Avoid downtimes: multidimensional energy chain in painting robots

triflex e-chain ensures a high level of planning security and short setup times in the automotive industry

Profile

The requirements for a painting robot are clear: it must function without problems under all operating conditions. Time is money, and accordingly low downtime and setup times should also be encountered in day-to-day operations. Since its installation more than two years ago, a multi-dimensional energy supply system has ensured error-free painting and round-the-clock availability of the robot.

What was needed: triflex R energy chain
Requirements: failure-free, planning security, robust, suitable for fast and complex movements, fast filling
Industry: automotive industry, robotics
Success for the customer: since the conversion, the painting robot has been operating without errors and has so far painted more than 1.2 million seals without incident.

"Since the conversion, the painting robot has been operating completely error-free. In plain language, this means that the painting robot has already painted around 1.2 million seals with the replaced energy supply system - and without a single failure."

Uwe Weißhoff, Process Development Manager

Problem

Used for painting door seals in the automotive industry are painting robots that have to keep up constantly with tight cycles and be in continuous operation. In this customer project, for example, approx. 2,000 parts are produced per shift. That makes approx. 600,000 parts a year.

The weakest link in the process chain was the cable guidance for the painting robot. The original solution consisted of a corrugated hose, which led to increasing problems. It tore off repeatedly and caused the painting robot to fail. In addition, there were no proper brackets, so the cables were very stressed during the complex movements. The high acceleration of the robot arm also added to this stress. For up to 800mm/s², high loads act on the cables and energy supply.

Then there are the conditions in the paint cabin. The paint mist leads to heavy soiling. It settles everywhere and leads to the related adhesions.Due to the high quantities required in production, the customer decided not to make any compromises when it came to the speed of the painting robot. A new cable guidance had to be found.

Solution

The corrugated hose of the painting robot was replaced by a multi-dimensional triflex R energy supply in the so-called "Easy" version (TRE). The energy chain has been specifically developed for robot applications and offers two main advantages here:

First of all, it guarantees a high level of security during operation. The triflex has a strong outer contour and flexibly follows the movements of the robot - including torsion and the bend radii. Together with a tested tensile force of up to 2,340N, it allows unlimited system availability.

The second advantage is in installation and filling. Thanks to the "Easy" principle, filling is carried out by pressing in the new cables from the outside. The cables or hoses do not have to be guided through the chain, and fittings or plug-in connectors do not have to be dismantled. This pays off when a media hose or cable soiled by paint dust has to be replaced quickly. In general, the setup times are very short. In order to exchange both energy supplies, the painting robot only has to stop for 15 minutes.

The energy supply can also be shortened or lengthened quickly. A screwdriver is enough to adjust the number of chain links. The painting robot uses 272 chain links with a total length of approx. 4m. In the event of damage, any chain link can be quickly replaced. The 'ball and socket principle' enables uncomplicated joining and separating.