Modular plug-in unit for the VISION-FLEX

• What was needed: Reliable, error-free and time-saving interface for connecting energy chains in CNC machining centres
• Requirements: Simple plug-in system for energy chain systems, high contact density, EMC protection, modular adaptability, space-saving design, error prevention during assembly
• Industries: Mechanical engineering, CNC machining centres/gantry machines
• Success for the customer: Significant time savings, simpler production and final assembly, error-free connection, easier maintenance and logistics

The main challenge in the assembly of the CNC machining centres from Reichenbacher Hamuel was the rapid and reliable connection of the energy chains required for the tool movements on the different axes. While the y-axis and z-axis are equipped with harnessed and closed energy chains, the energy chain series R4.56 of the x-axis previously had to be guided in the gantry's pre-assembly although it is only connected to the machine bed in the final assembly. Due to its length of 5.2m and its position on the gantry, this x-chain was always in the way: it made handling more difficult, disrupted the production cycle and led to considerable logistical challenges. When transporting the gantry by crane from one side of the hall to the other, the x-chain always had to be carried along, which required time and effort. Also, the many different connector elements of the conventional plug connections posed a risk of connectors being connected incorrectly, which caused errors and rework. The previous process was therefore inefficient and prone to errors, both for the machine builders and for assembly and logistics.

Together with igus, an innovative solution was developed that is specially tailored to the requirements of CNC machine assembly: the modular interface Module Connect. It lets operators easily connect the cables of the x-chain during final assembly without having to carry them along during the gantry's pre-assembly. The modular system of Module Connect allows for a customised configuration of the plug-in connectors, which can be adapted in terms of dimensions and regarding the number and type of contacts used. The individual modules are individually shielded and thus offer EMC protection that ensures interference-free data and power transmission. The flat, space-saving housing design fits perfectly into the confined dimensions of the machine. In addition, a wide variety of cable types are integrated, from motor and servo cables to fibre optic cables and pneumatic supplies. The self-coding plug connection prevents incorrect installation, which makes the assembly process much safer and easier. This modular system drastically reduces assembly time, minimises sources of error and also facilitates subsequent maintenance thanks to a clearly defined disconnection point.