hi helix available for high rpm Ball bearing (axial) version available for high rpm All stainless version available (SLW-1040 only) HTS(C): Our most flexible system, available in a variety of materials and configurations Hi helix available for high rpm All stainless hygienic version available Hi-temp to 356 F available Size adjustment in bag forming, filling and sealing machine with DryLin SET 18 HTSP: All-plastic table with aluminum or stainless shafting for low cost and corrosion resistance SET Easy Tube: Simple design for lowcost positioning

19 iglide PRT Ready to install, lubrication-free and economical iglide PRT slewing rings iglide PRT is an economical, maintenance-free slewing ring table with tribo-optimized iglide polymer sliding parts. Ready to install Robust, corrosion-resistant bearing for high loads For extreme torques Maintenance and lubrication-free For low to medium gliding speeds iglide PRT geared slewing rings Geared PRT's are now the standard for driving a PRT by belt, rack, or pinion gear. There are 4 different gear options offered in hard anodized aluminum. Maintenance- and lubrication-free Ready to fit Robust and corrosion-resistant Circular movement with iglide PRT and reverse bending radius (RBR) iglide PRT slewing rings, FDA compliant For use in food technology with inner rings made from the FDA-compliant material iglide A180 Both the stainless steel outer ring and iglide A180 are suitable for direct contact with food and pharmaceuticals Low profile and lightweight Totally lubrication-free iglide PRT slewing ring iglide PRT is an economical, maintenance-free slewing ring with tribo-optimized iglide plastic sliding parts. High rigidity Easy to install, iglide J sliding pads High wear resistance Available in aluminum or stainless steel iglide PRT in a semi-conductor handling-and-transport system iglide PRT geared slewing ring with squared flange The smallest PRT slewing ring (size 20) is also available with a space-saving square flange for direct mounting to flat surfaces. No intake hole necessary No separate spacer required Fixed in place with 4 screws iglide PRT in a semi-conductor handling-and-transport system More Information: 19

20 DryLin W DryLin W - The original flexible guiding systems DryLin W was developed to promote both design flexibility and quick assembly in both single and double rail configurations. DryLin W is available in several mounted assemblies,eliminating the need for shaft alignment and bearing assembly. All DryLin W systems are available with our enhanced J200 liners, which reduce friction and optimize bearing life. DryLin R linear bearings and DryLin W guides in drilling emulsion DryLin W used for a stop dog in the glass industry DryLin W - flexible linear guides DryLin W s design promotes flexibility and ease of assembly. The single rail system, which may incorporate a floating square bearing, efficiently compensates for extreme shaft misalignments. The double rail system eliminates the need for shaft alignment, offering a single bolt-on solution. Hard-anodized aluminum is used as the rail material, which means DryLin W is low wear, low friction, requires no lubrication, is resistant to dirt and dust, lightweight and quiet running. DryLin W in permanent use in a con veyor belt DryLin W Stainless Steel For the ultimate corrosion-resistant linear guide, our plastic lined linear bearings are coupled with 316 stainless steel. DryLin W for guid ing the igus Energy Chain in an inkjet printer 20 DryLin Specialists WJUME - Adjustable, allows radial clearance adjustment by the use os a simple allen key. WJRM - Rolling hybrid bearing with reduced drive power needed for hand powered and very low cycle applications.

21 iglide & igubal 34 self-lubricating materials iglide maintenance- and lubrication-free bearings Made from high-performance plastics Predictable lifetimes Corrosion resistant Dirt resistant Vibration dampening More Information: iglide D in tool changer chain Self-aligning spherical bearings igubal maintenance- and lubrication-free pillow block bearings Vibration dampening High tensile strength Compensate for misalignment Chemical resistant Lightweight iglide J in paper-polishing header More Information: igubal pillow block bearing in an interlacing machine 21

22 Applications Examples of successful applications with igus products in the Triflex R and Energy Chain System E4 on a lathe spindle Energy Chain on a horizontal, two spindle machine Pre-harnessed ReadyChain System with integrated strain relief on a machine Space-saving Energy Chain mounted on the x-axis of a machine cover High-temperature Energy Tube for hot chips and flying debris Plastic bearings in turning-and-grinding machines for printing industry 22 The terms igus, Chainflex, Energy Chain, Energy Chain System, Energy Chains, Energy Chain Systems, ReadyChain, ReadyCable, Triflex, iglide, DryLin, igubal and plastics for longer life are registered trademarks of igus inc.

23 machine tools industry DryLin HTS linear slide table in combination with electrical actuator DryLin delivers smooth and silent operation in the doors of this machine tool Energy Chain has been in operation for nine years in a highprecision turning-and-grinding machine DryLin R linear bearing in filling-shoe mechanism of a compaction unit Energy Chain E6 delivers smooth operation in a CNC grinding machine Energy Chain in a gear-grinding machine with a swivelling range of

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