Energy supply system saves assembly time

Profile

• What was needed: energy chain of the E4/4 light system from the 14240 series as a pre-assembled "readychain®" systems
• Requirements: fast assembly of the energy supply, high cycle times and tight bend radius require a hard-wearing 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 to save energy
• Industry: Wood and furniture processing industry
• Success for the customer: pre-assembled readychain® systems enable particularly short installation, the electrical installation time has been almost halved; resilient chainflex® cables withstand the high dynamic load and guarantee high system availability; weight has been reduced thanks to the smooth-running energy chain

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 specialised in handling. HOMAG machines can be used whenever wooden panel-shaped materials need to be transported, stacked, stored, turned or sorted. This ranges from the smallest craft business to international high-tech companies worldwide.
The number of portal systems ordered each year has increased rapidly. The good order situation leads to major space problems in production. We therefore had to reduce the throughput times of the individual systems. The specialist therefore has to save time in all areas, including in the area of energy supply systems, which have to be installed as quickly and easily as possible. However, HOMAG also has other requirements for the energy supply systems due to the way the machines work: High cycle times and tight bend radius put considerable strain on the energy supply system and cable. The travel distances of the gantry and storage systems are between 4 and 60 metres. Speeds of 60 to 290 m/min. are travelled at accelerations of up to 12 m/s². In addition, a cycle output of max. 20 cycles/min. is realised for loading and destacking systems. The operating conditions on site are typical for woodworking - dry, dusty and usually warm.
But weight also plays a major role for HOMAG. In addition to the issue of service life, another major challenge is rising energy prices. The plant manufacturer, who is planning to reduce the energy requirements of the systems by 20 or even 30%, is therefore focussing on lightweight construction, which must also be reflected in all machine components such as the energy supply.

Solution
For over twenty years, igus®-energy chain with matching guide troughs have been used in stacking and storage systems for feeding and destacking furniture parts. More precisely, prefabricated complete systems are used here, the so-called "readychain®" systems. The chains are delivered complete with cables and connectors from igus® and are ready for immediate installation. It also includes bend-resistant "chainflex®" cables to guarantee the increasing dynamic load and high system availability. Part of the product range has been successfully converted to these pre-assembled energy supply systems for some time.
The simple pre-assembled chain solutions also help the machine manufacturer to reduce throughput times. By using this solution, the electrical assembly time has been almost halved. The highly qualified employees no longer have to spend time inserting cables into the energy chain, but can be better utilised elsewhere.
The energy supply systems are also suitable for heavy-duty continuous use in the furniture industry and are characterised by low wear in their moving parts. High cycle outputs are realised with the latest drive and control technology.
Specifically, energy supply systems from the igus® system "E4/4 light", series 14240, were used for the horizontal travelling axis and the vertical lifting axis. They combine two technical specifications: firstly, a reduced wall thickness of the side links and a lighter crossbar, which means less weight and a better ratio of internal to external dimensions. Secondly, a form-fitting rear grip that provides even more lateral stability.
And finally, the smooth-running igus® energy supply systems also help to reduce the energy requirements of the entire system.