Permanently protected: 3D energy chain for 6-axis robots in automotive industry

• What was needed: twisterchain®, triflex® R, triflex® RS
• Requirements: the protective hose provided by the factory was permanently torn or had worn through, leading to downtime; the company was therefore looking for a solution that would provide reliable and long-lasting protection while being able to cope with the complex movements in all axes
• Industry: Automotive industry
• Success for the customer: the various chain applications play to their strengths perfectly on the different axes; they guide the cables safely during complex movement sequences, reduce downtimes and provide stability and safety

Wandres GmbH micro-cleaning specialises in the development and production of brush and air cleaning systems. The removal of dust, fibres and tiny particles from surfaces is a prerequisite for many manufacturing processes in order to produce high-quality products, especially in the automotive industry. In this environment, 3D micro-cleaning prior to final painting, a special cleaning process from Wandres using the so-called robotic heavy-duty brush, has proven its worth.
In the Wandres technical centre, endurance tests are carried out with a multi-axis robot to check the cleaning quality and results of the special brush on a wide variety of surface structures. The robot Sword Brush is particularly suitable for cleaning complex geometries that cannot be achieved using alternative methods. The travelling speed of the robot is approx. 300 to 400 mm/s. Both cycle and continuous operation are possible.
The cleaning process is based on the company's patented "Ingromat" process. This is a special wet wiping process. It significantly minimises frequently occurring electrostatic charges and reliably removes adhering dust and particles.
After the 6-axis robot had been in operation for around two and a half years, a new solution was sought for the cable routing. Originally, all robot cables were protected from mechanical damage with protective hoses provided by the factory. However, these were permanently torn or had worn through, with the result that the entire test system came to a standstill. The company was therefore primarily looking for a solution that was not only safe, but also provided long-term protection.

The surface cleaning specialist has been working with our cable routing products for over 20 years. These are used in almost all Wandres cleaning systems. Here too, all six axes of the cleaning robot were equipped with 3-dimensionally movable energy chains.
A twisterchain® has proved its worth for the circular movement of the rotary axis. The spiral-shaped modular energy supply system is suitable for circular movements of up to 540° and can be completely pre-assembled on request. hose and cable are safely guided, abrasion is significantly reduced and running smoothness is increased. On axis 2 to 6, the multi-dimensionally moving energy supply systems from the triflex® R family reduce downtimes and provide stability and safety, from large welding robots to small palletising robots. Thanks to the round design, the chain glides over the outer contour of the robot, does not tilt and does not get caught.
Axis 2 and 3 of the robot are equipped with the triflex® R light version, a reliable solution for less complex movements. In contrast, the compact triflex® RS set is used for axes 4 to 6. With the universal module, the chain is guided in a space-saving manner parallel to the robot arm. Applications can therefore be realised in the tightest of spaces. Spring rods within the chain create pretension to achieve complete or partial stiffening. Automatic retraction mechanisms prevent the formation of loops and cable stress on the robot head.
The " "trailer principle" enables the high tensile strength of the system. The individual elements are connected like a trailer coupling (housing pad principle). This enables a high degree of manoeuvrability in all directions. In addition, there is a defined freedom of movement in all directions, which also increases the service life of the chain, cable and hose.