Avoid downtimes with multidimensional energy chain in painting robots

• What was needed: a cable routing that follows the multi-dimensional movements of the robot
• Requirements: Failure-free and reliable planning, robust, suitable for fast and complex movements, fast and simple filling
• Industry: Automotive production, robotics
• Success for the customer: Since converting to the triflex® R-energy chain, the painting robot has been running faultlessly and has painted over 1.2 million seals to date without incident.

When painting door seals in the automotive industry, painting robots are used that have to keep up with the tight cycles and continuous operation. In this customer project, for example, around 2,000 parts per shift were produced in three shifts. That makes around 600,000 parts per year.

The weakest chain link in the process chain was the cable routing for the painting robot. The original solution consisted of a corrugated hose, which was increasingly causing problems. It kept tearing off and causing the painting robot to fail. In addition, there were no proper brackets, which meant that the cables were subjected to a great deal of strain during the complex movements. The high acceleration of the robot arm also contributed to this. At up to 800 mm/s², high loads act on the cable and energy supply system.

Added to this are the conditions in the paint booth. The paint mist leads to heavy soiling. It settles everywhere and leads to the corresponding adhesions.
Due to the high quantities required in production, the customer decided not to compromise on the speed of the painting robot. A new cable routing had to be found.

The ribbed hose of the painting robot was replaced by a multidimensional energy supply system triflex® R in the so-called Easy version (TRE). The energy chain has been specially developed for robot applications and offers two main advantages:

Firstly, it guarantees a high level of safety during operation. The triflex® has a stable outer contour and flexibly follows the movements of the robot - including torsion and bend radius. Together with a tested tensile force of up to 2,340 N, it allows unrestricted system availability.

The second advantage relates to assembly and filling. Thanks to the "Easy principle", the new cable is filled by pressing it in from the outside. The cable or hose does not have to be fed through the chain and fittings or connectors do not have to be removed. This pays off when a media hose or cable contaminated with paint dust needs to be replaced quickly. In general, the changeover times are very short. To replace both energy supply systems, the painting robot only has to stop for 15 minutes.

Shortening or lengthening the energy supply system is also quick. A screwdriver is all that is needed to adjust the number of chain links. The painting robot uses 272 chain links with a total length of approx. 4 metres. In the event of damage, any chain link can be replaced quickly. The 'housing pad principle' enables uncomplicated joining and separating.