"Intelligent robot control predicts your future"

The intelligent control prevents failures during operation through continuous monitoring and thus increases system availability. (Source: igus GmbH)

As the level of automation in industry increases, the number and speed of machine movements also rise, while the degree of networking within the factory continues to grow. With the world's largest Ethernet cable program for the e-chain, including a unique 36-month warranty, even the most demanding applications in the Smart Factory can be reliably networked. The next step is showcased by igus at Hannover Messe 2016: the intelligent robot cable that warns users in time before a cable failure.

In fixed installations, standard Ethernet cables are usually used. However, these have a very limited lifespan during movement. The largest program of Ethernet cables for energy chains developed by igus offers 27 types in copper and fiber optic, as well as 422 pre-terminated Ethernet cables, ensuring consistently excellent transmission properties during movement. With this program, igus covers the increasing variety of extensive applications in Industry 4.0 – from simple linear movements in dusty woodworking machines to complex 3D movements in cleanroom robots, from minimal bend radii to long travel distances. And soon also as a "smart" solution, because at Hannover Messe 2016, igus introduces a moving cable that continuously monitors itself: "The intelligent robot cable predicts the future," emphasizes Rainer Rösell, Head of the chainflex cable division at igus. If certain parameters are exceeded, the cable warns during operation in time, not only after failure, that a replacement must be made within the next four weeks. "This significantly contributes to preventive maintenance and thus increases plant availability," says Rösell.

High degree of networking requires secure supply solutions

For movement-optimized cables, additionally, movement-optimized routing solutions are required. And these must be tailored to the specific requirements, whether directly at the machine or within the factory. For example, igus offers the triflex series of e-chains, developed for 3D movement on robots. With the micro flizz system, fiber optic cables can be safely routed, for instance, in crane systems, as an alternative to busbars, allowing transmission rates to surpass the usual 100 Mbit. Secure and uninterrupted high-speed data transmission is also possible with the d-rover. The system can be attached to port cranes or RTGs and achieves data rates of 10 Gbit/s with fiber optic cables over a travel distance of more than 800 meters.

Order directly and receive quickly

But not only safety, but also the quick availability of individual and modular solutions in local markets is important for customers. Therefore, igus GmbH, which last year positioned itself among the top cable manufacturers for energy chains with a turnover of 100 million euros—out of a total turnover of over 500 million euros—has significantly expanded its production and warehouse capacities in North America, Asia, and Europe. Through cable production on three continents and from 14 warehouse and assembly centers worldwide, customers receive exactly the cable they need directly from stock: cut to individual length, coiled meter-length, pre-terminated, or as a ready-to-install energy chain system. In other areas, the motion plastics specialist offers highly customized options through the integration of selection, configuration, production, and delivery. Additionally, igus invests in the digital networking of the entire process chain, from customer inquiry to commissioning of customized applications. igus tests all cables and e-chains in a 2,750-square-meter test laboratory with over two billion test cycles annually, providing reliable safety through a unique lifespan calculation for cables and a 36-month warranty or 10 million double bends. The results from the igus test laboratory are continuously integrated into over 30 online tools that make finding, configuring, and ordering especially easy for customers. Mobile access is also available via 18 iOS apps. And worldwide, as the apps are available in up to 20 languages.