Quiet, low-vibration energy supply system for a dynamic machining centre

• What was needed: E6 series energy chain
• Requirements: detailed technical advice due to the demanding system, low space requirement, sensible organisation of the cables within the chain, high travel speeds and accelerations
• Industry: machine tool manufacturing
• Success for the customer: detailed and customised advice led to the use of the E6 series, which scores points for its particularly long service life, extremely quiet and low vibration operation and modular design, no failures have occurred to date despite heavy loads and high travel speeds

"We designed this machining centre especially for machining aluminium and light metal, even in small series," explains Dipl.-Ing. Torsten Keller, a design engineer at Saalfelder Werkzeugmaschinen GmbH (Samag Group) in Saalfeld since 1995. The two-spindle horizontal machining centre with linear drives 'MFZ 500 - 2 linear' in the 3-axis unit, additionally equipped with independent Z and A/B axes for 5-axis machining, is characterised by reduced non-productive times, increased accuracy, a generous clamping area for larger workpieces and multiple clamping solutions as well as fast job changes and high flexibility thanks to the double pallet changing system. It is mainly used in the automotive supply industry for machining cubic parts.
"With our complex machines, technical advice is essential in order to find the best solution. On the other hand, the machines are designed to minimise space requirements, which is why we are happy to take advantage of application engineering support in the run-up to the design stage," says Torsten Keller. "Among other things, it is also important to achieve a sensible organisation of all cables within the energy supply system. The large number of electrical, hydraulic, pneumatic and data cables must be organised in a clear, logical and space-saving manner.
Further requirements for the energy supply systems: Including the cable, they must be able to safely handle axis speeds of 100 or 120 m/min, accelerations of 1 to 1.5 g, spindle speed ranges of 50 to 15,000 rpm and travel distances of 450 to 630 mm at all times. Finally, a wide variety of cooling lubricants that are used in the system and can corrode the individual components must also be taken into account.

Energy supply systems from igus® have been used for many years in almost all of the company's horizontal machining centres and special machines, precisely matched to the respective design requirements.
In the case of the linear machine, igus® recommended the E6 series energy supply system. It shows its particular strength especially with high-speed axes. It has been used in the two-spindle horizontal machining centre with linear drives since 2005 and has impressed right from the start. Despite the high demands of everyday operation, there have been no failures of the energy supply system.
In addition to the long service life, it also offers numerous other advantages. For example, it is characterised by extremely quiet, low vibration operation. The so-called polygon effect, which can occur when an energy supply unwinds, is reduced to a minimum. The extremely low noise level (confirmed by an expert opinion from TÜV Rheinland) is just 46 dB(A).
Another advantage is the modular design of the E6-energy chain: the energy supply can be shortened and extended as required. This is characterised by the elastic spring element made of plastic, which connects the individual side parts to form a very robust energy supply system. Even after 220 million strokes in the endurance test, the connector shows no signs of wear. The absence of the usual bolt/hole connection results in low vibration and quiet running.
The quiet and low-vibration energy supply is tailored to the high speed and acceleration values in direct drive technology and ensures a continuous and reliable supply of all necessary media - from energy and compressed air to control information - even over long distances if required. "The technical consultation paid off for us in the overall concept right from the start," concludes Torsten Keller.