Low-vibration E4Q-series energy chains in DMF 200|8 milling machines

The DMG MORI milling machine is very precise and agile in five-axis simultaneous machining. Five axes move simultaneously: three linear axes in the XYZ directions, an integrated slewing ring in the machine bed, and the B-axis milling head. The machine features milling speeds of up to 20,000 revolutions per minute with maximum accuracy and precision (in the micrometre range). So it is important that cable and hose guidance cause no vibrations. That is why the manufacturer uses igus E4Q-series energy chains.

Profile

  • What was needed: E4Q energy chain series
  • Requirements: No vibrations during cable and hose guidance
  • Industry: machine tool manufacturing
  • Success for the customer: The E4Q energy chain series ensures low-vibration cable and hose guidance. This energy chain also features low weight and quick installation.
DMG MORI DMF 200|8 five-axis milling machine Machining workpieces with highly complex geometries: The DMG MORI DMF 200|8 five-axis milling machine was developed for the automotive and aviation industries, among others.

Problem

DMG MORI develops and produces five-axis milling machines for the automotive and aviation industries, among others. One of the company's latest developments is the DMF 200|8, a sliding column machine that can be used to process workpieces with highly complex geometries, such as aircraft structural components. The machine features milling speeds of up to 20,000 revolutions per minute with maximum accuracy and precision (in the micrometre range). One of the challenges is guiding cables and hoses so that there is no vibration. Even slight vibration can cause ripples on the workpiece surface.

Solution

To ensure that cables and hoses are guided safely and with little vibration in DMF 200|8 milling machines, DMG MORI decided on the igus E4Q energy chain series, a new energy chain that allows long unsupported travels in machine tools all over the world. The E4Q e-chain guides cables and hoses for energy, hydraulics, pneumatics, and lubrication along the X-axis (2,000mm), the Y-axis (800mm), and the Z-axis (850mm). It is ten percent lighter than its predecessor series, the E4.1. The shaped contours and integrated starting brakes in the chain link stop-dog system reduce noise and vibrations and ensure that the energy supply system starts up and brakes gently. E4Q-series energy chains are not only quiet and low-vibration, but also durable and easy to maintain. DMG MORI also used the igus readychain service. This means that igus experts fill the energy supply systems with the highly flexible cables and hoses and use separators and shelves for interior separation, ensuring that the cables and hoses do not rub against each other during motion and wear out prematurely. The energy chain can also be easily opened to install new cables when maintenance is needed because it has crossbars that can be opened without tools.

Products used

E4Q energy chain series

E4Q e-chain

Tool-free energy chain opening and closing. Low-vibration, maintenance-friendly, and lightweight.
To the product
readychain

readychain

Ready-to-install energy chain system: Have energy chain, cables, connectors, and accessories delivered fully harnessed. 
To the product
Milling machine DMF 200|8 without housing: The milling giant works with a machine bed measuring 2.3m in length and 0.85m in width made of grey cast iron that is suitable for workpieces weighing up to three tons.
Milling machine The e-chains reach DECKEL MAHO in a pre-assembled condition. chainflex cables and hoses for energy, hydraulics, pneumatics, and lubrication are already securely in place in individual chambers.
Milling machine X-, Y- and Z-axis: E4Q-series energy chains ensure safe, low-vibration guidance of the cables and hoses in the milling machine.