Bread packaging machine: avoid cable breaks with chainflex and smart plastics

• What was needed: E4.1L series energy chain and  highly bend-resistant chainflex® cable (control cable and measuring system cable ), supplied as a pre-assembled readychain® system, CF.Q isense sensors, connector concept Module Connect, drylin® W linear bearing
• Requirements: minimum bend radius of only 63 mm, high bending strength cable, high load of up to 80 double strokes per minute
• Industry: Packaging technology
• Success for the customer: The E4.1L is characterised by high force absorption and is used together with highly bend-resistant chainflex® cables. The isense sensors with CF.Q module detect wire breaks before they occur and save the user high downtime costs.

GHD Georg Hartmann Maschinenbau GmbH offers machines for cutting, packaging, sealing, grouping, transporting and handling baked goods and food products. From individual machines to customised complete turnkey systems, the company supplies everything from a single source: planning, production, commissioning and service. Based on a particularly high level of vertical integration, customers appreciate the constant availability and first-class supply of replacement and wear-resistant parts.
For a current packaging machine for industrial bakery products such as toast, the right energy supply components and linear technology for reliable format adjustments had to be found. The GBK 440 automatic packaging machine offers secure packaging and sealing of product pouches in a single operation. The machine can be used to pack a wide variety of food formats in the shortest possible cycle times. The speed can be varied according to requirements and application. The machine is designed for up to an incredibly fast 80 cycles per minute, i.e. significantly more than one packaged unit per second.
The machine works with really high stroke rates in a comparatively short installation space. For this reason, high-strength cables are required, which must not exceed a bend radius of 63 mm. In addition, a preventive warning system had to be found to avoid a possible cost-intensive breakdown of this machine with its high output.

In order to realise a particularly low bend radius, an energy chain from the E4.1L series was chosen, which is characterised by its high force absorption. Highly bend-resistant chainflex® cables  specially designed for moving applications are also used. For example, chainflex® control cables of type CF10.UL.05.04 with a minimum bending radius of 5 x d and type CF9.03.04.INI are used. A chainflex® measuring system cable of type CF113.028.D with a minimum bending radius of 7.5 x d, a 6 mm pneumatic hose and two further CF9 sensor cables complete the range. All cables, including the chain, were supplied to the customer as a ready-to-install and final-tested readychain® complete system.
Despite a 36-month warranty or ten million double strokes, the high cycle rate of up to 80 double strokes per minute for the packaging machine was not covered by the standard warranty. For this reason, the cables are supplemented by intelligent solutions for predictive maintenance. isense sensors together with the CF.Q module continuously monitor the condition of the cables. The onset of core rupture is recognised by changes in the electrical specification. This is reported to the so-called icom module, which transmits the data to a cloud system.
A plug-and-play system was to be made available for maintenance in order to complete this task quickly. The  Module Connect connector concept for connecting electrical cables, fibre optic cables and pneumatic hoses is used here. Thanks to the simple modular principle, a customised insertion/separation point can be configured as a module - extremely simple and absolutely concealable.
Finally, a simple but reliable format adjustment was also required for the cross-feeder with rotating device for half loaves. linear technology from the drylin® W modular system with manual clamp enables the cross-feeder to be positioned quickly in just a few simple steps.