igus e-chain achieves the highest cleanroom class even after 60 million double strokes

A unique branch test shows: The modular e-skin flat from igus still achieves the highest cleanroom classification after 1.5 years of continuous use and 60 million double bends. (Source: igus GmbH)

Cleanroom-compatible energy chains of the e-skin flat series still meet the highest cleanroom class after 1.5 years of continuous use and 60 million double strokes. This conclusion is based on a test that is unique in the industry so far – conducted in a cleanroom laboratory built by the motion plastics specialist igus together with the Fraunhofer Institute for Production Technology and Automation (IPA).

Dusting in the living room can be annoying. Just when you are pleased with spotless surfaces, the first dust particles are already there again. The same goes for manufacturers of displays and semiconductors. However, with more serious consequences. Because every tiny particle, invisible to the eye, can damage electronic components. In the strictest cleanroom class, ISO Class 1 according to DIN 14644-1, no more than ten particles of 0.1 micrometers in size are allowed per cubic meter of ambient air – which corresponds to 0.0001 millimeters. To achieve this level of purity, all suppliers of components for cleanroom production equipment must meet the strictest requirements. igus has developed the e-skin flat for these purposes. The flat cable management system made from abrasion-optimized high-performance plastic ensures safe and particle-free guidance of power and data cables in moving production systems, thereby achieving suitability for ISO Class 1.

Unique test setup: e-chain runs 1.5 years in dirty and dusty environment

“The cleanroom energy chain e-skin flat is ideal for robots and other automation systems in electronics manufacturing, for example in the semiconductor and display production sectors,” says Andreas Hermey, Head of Development for e-chain systems at igus. “They are so abrasion-resistant that contamination from airborne particles is no longer an issue.” However, it was previously unclear how much the particle abrasion of the high-performance plastic would be after long and intensive use. To find an answer, igus launched a test setup that is unique in the industry so far. Part one of the experiment took place in their in-house laboratory. The energy chain moved in an environment with normal dust and dirt load for about one and a half years and performed 60 million double strokes during this period.

Still meets the highest cleanroom class after 60 million double strokes

The second part of the test was conducted in a cleanroom laboratory, which igus has set up in Cologne together with the Fraunhofer Institute for Production Technology and Automation (IPA), a development and certification partner of igus for over 17 years. The core of this setup are three so-called laminar flow boxes with high-performance filters, enabling tests in uncontaminated air. There, the retired e-chain was moved for 100 minutes. Sensors detected the particle concentration in the surrounding air. “Even after 60 million double strokes, our e-chain e-skin flat still achieved the highest cleanroom class,” Hermey is pleased to report. “An insight that provides additional security for operators of cleanroom productions.”

Modular design principle for flexible filling

The e-skin flat impresses not only with its extreme abrasion resistance but also with its modular construction. If a defect occurs in a profile into which the cables are inserted, the user only needs to replace that module. In many market solutions, the entire system would need to be replaced. Additionally, the modular plug-in design allows individual profiles to be connected with each other. This cable management system grows with the requirements and guarantees investment security. In combination with the specially coordinated chainflex stranded cable assembly CFCLEAN, the complete system offers particularly high reliability. Furthermore, the entire system has a globally recognized certification from the renowned American organization Underwriters Laboratories (UL). Not least, the cable guides are 9 dB (A) quieter and 20 percent cheaper than typical flat ribbon cables on the market.