The fins dust generated in the production of roof tiles gets into all machines and facilities. The production must go on nonetheless. It has been a year that multidimensional energy supply systems have been used to ensure high cycle times in palleting. From the start they have been tested and proved in the harsh environment. The holding times of robots has clearly improved.
"We procure our machines and plants completely from one machine manufacturer", says the electrical engineering foreman, Andreas Wals, of the roof tile factory Dachziegelwerk Jungmeier GmbH & Co. KG in Straubing. "As such, we have no influence on the components put to use. In the course of maintenance and repair works, we replaced the energy supply in two robots. The originally employed solutions did not withstand the harsh conditions on site. And we could not afford machine breakdowns in these economically difficult times. "
)
The conditions of application are more than harsh. Tile dust stick to practically everything. After the palleting robot has been equipped with a multidimensional energy supply system, the running times have increased substantially.
Since more than a year, the multidimensionally moving energy supply system Triflex® R specially intended for robotic applications has been in use at Jungmeier. A high flexibility in complicated movements even in the 6th axis makes them stand out. The product from the company igus® GmbH, Cologne, has been proved and tested. The closed 'TRC' version is not affected by the aggressive tile dust. "Our production operation runs in two shifts from 5 in the morning to 22 hours in the night. Essential repairs must also take place either in the night or during weekends. As the machine breakdowns have distinctly reduced, these costly operations are also dispensed with," observes a satisfied Andreas Wals.
The roof tile company Dachziegelwerk Jungmeier GmbH & Co. KG has been operating for more than 180 years. The still family-owned business was founded in 1820 in Straubing, Germany, at the site of a brick kiln operated by the Romans around the turn of the common era. Around 200 employees work at this location accounting for an annual turnover of 50 million pieces. "We deal exclusively with the production of clay roof tiles," says Andreas Wals. "Therewith we can lay around 15,000 roofs of one and two family houses in a safe, reliable and environment-friendly way. "
Ten different basic models as well as extensive accessories are manufactured in Straubing in five plants with six conveyor lines. "Our management recognized the signs of the times early and invested in the machinery, so that we produce according to the latest technology and maintain our position in the tough competition," observes Andreas Wals.
Two robots are employed for palleting the tiles. A robotic arm takes the tiles from the belt each time, turns around 180 ° and stack them in packs of 8 or 10. It occurs at a speed of 2 m/s. The travel amounts to about 60 cm. The air is thick with tile dust. "We had used a series of energy chains from another manufacturer and even tube packets, but they didn't stand up to the test. Due to the extreme movement and the short cycle times, they tore as a rule within a short period. In addition were the harsh conditions of application. The cables were bruised so many times that we had to undertake extensive repairs," reports Andreas Wals. "After the installation of Triflex® R the holding times of the two robots have at least tripled, so that the investment paid off for us in any case both technically and economically. "
)
)
The multidimensional energy supply system is about a meter long and filled with an electric cable and a vacuum cable. They manage without additional guidance by means of fiber rods. If required these can be subsequently integrated through openings designated for this purpose. "Our operating experiences with the new technology are so good that we are installing the supply on seven other robots. Indeed the cycle times and therewith the abrasion are much lower, but we also hope for still more holding times," points out the electrical engineering foreman his concern.
As the Triflex® R has a modular design, individual links can be replaced without any problem. The excellent mechanical properties - impact resistant, dirt repellent, rugged, abrasion resistant and chip proof - become especially obvious in the production conditions of the roof tile production. The smooth interior and exterior contours enable a safe gliding over interfering edges and at the same time protect the cables.
"We came to know about the technical advantages of the multidimensional energy supply system at a trade fair in autumn 2004," narrates Andreas Wals. "And we immediately decided on a trial. They have been in use at our place since the beginning of 2005. We were convinced by their advantages in our daily operations during a test phase. "
On a visit to the Straubing site, the then igus® employee, Oliver Köhler, took a picture of the conditions of application. Thereby the chain length and the suitable connections were determined. A generous term of payment during the test phase completed the offer. Today the company Jungmeier keeps the energy supply system with the corresponding mounting brackets in stock, so that if required a replacement can be undertaken and/or other robots can be independently equipped any time.
)
"We focus not only on the original equipment manufacturer, but also stand by any time for retrofitting and conversions in word and deed," adds the technical sales consultant of igus®, Oliver Köhler. "And the marked increase in the operating times of the robots indicates the clear advantages of the multidimensional energy supply system in this application. "