Smooth operation with energy chains in automatic stamping/bending machines

Bihler uses complete energy chain systems from igus for supplying servo units.

With its RM-NC and GRM-NC machines, Otto Bihler Maschinenfabrik GmbH & Co. KG has developed the fastest stamping and bending servo machine in the world Its key characteristic is a new drive and control concept for the moving tools. Energy is supplied in energy chains containing chainflex cables from igus, delivered as pre-assembled, ready-to-install readychains.

  • What was needed: E2/000 energy chain, triflex R chains, chainflex cablesdrylin linear unit
  • Requirements: Flexible energy supply in mobility and length, compact solution due to limited space in the machine, punching residues require safe solutions that do not get blocked or damaged
  • Industry: Machine factory
  • Success for the customer: Energy supply system perfectly adapted to the requirements of the machines, space-saving and reliable solution
Bihler With a new drive concept to a world record: the fastest servo machine for stamping and bending moves and positions the individual units servo-electrically. Highly visible: the energy chains from igus

Problem

The high-speed servo machines, RM-NC and GRM-NC, of Otto Bihler Maschinenfabrik GmbH & Co. KG produce up to 300 precision parts per minute, and from the customer's point of view, they have the advantage that they are completely compatible with the widely used machines in the RM and GRM series. The Bihler machines work with servo drive technology, a sophisticated control technology with intuitive operation.  The servo drives of the individual units ensure highly precise and fast punching and bending processes.
During the development of the new machines, the question of the energy supply to the six units also came up. Since the arrangement of the units in relation to each other is not fixed, the energy supply system must be very flexible - not only in terms of mobility, but also in terms of length. Furthermore, the movements of the energy supply systems towards each other are not defined. As the space required in or on the machine is limited, the energy supply system must not take up much installation space. And during stamping/bending, sharp and pointed stamping residues can occur at any time, which may block the energy chain or damage the cables.

Solution

Bihler's designers tested various energy supply systems. In combination with the chainflex cables, the E2/000 energy chain from igus proved itself best. A closed version of the chain with an additional protective fabric hose is used in some places within the machine. This prevents stamping residues from getting into the chain. The energy chains in the upper and lower areas have zones with a reverse bend radius so that they can adapt themselves to any desired position and therefore save space. The cables used are [ chainflex servo cables of type CF270.UL.D and encoder cables of type CF113.027.D on the units and for the adjustment drive.
Bihler factory personnel require six energy chains per press, which are filled not only with the comparatively heavy servo cables and signal cables but also with hoses for cooling and lubricant. Each of the six chains has a different length and a defined configuration.  And because Bihler wants to be just as fast and flexible in its own assembly as the users of the Bihler servo machines are in their work, igus supplies a set of six completely filled and assembled chains as "readychains" in a readychain rack specially designed for this purpose.
"Since the arrangement of the units is not fixed, the energy supply system must be very flexible. As the space required in or on the machine is limited, the energy supply system must not take up much installation space. And during stamping/bending, sharp and pointed stamping residues can occur at any time, which block the energy chain or damage the cables. "
 
Dipl.-Ing. Paul Maldoner, Head of Machine Development at Bihler on the requirements for the energy supply system
triflex R energy chains Piggyback principle: A second optional unit level is supplied with power by means of a three-dimensionally movable triflex® R energy chains.
energy chain The energy chains underneath the press and the units must be protected against the ingress of punching residues.

Additional units: Second level with triflex chains

The E2/000 chains are not the only energy chain application in the world's fastest servo punching and bending machines. Customers can order the machines with additional units, which are mounted directly on the existing units on a second level. This option is also frequently used by customers. The servo drives of these units are then supplied - again on a second level - with energy, signals and cooling medium using three-dimensionally moving triflex R chains from the igus product range. The chains are then mounted outside the machine housing. Plain bearings from the igus portfolio are also used in the RM-NC and GRM-NC: The linear axis of the complete press unit travels with a drylin linear unit.
readychain Six at one stroke: igus supplies a complete set of harnessed and filled energy chains in the readychain rack for each machine.