Installed 75% more quickly – safe cable guidance with connector system in all-terrain ambulances

What was needed: A compact and reliable cable guide to supply the motors and sensors with power.

Requirements: Little available installation space, UV radiation, water and dust.

Sector: Commercial vehicles & trucks

Success for the customer: Thanks to ready-to-install compact energy chain systems including cables and connectors, BINZ saves up to 75% assembly time. A plug-in connector simplifies the connection and saves space in the application. The solution works smoothly and quietly.

BINZ Automotive GmbH specialises in the construction of special vehicles for rescue services, fire brigades, police, technical relief organisations and many other organisations and authorities.

The converted vehicles are used in disaster areas, for example, where they are exposed to particularly adverse environmental conditions. This includes the UNIMOG U4023 small truck from Mercedes-Benz, which has been converted into an all-terrain ambulance (KTWgl) for use in disaster situations and on rough terrain.

A special feature of the vehicle is the innovative gurney system installed in it, which moves out of the patient compartment at a height of 1.20 metres at the touch of a button and lowers to a standardised height of 80 centimetres. An integrated sensor always recognises the distance to the ground. If the vehicle is on a slope or above a rock, for example, the distance to the ground is adjusted. This makes the work of the emergency services much easier. At the same time, the lying surfaces always remain horizontal during the process.

In order to supply motors and ultrasonic sensors with power, BINZ needed a reliable energy supply system that would operate safely even under the constant influence of UV radiation, water and dust. As the installation space is limited, it was necessary to find a compact and modular solution that could also accommodate the flexible movements of the gurney.

Due to the high demands, a lot of time was invested in the development of the cable solution. The company ultimately decided on two readychain energy chains per vehicle. The systems are supplied completely ready for installation, including harnessed chainflex cables and connectors, thus saving BINZ 75% assembly time.

Specifically, the vehicle specialist relies on an E2i.21 energy chain with an inner height of 21.2mm, which is characterised by its long service life, easy filling and particularly quiet operation. This allows the gurney to descend to working height almost silently. In addition, a particularly compact and robust E2C.15 micro energy chain with an inner height of 14.9mm is used, which saves installation space in the application.

Another speciality in cable technology is a plug-in connector system, which increases both efficiency during installation and reliability in use. The Module Connect plugs a large number of cables into a particularly small space. Instead of five connectors, the plug-in connector only requires a single, concealable interface. The transverse displacement, which acts on the system while the motor moves along above the connector, also required a compact plug connection.

In an emergency, the paramedic must be able to rely on all components working reliably. The energy chain systems and the plug-in connector are delivered ready to use, minimising potential sources of error. At the same time, BINZ saves significantly on assembly time: Instead of one day, only a few hours are now required for installation.