igus Blog https://blog.igus.eu News from the igus® divisions Thu, 01 Feb 2024 09:59:56 +0000 en-US hourly 1 https://wordpress.org/?v=6.4.3 https://blog.igus.eu/wp-content/uploads/2018/05/cropped-icon-32x32.png igus Blog https://blog.igus.eu 32 32 The solution to a shrinking circular economy: a simple, reliable recycling platform https://blog.igus.eu/the-solution-to-a-shrinking-circular-economy-a-simple-reliable-recycling-platform/ https://blog.igus.eu/the-solution-to-a-shrinking-circular-economy-a-simple-reliable-recycling-platform/#respond Thu, 02 Nov 2023 00:00:00 +0000 Corporate content]]> https://blog.igus.eu/?p=21787 The global circular economy is shrinking. It is high time to act. One solution would be to recycle technical plastics, but that has so far been quite cumbersome. We will show you how plastic recycling is finally becoming easy.

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The global circular economy is shrinking. It is high time to act.

One solution would be to recycle technical plastics, but that has so far been quite cumbersome.

We will show you how plastic recycling is finally becoming easy.

Climate change is progressing, and more and more branches of industry are struggling with material shortages. These are two good reasons why valuable materials should, in the future, no longer be disposed of with industrial waste and incinerated, but instead be reused. The term “circular economy” is on everyone’s lips, suggesting that recycling rates are increasing. Unfortunately, the opposite is the case.

The circular economy is shrinking

The Circularity Gap Report 2023 by the Circle Economy Foundation and the Deloitte Group shows this clearly: The global circular economy has shrunk from 9.1 per cent in 2018 to 7.2 per cent now.

“The circular economy is the key to curbing both the climate crisis and the loss of biodiversity. So the size of the gap between the current global economy and a comprehensive circular economy is alarming, even though the importance of the latter is repeatedly underscored by politicians and companies,” says Rebecca Tauer, Circular Economy Programme Manager at WWF Germany. “And the widening of this gap is dramatic because we are taking more and more resources from the planet, using them for far too short a time, and throwing them away. We’re on the wrong track. The report’s message is clear: We need to move from talking to doing.”

From talking to doing – igus has heard the call

To accelerate the transition from a linear economy to a circular economy, igus launched a technical plastics recycling programme: chainge.

Recycling made easy – with chainge

The idea is to make recycling simple at long last. But it has so far not been obvious that this can be done. For example, users of energy chains for guiding power cables and hoses in machines and systems are repeatedly faced with several questions: Who is responsible for recycling the chains? Will they be recycled properly? And what happens to the recycled material?

The answers are often so complicated that the chains simply end up in industrial waste and are incinerated. The emissions pollute the environment, valuable plastics are lost to the circular economy forever, and there is an uneasy feeling that things aren’t going as they should. And then there are the disposal fees.

Recycling is easy with chainge

But it doesn’t have to be like that. The chainge.igus.de online platform offers a simple, reliable alternative. Owners of worn-out energy chains can have them recycled on the platform, keeping them in the circular economy. They can do this in just a few steps:

  • Collect, clean, and weigh old energy chains
  • Make a recycling request
  • Send old chains to igus
  • Receive a voucher from igus
Environmental protection, renewable, sustainable energy sources. Plant growing in the bulb concept

At igus, old chains are processed into recycled material used to manufacture new products, such as the cradle-chain E2.1.CG, the first energy chain made entirely from recycled plastic. The voucher can then be used to purchase these or other igus products.

“The special thing about igus is that you get everything from a single source. We are a plastics producer and supplier, an assembly service provider, a disposal company, and a producer and supplier of recycled material used to create new products,” says Michael Blaß, igus e-chain systems CEO. “What we offer is unique in this form and enables us to work with our customers to turn plastic into a sustainable resource.” So the company also strives to integrate further locations into chainge and increase capacities in order to make an even greater contribution to the circular economy.

The first steps towards sustainable plastic utilisation have been taken

Since the chainge launch in 2019, the programme has rapidly gained momentum. igus has saved almost 100,000 kg of high-performance plastic from incineration and returned it to the circular economy. Recycling has now been extended beyond energy chains to smaller components made of technical plastics, such as gears and bar stock.

“It is the innovative power of entrepreneurs that finds, applies, and passes on solutions,” said Sven Gebhard, Vice President of the Cologne Chamber of Industry and Commerce, during his laudatory speech at the Going Circular competition, in which igus took first place with chainge. The contest, he said, is aimed at raising awareness of the circular economy mega-issue and motivating other companies to look for ways to conserve resources themselves. “This is how global climate protection can succeed.”

Plastics production in Germany is to be independent of crude oil by 2045

Politicians are pursuing an ambitious goal for the circular economy, that of largely using circular raw materials in plastics production starting in 2045. To accelerate this development, chainge offers more than plastic recycling. Injection moulding companies from all over the world can also purchase recycled materials on the platform from which sustainable products can be manufactured. The platform can also be used to sell recyclates. Recyclers can become chainge partners and sell their material on the marketplace.

“The holistic closing of material cycles is a central key to sustainable economic activity and thus to achieving climate targets,” says Holger Lösch, Deputy Managing Director of the Federation of German Industries (Bundesverband der Deutschen Industrie, or BDI), on the founding of the BDI Circular Economy initiative. “Thanks to its high level of technological expertise, Germany as an industrial location has enormous potential to become a leading provider of new technologies that allow economically viable raw material recycling and reduce dependence on raw material imports.”

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The chainflex® service oasis https://blog.igus.eu/the-chainflex-service-oasis/ https://blog.igus.eu/the-chainflex-service-oasis/#respond Mon, 16 Oct 2023 23:00:00 +0000 https://blog.igus.eu/?p=21776 In today’s increasingly globalised world, service is often a nuisance for everyone. You have a problem with a household appliance, perhaps an oven, and you have specifically chosen a German brand. Luckily, the instructions also include a flyer with service numbers for each country. But when you enter the number into your phone, you always […]

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Group of light bulbs with shining fibers in shapes of Service, Advice, Quality, Help and Customer concept related words isolated on black background

In today’s increasingly globalised world, service is often a nuisance for everyone. You have a problem with a household appliance, perhaps an oven, and you have specifically chosen a German brand. Luckily, the instructions also include a flyer with service numbers for each country. But when you enter the number into your phone, you always end get the same call centre. On the other end of the phone, a computerised voice asks about the problem so as to connect you correctly: “Please say ‘defective device’.”

Opened broken oven door in the kitchen, side view, close-up. Broken glass from overheating. Broken glass from impact. Warranty repair. Repair of electric stoves and ovens

After you have said ‘defective device’ ten times, with a bit more emphasis the last time, you are finally connected – and find yourself on hold. After what feels like half a day of listening to elevator music, you finally have a real person at the other end of the line. You describe your problem in detail but, as is unfortunately often the case, the problem cannot be solved there. Everyone hates this experience, which has little to do with service.

Fortunately, this will not happen to you at igus®!

With our customer service right in Cologne, branches worldwide and countless service partners, you always have the right contact person where you are. Regular employee training by our experts guarantees excellent service “Made in Germany”. You can find out more about the igus® advantages here. However, igus® doesn’t stop at a simple telephone service and a personal point of contact.

But what exactly does service mean at igus®, and what does it mean for you?

Let’s start in a really simple way: you are looking for a replacement cable for your defective system, and you find a link to our website in a blog article like this one. In addition to the blog, you find other sources of information about the right cable, and you find what you were looking for.

At this point, you have already familiarised yourself with a variety of igus® services without consciously noticing them. The countless online tools, the wiki and the blog have enabled you to find the right cable quickly and easily. This blog article will tell you more about our digital means of assistance.

You have now arrived in the shop and placed your cable into your shopping cart. Since this is a repair, you need only a few feet of this cable, not an entire drum. Still, the price per metre is the same as the initial list price for 100m. There are no additional costs apart from the copper surcharge and shipping costs. You are puzzled and investigate, even though the answer is so simple.

There are no hidden costs for chainflex®.

No cutting charges! No minimum quantity surcharges! No packaging costs!

There are no cutting charges or minimum quantity surcharges for our chainflex® cables, nor are there any minimum order values or price increase surcharges. If you need only eight metres of cable, you should pay for eight metres of cable.

Kosten (German for Cost) message on torn blue paper revealing secret behind ripped opening.

The best part is that you will receive cables in stock after just a few days and with a 36-month guarantee! This gives you the necessary security and reliability and helps to avoid failures and unplanned downtimes.

We have summarised further information about the chainflex® benefits for you here.

Contacting igus

Speaking of downtimes, perhaps one of our experts should visit you to find out whether there is potential for improvement in your systems. This prevents expensive downtimes. The service is free of charge – the igus® motto is “The easiest company to deal with”, and we prove every day that we are.

If you would like to experience the igus® service for yourself, just call your contact person . A motivated and technically interested team will be happy to respond to your request.

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How did the TRX come about and is it THE robotics innovation? https://blog.igus.eu/how-did-the-trx-come-about-and-is-it-the-robotics-innovation/ https://blog.igus.eu/how-did-the-trx-come-about-and-is-it-the-robotics-innovation/#respond Wed, 06 Sep 2023 23:00:00 +0000 https://blog.igus.eu/?p=21769 One day after the trade show It happened near the beginning of the Hannover Messe, not all that long ago. They say that sometimes the best ideas come from a mix of nonsense and a little alcohol. Something like that must have been in play when the idea for the TRX emerged. Two exhausted, thirsty […]

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One day after the trade show

It happened near the beginning of the Hannover Messe, not all that long ago. They say that sometimes the best ideas come from a mix of nonsense and a little alcohol. Something like that must have been in play when the idea for the TRX emerged. Two exhausted, thirsty igus employees sat at a hotel bar a little too long after a tough day at the trade show and started talking: “Hey, what would happen if…?” The result would be nothing less than THE next innovation in robotics.

How an idea became a product

One of them was responsible for flexible cables (chainflex®), and the other was working with the round triflex R chain, which could be moved in three dimensions. They wanted to create the perfect product for both areas. The first idea was the telescoping cable, which was quickly rejected as a “nutty idea”. So they thought about how to further optimise the movement of a retraction system with a flexible cable by eliminating components. At the time, there was no alternative to the retraction system on an industrial robot. (In many applications, there still isn’t.)

triflex R chain: a retraction system for an industrial robot

But something was missing: Something could be adapted to save space and weight, and, most importantly, reduce costs. Why can’t the triflex R energy chain also do the retraction system’s work? “Like a rubber band,” one of them said. The other replied, “Yeah! Just like a rubber band!” With that, they went off to bed, because there was more trade show the next day.

“After the trade show is before the trade show”

There must not have been too much alcohol involved because on the next day of the trade show, both of them remembered the rubber band concept very well, and they decided to present their crazy idea to a developer when they got back to Cologne. Design engineers are not known for their patience with craziness. Their response is generally “What has sales come up with now?” The idea was viewed critically, but not dismissed as impossible.

As we all know, after the trade show is before the trade show, so they decided to give the idea a chance. It did provide a potential innovation for next year’s trade show, and there was a whole year of development time. Perfect. One of the two employees from the beginning of the story recently told me that “innovation by elimination” was one idea behind the TRX: “Develop something new and try to get rid of as much as possible.”

But, as with every good story, the devil was in the details. You couldn’t simply repurpose an existing, established TRE.60.087.0.B by putting a rubber band through it. The high-tensile-strength core element that can be moved in three dimensions is one of the triflex R TRE chain’s special features and strengths and cannot simply be replaced.

The development and sales team decided to attempt a completely new design, which has much the same look as the existing TRE chain, so the two can be connected.

After countless meetings and tests, the TRXE was presented as a design study at the 2021 Hannover Messe.

TRXE design study with cables and hoses

What the TRX was to achieve as a robotics innovation

In the world of automation technology, reliable energy supply plays a crucial role. Companies are constantly looking for innovations that are both durable and efficient. In this context, a “crazy idea” became a robotics innovation. It was groundbreaking and became especially popular in the area of handling packages.

TRX structure + durability + efficiency

The TRX consists of special modules that allow the energy chain to bend in any direction. This increases flexibility and prevents unnecessary tension or kinks in the cables. Flexibility is not limited to 3D movement; the wobbly chain link shape also allows telescoping movement. The rubber band in the middle of the TRX ensures that the chain contracts again.

Long service life and freedom from maintenance: One of the greatest strengths of the TRX is its long service life. The energy chain is made of high-quality, wear-resistant plastic, ensuring reliable function even under extreme conditions. The small number of add-on parts (the retraction system has been eliminated) greatly reduces maintenance costs.

Energy efficiency and safety: The TRX is also energy-efficient. The optimised design minimises friction, wear, and especially weight, reducing energy consumption. This benefits both economy and ecological performance.

Conclusion

Conclusion: The igus TRX is undoubtedly a milestone in energy chain development. Its innovative design, durability, energy efficiency, and simplicity make it a future-oriented solution for energy supply to robots and industry in general. The TRX reduces maintenance costs in the area of handling packages and extends service life. The igus TRX proves that relaxed banter can return a high-tech innovation. You just have to believe in yourself.

Sources:

Telescopic triflex R TRX | 3D movements | igus®

https://www.igus.eu/product/21456

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Changes in the economy due to the industrial metaverse: More than just hype https://blog.igus.eu/changes-in-the-economy-due-to-the-industrial-metaverse-more-than-just-hype/ https://blog.igus.eu/changes-in-the-economy-due-to-the-industrial-metaverse-more-than-just-hype/#respond Thu, 13 Jul 2023 23:00:00 +0000 https://blog.igus.eu/?p=21738 The industrial metaverse is like a digital parallel universe where people from all over the world work together as avatars – faster, more efficiently, and in a more environmentally friendly manner than in the real world. But what does it mean in concrete terms for our economy? Imagine you are Robert Müller, an engineer working […]

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The industrial metaverse is like a digital parallel universe where people from all over the world work together as avatars – faster, more efficiently, and in a more environmentally friendly manner than in the real world. But what does it mean in concrete terms for our economy?

Imagine you are Robert Müller, an engineer working for a machine tool manufacturer. On a Monday morning, you are preparing for an important meeting with engineers from all over the world. The special thing about the meeting is that nobody has to take a long, expensive journey. Everyone just puts on a virtual reality headset and immerses themselves in the industrial metaverse, where they work together on 3D models as avatars.

Picture: Virtual engineering, here on a realistic model of a machine tool (Source: igus/Holo-Light)

Many might dismiss the metaverse as temporary, but Dr Dietmar Laß, Senior Research Manager for the Fraunhofer ICT Group, says, “The metaverse is more than hype. It is coming in some way and to some extent.” Large companies such as Siemens Energy, BASF, Kawasaki, SAP, ABB, and Rockwell Automation are already experimenting with it and using the technology to do such things as set up virtual laboratories and agile robot factories and plan maintenance work.

But large companies are not to be the only ones to enjoy the advantages of the metaverse. They are for SMEs as well. This is where igus comes in with the iguverse, a kind of software-as-a-service planned for the medium term. So even companies with a low degree of digitalization and a limited budget can harness the advantages of virtual reality – without incurring their own development costs. igus builds digital, copy-protected twins for the digital space and even offers digitalisation for old products. Suitable VR headsets and controllers for rent are also in the plans.

Video: SK Laser’s customer machine in the iguverse. Shows the picking process with an igus delta robot (source: igus, RAUM)

The iguverse offers a multitude of new possibilities, such as the presentation of virtual twins of products and the implementation of complete engineering projects with engineers and material experts from all over the world. It even allows designing a virtual shop floor with suppliers and then transferring it to the real world – with augmented reality.

Picture: An AR model of a robot with real-size igus products projected into a production hall (source: igus)

Do you think the industrial metaverse is hype or the future? Let us know in the comments!

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Is professional energy chain installation worth it? https://blog.igus.eu/is-professional-energy-chain-installation-worth-it/ https://blog.igus.eu/is-professional-energy-chain-installation-worth-it/#respond Wed, 12 Jul 2023 23:00:00 +0000 https://blog.igus.eu/?p=21737 Today I would like to introduce a topic that is often overlooked or not taken seriously, but can have a significant impact on the success of your business: professional energy chain installation. Whether you run a small manufacturing operation or manage a medium-sized facility, investing in the right expertise for your energy chain systems can […]

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Today I would like to introduce a topic that is often overlooked or not taken seriously, but can have a significant impact on the success of your business: professional energy chain installation. Whether you run a small manufacturing operation or manage a medium-sized facility, investing in the right expertise for your energy chain systems can save you lots of hassle. So let’s find out why professional installation services are worth every penny.

Why settle for less than optimal functionality?

For energy chain systems, functionality is key. Of course, you might be tempted to install such systems yourself, but there are several things that can go wrong if you don’t have the expertise. When you choose our professional installation, you are enlisting the help of our experts, who will assess your specific application needs and select the components that will ensure that your energy chain system runs smoothly.

Specialists install a ready-to-connect energy chain system.

Extend the service life of your cables and hoses

You’ve probably heard horror stories or even seen photos showing premature cable wear and damage. It is often the result of improper design or poor installation practices. Our fitters will avoid such nightmares. They ensure optimal installation for your energy chain system, guaranteeing function and maximising service life.

Minimise downtime, maximise reliability

Downtime is a productivity killer and can affect your operating results. This is where the professional installation service comes in. Our experts can install your energy chain system efficiently and safely so that it works perfectly right from the start. By detecting and correcting potential problems such as misalignment, cable stress, and insufficient support right at the point of implementation, they significantly reduce the risk of unexpected failures and minimise costly downtime and damage.

Installation on a sand extractor.

Take advantage of our experts’ industry knowledge

When dealing with energy chain systems, it pays to have access to industry knowledge. Our staff keep abreast of the latest trends, advances, and best practices so that you can benefit from their insights. The experts can advise you on system selection, customisation options, and maintenance strategies, enabling you to make sustainable decisions. Your energy chain system will then always be optimised for your specific requirements.

Yes, professional installation is always worth it!

I have given you a few arguments showing why professional installation by energy chain experts is worthwhile for your company. When you invest in our experts’ knowledge, you ensure optimal system functionality, extend service life, enhance safety in the workplace, minimise costly downtime, and prevent damage.
Remember: Leave energy chain installation to professionals who know the subject inside out. Don’t settle for less than exceptional results for your business. And did I also mention that when you order a complete system, you get a guarantee of up to 36 months on the energy chain and chainflex cables?

Acceptance of an installed energy chain system.

What are you waiting for?

If you are ready to unleash the true potential of your energy chain systems, contact our reliable, professional project planning team. Your business deserves the best, and the right installation services can get you there.


Stay tuned for more technical insights and practical tips for improving your processes. Until next time!

More about project planning

Discover general information

Find out about the installation service

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Changing airport gangways: igus® e-chains® and smart plastics for the future https://blog.igus.eu/changing-airport-gangways-igus-e-chains-and-smart-plastics-for-the-future/ https://blog.igus.eu/changing-airport-gangways-igus-e-chains-and-smart-plastics-for-the-future/#respond Tue, 20 Jun 2023 23:00:00 +0000 https://blog.igus.eu/?p=21736 Airports rely on gangways to allow passengers to board and disembark conveniently. If the gangways fail, getting into the aircraft is much more difficult. One way to prevent gangway disruptions is to use igus e-chains and i.Sense EC.P condition monitoring.

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Airports rely on gangways to allow passengers to board and disembark conveniently. If the gangways fail, getting into the aircraft is much more difficult. One way to prevent gangway disruptions is to use igus e-chains and i.Sense EC.P condition monitoring. With e-chains, gangways function smoothly, and the need for maintenance is also recognized at an early stage with i.Sense EC.P condition monitoring. igus smart plastics provide a reliable, maintenance-friendly solution for gangways.

Efficient gangways at Cologne Bonn Airport thanks to igus e-chains

Cologne Bonn Airport is one of the busiest in Germany. Coping with increasing passenger traffic requires continuous infrastructure improvement. A decisive factor in this refinement is efficient, reliable passenger handling. This is where igus applies its innovative solutions.

The airport chose energy-saving, easy-to-maintain e-chains from igus. These e-chains not only ensure a secure energy supply, but also allow flexible gangway movement. They also reduce operating costs and enhance gangway availability and safety. The e-chains feature a robust design and resistance to environmental influences. They offer protection against dust, dirt, and moisture, which is particularly important at airports. The e-chains’ energy-saving properties also contribute to sustainable airport operation.

e-chains are replacing festooning systems

Many airports used to use festooning systems for their gangways, but those systems entailed frequent disruptions and high costs. Festooning systems consist of a large number of parts, such as pull ropes, shock cords, bearings, and wheels. These parts must be lubricated frequently. The cables hang freely, so they require a great deal of space. They are also exposed to the elements and therefore highly susceptible to damage. And they are bundled together in a jacket, making maintenance longer and more difficult.

To avoid these problems, many festooning systems are being replaced by energy chains. The e-chains are made of wear-resistant, lubrication-free high-performance plastic with a long service life. And e-chains do not hang freely, but are guided as a chain. The chain links keep the cables from snagging and bending. The e-chain protects the cables from environmental conditions and dirt. Crossbars make servicing cables and chain easy, avoiding long downtimes.

i.Sense EC.P condition monitoring – The smart monitoring solution for gangways

To further improve gangway efficiency and reliability, igus has developed the i.Sense EC.P condition monitoring system. This innovative system allows continuous monitoring of important components in real time to detect failures at an early stage.

The i.Sense EC.P system is based on smart plastic components that are equipped with sensors and collect data on various parameters such as temperature, wear, and vibration. This data is transmitted to a central system, where it is analysed to predict maintenance needs and allow targeted action before there is a failure.

These smart plastics now enable Cologne Bonn Airport to proactively identify potential problems and plan appropriate maintenance measures. Gangway operating time improves, as does passenger safety.

In addition to preventive maintenance, the i.Sense EC.P system allows data-based decision-making and helps airport staff to develop long-term maintenance strategies. Analysing the collected data reveals anomalies at an early stage, so gangway availability can be continuously improved.

Gangways play a crucial role in passenger handling at airports. Maintenance-friendly igus energy chains and the i.Sense EC.P condition monitoring system are smart solutions that greatly improve gangway efficiency, reliability, and safety. Cologne Bonn Airport is a great example of how innovative igus solutions optimise operations and contribute to a pleasant travel experience. With igus on board, the future of gangways is moving in a smart, effective direction.

To find out more about intelligent, reliable smart plastics, visit our website:

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Innovative, efficient washing facility solutions with igus® e-chains® https://blog.igus.eu/innovative-efficient-washing-facility-solutions-with-igus-e-chains/ https://blog.igus.eu/innovative-efficient-washing-facility-solutions-with-igus-e-chains/#respond Tue, 13 Jun 2023 23:00:00 +0000 https://blog.igus.eu/?p=21755 Defective conveyor belts in washing facilities repeatedly lead to expensive damage and breakdowns. So more and more companies are switching to sensor-supported, networked igus e-chains as part of a modernisation effort.

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Defective conveyor belts in washing facilities repeatedly lead to expensive damage and breakdowns. So companies are switching to sensor-supported, networked igus e-chains as part of a modernisation effort. The interaction of condition monitoring and predictive maintenance enables operators not only to avoid total loss, but also to know exactly when damage will occur and how it can be avoided. Unplanned downtime is a thing of the past.

Challenges due to extreme operation in washing facilities

Washing facilities play a crucial role in the cleaning and maintenance of various vehicles and machines. However, for smooth, efficient operation, washing facilities must overcome a variety of challenges. One of the main problems is the extreme environmental conditions to which the facilities are exposed. High humidity, strong water jets, temperature fluctuation, and aggressive cleaning agents put an enormous strain on materials. Conventional solutions often reach their limits and are unable to meet the long-term requirements.

The advantages of igus smart plastics

There are many advantages to using igus smart plastics in washing facilities. The e-chain ensures reliable cable guidance in the facilities. It adapts flexibly and without friction to system movements and protects cables and lines against damage from cleaning agents and dirt. The solution requires no lubrication or maintenance and increases facility efficiency and reliability. igus smart plastic solutions are tailored specifically to industry requirements and offer an optimal combination of durability, resistance, and efficiency.

Flexible protective hoses can also be used to protect cables and lines from external influences. These hoses are flexible, durable, and very resistant to water and cleaning agents.

Smart sensors allow for energy chain condition monitoring and predictive maintenance in real time

But even the most reliable energy chain can develop defects. A tool or other foreign object may accidentally be left in the guide trough. To prevent total loss in such a case, igus can equip washing facility energy chains with i.Sense, a condition monitoring system that consists of several components. A force sensor called EC.P measures the push/pull forces during operation. Information then reaches an evaluation module to stop operation and sound an alarm when there are deviations from the normal force range to prevent complete failure.

For even more control, the optimal intervals for servicing the system can be calculated with predictive maintenance. To this end, igus has installed an i.Cee module in the washing facility control cabinet. Like the evaluation module, it receives the force values from the EC.P sensor. There are also data from other sensors that measure e-chain abrasion and the ambient temperature, so just a few staff can maintain a full washing facility overview.

igus smart plastics application examples in a Luxembourg train washing system

Defective energy chains in the train washing station of Luxembourg’s state railway company repeatedly led to expensive damage and train cancellations. So those responsible switched to sensor-supported, networked igus e-chains as part of a modernisation effort.

The 200-metre washing station consists of eight washing trolleys, four on each side, which travel along the train on a rail system of around 50 metres, cleaning it with rotating brushes. Hoses and cables for energy, compressed air, water, cleaning agents, and data follow the vehicles in robust energy chains made of igus high-performance plastic.

The interaction of condition monitoring and predictive maintenance enables the operator not only to avoid total loss, but also to know exactly when damage will occur and how it can be avoided. This means that unplanned downtime is a thing of the past.


Interested? Would you like to verify the quality of igus motion plastics for yourself? Then visit our website with all the products that we manufacture for washing facilities:

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Technical plastics vs. high-performance plastics vs. plastics for movement https://blog.igus.eu/technical-plastics-vs-high-performance-plastics-vs-plastics-for-movement/ https://blog.igus.eu/technical-plastics-vs-high-performance-plastics-vs-plastics-for-movement/#respond Sun, 04 Jun 2023 23:00:00 +0000 https://blog.igus.eu/?p=21754 Technical plastics Technical plastics are a subgroup of thermoplastics that differs from standard plastics, high-performance plastics, and functional plastics in terms of properties and price (1). They are used for many applications including bearings, rollers, wheels, seals, and moulded parts (2). Examples of technical plastics include polyvinyl chloride (PVC), polyamide (PA), polyoxymethylene (POM), polycarbonate (PC), […]

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Technical plastics

Technical plastics are a subgroup of thermoplastics that differs from standard plastics, high-performance plastics, and functional plastics in terms of properties and price (1). They are used for many applications including bearings, rollers, wheels, seals, and moulded parts (2).

Examples of technical plastics include polyvinyl chloride (PVC), polyamide (PA), polyoxymethylene (POM), polycarbonate (PC), and polyetheretherketone (PEEK) (3) (2) (4). These materials have specific electrical, thermal, and mechanical properties that make them suitable for specific applications (5). Technical plastics are usually produced in injection moulding, extrusion or other special manufacturing processes (6).

Sources:
1) https://en.wikipedia.org/wiki/Engineering_plastic
2) https://tecoplast.de/technische-kunststoffe
3) https://www.fritsche.eu.com/produkte/kunststoff/technische-kunststoffe/
4) https://kdfeddersen.com/competencies/engineering-plastics/polymers/
5) https://www.buckundsohn.de/fertigteile/bearbeitung-technischer-kunststoffe/
6) https://www.ggbearings.com/en/why-choose-ggb/faq/bearings-faq/what-ep-or-engineered-plastics

High-performance plastics

High-performance plastics, also known as high-tech plastics or high-performance polymers, are a subgroup of plastics that meet higher requirements than standard or technical plastics. They are more expensive and used in smaller amounts. High-performance plastics differ from standard plastics and technical plastics primarily in their temperature stability, chemical resistance, and mechanical properties. They are used where standard plastics or technical plastics cannot meet the requirements. High-performance plastics are an alternative to metal or ceramics and offer a number of advantages. In many cases, they can replace metals or ceramics. Examples of high-performance plastics include liquid crystal polymers (LCP), polyethersulfone (PES), and polyphenylene sulphide (PPS). In the category of high-performance plastics, one or more properties are greatly improved, depending on the application (7) (8) (9) (10).

Sources:
7) https://www.tw-plastics.de/en/products/high-performance-plastics/
8) https://www.terplastics.com/en/products/technical-plastics/high-performance-plastics.php
9) https://en.wikipedia.org/wiki/High-performance_plastics
10) https://tecoplast.eu/high-performance-plastics

Picture igus GmbH: igus igubal plastic spherical balls, or motion plastics

motion plastics

motion plastics, or tribo-polymers, are a type of high-performance plastics optimised for friction and wear. They are used where standard plastics or technical plastics cannot meet requirements. motion plastics are designed to reduce costs and extend service life. They have enormous potential in industry and offer a multitude of advantages. The technology consists of tribo-polymers, or high-performance plastics that have been optimised for friction and wear. These materials are used in moving applications such as plain bearings, linear guides, and vertical farming automation. motion plastics are lubrication-free, often FDA-compliant, and resistant to dirt, dust, and soil. They are also corrosion-free and low-maintenance. igus is a manufacturer of motion plastics and develops and tests tribologically optimised high-performance plastics for moving applications (11) (12) (13) (14) (15).

Sources:
11) https://www.igus.eu/info/products
12) https://jisigus.com/brochures/EU_industry-solutions_web.pdf
13) https://insights.globalspec.com/article/19186/ecological-plain-bearings-made-from-regranulated-tribo-plastics
14) https://www.igus.eu/info/linear-guides-dry-tech-tribopolymer
15) https://www.foodmanufacturing.com/products/food/product/21114597/igus-how-motion-plastics-make-vertical-agriculture-sustainable

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Revolutionizing the circular economy with the igus® Chainge program – redefining technical plastics recycling https://blog.igus.eu/revolutionizing-the-circular-economy-with-the-igus-chainge-program-redefining-technical-plastics-recycling/ https://blog.igus.eu/revolutionizing-the-circular-economy-with-the-igus-chainge-program-redefining-technical-plastics-recycling/#respond Sun, 04 Jun 2023 23:00:00 +0000 https://blog.igus.eu/?p=21753 The igus Chainge program is a recycling program (post-consumer recycling or post-industrial recycling) for energy supply systems and energy chains. The program enables customers to recycle their old energy chains in exchange for a voucher. The old energy supply systems and energy chains are sent to igus, where the plastic material is separated and shredded […]

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The igus Chainge program is a recycling program (post-consumer recycling or post-industrial recycling) for energy supply systems and energy chains. The program enables customers to recycle their old energy chains in exchange for a voucher. The old energy supply systems and energy chains are sent to igus, where the plastic material is separated and shredded on site. The unmixed granulate is then sent to the igus recycling partner. The program has expanded with the launch of the new Chainge recycling platform, which enables owners of old plastic parts to submit a recycling claim, process returns, and manage recycling credits. The program aims to simplify recycling and promote a circular economy. It is aimed at such parties as recyclate dealers, recyclable material dealers, and suppliers, and compounders.

In a world increasingly focused on sustainability and resource efficiency, technical plastics recycling is at the heart of efforts to promote the circular economy. In this context, igus, one of the world’s leading manufacturers of technical plastics, has set new standards with its innovative “Chainge” program.

Technical plastics play a central role in many sectors, from the automotive industry to medical technology. Their durability and versatility make them essential, but their disposal and reuse poses a significant challenge. This the challenge that igus accepts with its Chainge program, which recently won first place in the Cologne Chamber of Industry and Commerce’s “Going Circular” competition.

The Chainge program is igus’ answer to the need for effective technical plastics recycling. It offers a holistic solution by focusing on the entire plastic product life cycle – from manufacture to use to recycling. By offering solutions for taking back and recycling used plastics, igus demonstrates the feasibility of an efficient technical plastics circular economy.

A crucial part of the Chainge program is the igus return policy. Customers can return their worn-out technical plastic products to igus, where they are efficiently recycled. This helps reduce the amount of plastic waste and minimise raw materials consumption.

The igus Chainge online platform enables customers to recycle used plastic components, especially energy chains, and reuse them in new products. Its goal is to promote a circular economy in which waste is minimised and resources conserved.

The igus recycling process with chainge is simple and easy. Customers can send their used energy chains to igus and, in return, receive a voucher that they can use to buy new products from igus. The recycled plastic is used to make new energy chains, closing the circle and eliminating waste.

The Chainge platform is part of igus’s commitment to sustainability and the circular economy. igus has been recycling technical plastics for more than 50 years, and the Chainge initiative is a natural extension of this commitment.

Since 2019, igus has collected more than 80,000kg of plastic waste from old energy chains as part of the Chainge program. However, this is only a fraction of what igus has planned.

The igus Chainge program takes things one step further. It also provides maintenance and servicing for technical plastic products to extend service life, reducing the need for new products.

The igus Chainge program demonstrates that technical plastics recycling can go hand in hand with the circular economy. A sustainable, efficient model for such recycling is an important igus contribution to promoting the circular economy and tackling the global plastic waste crisis. At a time when the need for sustainable resource use is becoming ever more urgent, the igus Chainge program is a big step in the right direction.

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The issue of resistance https://blog.igus.eu/the-issue-of-resistance/ https://blog.igus.eu/the-issue-of-resistance/#respond Wed, 26 Apr 2023 23:00:00 +0000 https://blog.igus.eu/?p=21729 Most people remember the term resistance from physics lessons. In electrical engineering, on the other hand, the term is not only common, but also important for understanding. With regard to cables, too, it is important to take a closer look at the topic of resistance. In today’s post we will look at the issue of […]

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Most people remember the term resistance from physics lessons. In electrical engineering, on the other hand, the term is not only common, but also important for understanding. With regard to cables, too, it is important to take a closer look at the topic of resistance. In today’s post we will look at the issue of resistance and the correlation between cables and resistance.

The resistance

Let’s start at the beginning. In the basics of electrical engineering, one learns that there are electrical charges. When they move, we get electricity. The electrical voltage provides the drive. If the movement of the charge is impeded, we have resistance.

So there is a relationship between current, voltage and resistance. Basically, the resistance of a component indicates how much the electric current is impeded in it. The symbol for resistance is R. The unit of resistance is ohms. This correlation is established with Ohm’s law.

Ohm’s Law triangle drawn on a blackboard with chalk

Which types of resistance are relevant for cables?

Conductor resistance – resistance of the copper conductor

The conductor resistance depends on various factors. For example, the length is relevant, just as the cross section and structure of the conductor. The conductor material used also plays a role, e.g. copper has a different conductivity than aluminium.

This conductor resistance is specified in DIN VDE 0295 for each cross section. Since the conductor cross section of cables is defined by the electrical resistance, we speak of the electrical cross section.

The mechanical or optical cross section can therefore deviate from the electrical cross section. This depends on whether the conductors are solid, multi-wire, fine-wired or even super-fine stranded wire conductors. In electrical engineering, however, the mechanical cross section only plays a subordinate role, since conductivity is more relevant here.

Installation materials, e.g. wire-end sleeves and compression cable lugs, are also designed for the electrical cross section, just like the conductors for which they are made.

This can be seen particularly well if you place cable lugs for multi-wire conductors and for extra-fine-wire conductors next to each other.

Difference between 150mm² compression cable lug for multi-wire conductors (left) and fine-wire conductors (right)

Insulation resistance – resistance of core insulation

The insulation resistance of cables is specified in Ω/km, as this depends on the length. In the ideal case, insulation has an infinite resistance in order to provide the greatest possible safety against short circuits.

This is only theoretically possible. A minimum resistance of 1 MΩ/km is therefore specified in DIN VDE 0100 Part 600. In general, the shorter the cable length, the higher the measured insulation resistance. The insulation resistance can be in the GΩ range for short cables.

In addition, the insulation materials used also influence the level of the insulation resistance.

Characteristic wave impedance/Cable impedance

The cable’s characteristic wave impedance describes the ratio of the current and voltage waves propagating in a common direction. The characteristic wave impedance depends on the frequency and basically affects every cable. You can see the correlations very well particularly in bus cables.

In order to prevent reflections of the signals to be transmitted during bus transmission, it is important that a specific characteristic wave impedance is defined so that the end of the cable can be terminated accordingly. If this is not done, transmission errors can occur which can even lead to failure of the respective bus system.


Depending on the bus system, the required characteristic wave impedances can be different. For a better understanding, here are some examples:

  • Ethernet, Profinet, EtherCat 100Ω
  • Profibus 150Ω
  • CAN bus 120Ω
  • CC-Link 110Ω
  • USB 90Ω

Conclusion

A cable is also an electrotechnical product that must be designed to suit the application. Moving cables pose an exceptional challenge, as the movement changes the position of the cores in relation to one another, as well as to the centre of the cable. This has an effect on capacitance and thus also on the characteristic wave impedance. The cores of a moving cable can break at some point due to the permanent strain. However, this happens gradually. The result is a constantly increasing conductor resistance and thus also an increasing voltage drop. This also affects the signal to be transmitted.

Do you need help selecting a suitable cable for your application? Talk to us or visit us at www.igus.eu/chainflex. In our online shop you will find all the relevant data about our cables, e.g. data sheets.

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