Resilient energy supply systems and cables for linear drive technology from HIWIN
Highest requirements in automation: e-chains and cables in continuous operation
Direct drive technology is now an important part of automation. Linear motor axes for high-end positioning are becoming increasingly popular. The highly complex technology requires detailed technical advice in advance for each application and accordingly robust components during implementation. For example, energy supplies and cables must guarantee a long service life despite extreme acceleration. After several years of working with the automation expert HIWIN, a positive balance could be drawn.Profile
- What was needed: chainflex servo cables and measuring system cables, delivered harnessed with connectors on both sides as a so-called readycable; E2/000 type energy chains
- Requirements: high accelerations of up to 10g, speeds of up to 5m/s, little available installation space, high expectations in terms of service life and nominal voltages of 600V for the cables, as well as a required UL approval.
- Industry: automation technology
- Success for the customer: the chains and cables prove themselves worldwide and in a wide variety of applications. For example, when cutting pipes in the automotive industry, energy supply system and cables operate practically without wear, despite the large amount of chips.
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Problem
To enable even more precise and even faster positioning tasks in handling technology, lead screw and toothed belt drives are increasingly being supplemented or replaced by linear motor axes.As a universal supplier, the Taiwanese manufacturer of linear technology, HIWIN, offers standard solutions for the majority of applications that require linear, planar or three-dimensional movements. The product portfolio ranges from simple profile rails and ball screws to complete positioning systems with motor axes, linear modules and position measuring systems.In addition to profile rails and motors for the drive technology, other components such as the energy supply and cables must also be offered. For the demanding fields of application of the linear systems, which range from automotive engineering to the semiconductor industry, the purchased parts must also be of topmost quality. The ambient conditions can demand everything from the components: use in cleanrooms is just as possible as in extremely dirty environments.
In addition, the e-chains and cables have to withstand high accelerations of up to 10g, speeds of up to 5m/s, little available installation space, high expectations in terms of service life and, for the cables, nominal voltages of 600V as well as a required UL approval. In the search for a supplier for these components, other economic considerations, such as the commitment of a steady supplier, were also relevant for HIWIN. This should offer the widest possible range of products in the portfolio and thus have a solution ready for every requirement.
Solution
We have been supplying both the energy supplies and the cables for HIWIN for years. Our servo cables from the chainflex CF27 series and measuring system cables from the chainflex CF211 and CF111.D series meet the cable requirement. Due to the compact design, with gusset-filling extruded inner jacket and highly abrasion-resistant PUR outer jacket, the 'CF27' series is suitable for the highest demands. With it, an acceleration of up to 100g can be achieved without any problems. In order to be able to ensure the highest possible electromagnetic compatibility security, a shield with special braiding with an optimised braid angle and 90% optical coverage is used, which does not lead to shield wire breakages even with high stroke rates of linear drives. Additionally used are the measuring system cables 'CF211' for high demands and 'CF111.D' for particularly oily wet areas. Both the servo and the measuring system cables are supplied as so-called readycable, i.e. they arrive at the customer pre-assembled with connectors on both sides.The cables are guided in the two-piece energy supply lines of type E2/000 in the 1400 and 2400 series. The energy chains with integrated strain relief in the connection area are characterised by their high mechanical strength combined with quiet operation. The design and material ensure a long service life - including the internal cables. They can easily be replaced using the simple openable mechanism. Today, the energy supply systems have proven themselves worldwide in a wide range of applications.
Pipe cutting machine, inspection machine, welding machine: areas of application for linear motors in detail
These three examples show that linear motors have a wide range of requirements: a customer from the automotive industry wanted to cut stainless steel tubes with holes. For reasons of optics, the cut should not go through a hole, but between two holes, which is done with the help of a camera. The tube is positioned using a camera. The actual position is transmitted in the 50 microsecond range. The axis positions to 2µ in 3.5m/s; the acceleration is in the 2g range. Accuracy, dynamics and a high number of cycles were the design challenge. The entire system with energy supply and cables operates practically wear-free - despite the high chip volume.Other applications are in the quality control of wafers. Here, high-precision XY tables with air bearings are used in the cleanroom as a prerequisite for surface inspection. An air bearing table moves here with an accuracy of half a µ. Or in a horizontal high-speed heating element welding machine for welding plastics: linear axes with absolute position measurement are also used here. The tubes are pressed against the heating plates. If you press too hard, the bulge will be too strong; if you press too little, there is no support. This means that force-controlled pressure must be applied to avoid the 'stringing' of the material. The mixture of dynamics and force control is another argument for linear motors.
