Extreme service life requirements
The approach taken by the design engineers to solve these challenges becomes apparent when the machine panels to the right or the left of the workspace are opened. While the workspace impresses with its extremely clean design in order to provide the user with the greatest possible configuration freedom and straightforward setups, the drive and spindle cavities are densely packed with drive units, spindle sleeve guides and the moving energy supplies to the machining modules. Dr.-Eng. Guido Spachtholz, Design Engineering Manager, Multi-spindle CNC Lathes: "Each specific orientation must be supplied with a variety of media, such as coolant or lubricant for the tooling stations, as well as energy" “
100,000cycles after 17 shifts
The application places extreme demands on the service life of the energy chain: "Executing achievable cycle times of 5 to 10 seconds results in 5,760 cycles per shift –and a corresponding number of movements by the energy chain. " This means: the first 100,000 cycles are completed after only 17.3 shifts. Based on 24 hour/5 day operation, a full year would result in more than 4.5 million cycles! And Schütte would never be satisfied with a component that only has a one-year service life: The machines are known throughout the world for their long service lives.
Continuous improvement: New energy supply systems
From the very beginning, an energy chain was intended for the energy supplies to the machining modules and spindles. But the originally selected model was unable to meet Schütte's high demands. Design engineering manager, Dr. Spachtholz: "When the first units were being produced, our colleagues from the assembly department gave us the feedback that the energy chains were difficult to fill. We then started looking for an alternative." “
The solution was found not far from Schütte' s manufacturing facility, which is ideally located directly along the Rhein River and only a few kilometers away from Cologne's inner city: The triflex® R energy chain from the Cologne-based energy chain experts, Igus, was originally developed for demanding six axes robot applications in rough industrial environments, e.g. for axial and rotational chain movements.
Easy filling down to the last centimeter
The "R" in the product designation stands for "round", and with a construction kit of more than 100 individual components, the triflex® R can be precisely configured for any application. In spite of its tensile strength, the three section 3D chain can be filled with ease –down to the last centimeter. Dipl.-Eng. Markus Rudat, who managed the project design engineering effort: "Even media lines that have a fairly large cross-section, such as coolant lines, can be effortlessly clipped into the chain." “
Consequently, Schütte's assembly staff was quickly won over by the new e-chain®. And the design engineers favored the compact design, which is of particular importance given the limited space availability in the machine. The triflex® R provides more space for lines than the previously used model, and since it does not need a steel cable due to its accurately manufactured ball joints, it is also highly flexible.
Long service life confirmed under real-world test conditions
It was of particular significance to Schütte's design engineers that the chain performed at least as well as the previously used competitive model with respect to service life. Dipl.-Eng. (FH) Markus Kogelmann, Igus Sector Manager for machine tools, took the Schütte tests in stride: "The triflex® R is fundamentally designed for a very long service life, even under the most demanding loads." “