igus develops first certified robot energy supply system for dry cleanroom

The triflex R TRC from igus ensures maximum safety in battery manufacturing thanks to dry-cleanroom certification, ESD material, and maintenance-free operation. (Source: igus GmbH)

With the growing demand for electric vehicles, the need for high-quality lithium-ion batteries is also increasing. For this reason, they should ideally be manufactured in cleanrooms with minimal humidity and as free of particles as possible. At the same time, automation is necessary in this environment because humans are not allowed to stay long in cleanrooms. To ensure a safe and reliable power supply for robots in this setting, the motion plastics specialist igus has developed the triflex R TRC: the first robot energy supply system with a cleanroom certification from Fraunhofer IPA for ISO classes 4-5.

What a robot energy supply system that reliably operates at high speeds and with ever smaller wheel diameters can look like has been demonstrated by igus for several years with the triflex R: a three-dimensionally movable energy chain made of high-performance plastic for multi-axis robots. However, specialized applications such as battery manufacturing impose increasingly higher demands on the machine components used. With the triflex R TRC and the associated spring strip module, igus now offers the first robot energy supply system certified for cleanroom applications. It was specifically developed for power supply lines of industrial robots used in battery cell manufacturing. The additional ESD certification broadens its application possibilities.

ESD material for double safety

The system essentially consists of two components: a three-dimensionally movable energy chain and a spring strip module. The e-chain is a closed variant of the triflex R, made entirely from dissipative ESD material—including connection elements with strain relief. This eliminates the risk of damage to ESD-sensitive parts due to sudden discharge. "We decided to manufacture the triflex R TRC from ESD material from the outset because this is requested even more often in battery manufacturing than cleanroom compatibility," explains Matthias Meyer, Business Unit Manager for triflex e-chains and robotics at igus. "Our high-performance plastic igumid ESD has been tested with over 10 million cycles in our in-house laboratory and has proven itself in various applications for years." With the triflex made of igumid ESD, customers benefit twice: they save costs because the material has become part of the standard program, and they gain more security through a material and product that has been tested for years. igus also offers other ESD chains as standard. An additional advantage of igus high-performance plastics: thanks to integrated solid lubricants, they require no lubrication grease, which would cure immediately in the cleanroom.

Simple and quick assembly with prefabricated modules

The triflex R TRC consists of the energy chain as well as a spring strip module. The system resembles a rod and line. Two integrated glass fibers serve to stabilize the energy chain up to the 5th axis and prevent contact between the robot and the energy chain. This allows for an almost contactless production process, so no particles are generated during rotational movements. The prefabricated modules also enable easy and quick assembly. Since there are no contact points, the energy supply system can also be used seamlessly with other separately certified products in the cleanroom, offering the customer greater flexibility.

Test passed with optimal results

The TRC.40 was tested in a cleanroom of Fraunhofer IPA with a dew point of -40 °C, corresponding to a relative humidity of less than one percent at 22 °C room temperature. After testing, the complete system consisting of chain and spring strip module received the certification for ISO class 4—the best possible result achievable with current technology. Only at higher speeds (v = 2.0 m/s // a = 4.0 m/s²) does the system attain ISO class 5. In addition to the triflex R TRC, the E6.29 energy chain from igus also achieved the best possible result with ISO class 4 last year as the first cleanroom-certified solution. This ensures they meet the highest standards for use in cleanrooms.