No system downtime: 3D energy supply system for robots in the production of body shells

• What was needed:

triflex® retraction system
E-chain package for retraction system

• Requirements: the energy supply had to have a very high tensile strength and a low dead weight, it had to withstand very high forces at a high acceleration of 0 to 2 m/s, in addition to the most adverse environmental conditions such as welding dust.
• Industry: Automotive industry, car body construction
• Success for the customer: no more system downtimes due to cable harnesses breaking off, all robots run trouble-free, the investment was amortised within a very short time

Three press lines and eight body-in-white lines as well as around one hundred robots are in use at MA Automotive of MA Automotive Germany, the highly complex machine park. The company is part of CLN Holding (including MA Automotive), Italy's largest steel service centre based in Turin. The group has 34 locations in Europe and two production sites overseas. 
The site in Vogtland concentrates on the production of individual, structural and outer skin parts made of steel and aluminium. 
Fully automated robot systems characterise the body shell production. In one area, a robot is responsible for handling tailgates. In the past, unforeseen system downtimes have repeatedly occurred here, as the factory-fitted dress pack on the robot could not withstand the cramped conditions on site. It got caught, got stuck and kept tearing off. On average, the entire trade show system stood idle for 657 minutes a year. This meant costs of more than €100,000 per year.
The robot operates a total of eight different stations in the system. It picks up the individual parts very precisely in the fixtures, feeds them to other fixtures before finally stacking the tailgates in two container towers. The space conditions on site are so tight that collision values of a maximum of 3 cm are present in the system.
The key requirements for the energy supply system are correspondingly high. The energy chain system must have a very high tensile strength and the lowest possible dead weight. With a high acceleration of 0 to 2 m/s, it must also be able to withstand very high forces. Added to this are the most adverse environmental conditions, such as welding dust.

Energy supply systems from the triflex® RS system, a compact universal module that guides the energy chain parallel and close to the robot arm in a space-saving manner, have been in use since 2008. It is quick and easy to install on the robot. Thanks to the very low installation height and the slim chain guide, all robot movements can be reliably realised even in the tightest of spaces. The grease-free chain system has an integrated fibre-rod, which means that the energy chain is always kept under tension. In this way, the chain is always guided close to the robot head, even during complex three-dimensional movements, and no loops or cable stress are created.
The triflex® TRC70 used ensures high flexibility for complicated movements. The high tensile force absorption of the chains is achieved by the so-called "trailer principle" (similar to the "ball/housing pad" mechanism). Once engaged, the socket and ball form an extremely flexible connection that combines smooth movements with optimum traction, thus ensuring high tensile strength. Finally, the universal flexibility of the overall system also enables quick teaching.
Another point is the very good mechanical specification of the chain. Impact and abrasion-resistant, robust and dirt-repellent, it repels welding dust in harsh industrial environments. Set-up times are minimised by a simple connection and suitable accessories, such as strain relief systems and clamps in this case.
A total of four problem robots were retrofitted with triflex® R sets. The previous system downtimes are now a thing of the past. All robots are running trouble-free and the investment had already paid for itself within a very short time.