Intelligent breakage monitoring in 22-ton automotive driving simulator

Smart igus e-chains reliably guide energy, data and media in highly dynamic applications

Moving driving simulators have been used in the German automotive industry for 35 years. The world's most modern driving simulator now impresses with the following key data: 2.2MW of electric drive power, "22 tons of agility" and a total value of over euro 25 million.

Description

What was needed: P4.1 rol e-chain, i.Sense EC.B for breakage monitoring, chainflex® 케이블
Requirements: high dynamics of up to 10m/s as well as enormous loads, safe guidance of power, data and other media in one, intelligent accident prevention
Industry: automotive
Success for the customer: increase in plant safety and availability; complete project implementation from a single source; smart early-warning system

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Problem

With its 360° screen, high-speed electric drive and twelve-metre rail for "air-bearing motion", the plant is one of the most powerful systems in the automotive industry. Therefore, it is necessary to safely guide and protect all required cables for the power supply, control system, network technology as well as cooling water and pneumatic hoses in the most efficient way possible.

Solution

Energy chains are like an umbilical cord, supplying energy, data and media, all the while remaining in constant motion.To further increase plant safety and availability, those responsible decided to install new energy chains of the P4.1 series, including a breakage detection system.Should an unforeseen difficulty arise during actual operation in such a highly dynamic application, this can be identified directly with the unique breakage detection i.Sense EC.B from smart plastics. This detects chain breaks at an early stage and avoids high costs due to downtime of the entire plant.

Overview rol e-chain P4.1

Overview condition monitoring EC.B