Bearing technology and energy chains for training robots

• What was needed: dryspin trapezoidal lead screw drives, iglidur plain bearings, drylin shafts and profile guides, energy chains
• Requirements: 100% freedom from lubrication and maintenance, resistance to dust and dirt, robustness, durability, quiet operation
• Industries: mobility and rehab, rehab and fitness
• Success for the customer: the igus components used are quiet, clean, lubrication-free and maintenance-free and have been used in the training robot for more than ten years - without any complaints.

ddrobotec training robots are self-learning systems that adjust to the specific needs, fitness level and progress of each user. Training takes place in a standardised environment where training intensity, duration and cognitive engagement are accurately measured and analysed.Artificial muscles replace classic weights and electric motors. Sophisticated control algorithms ensure smart load adaptation - individually, in real time and independent of the leg. The technology allows for highly dynamic, performance-based strength training that can be precisely adjusted and is gentle on the joints.

To offer a maintenance-free and absolutely safe system, the designers at Dynamic Devices were looking for suitable components. The initial requirement was for a plain-bearing solution without grease and constant lubrication as dirt, dust and grime were constantly collecting.

When the design engineers first heard about igus's lubrication-free plastic solutions, they were somewhat sceptical about replacing the bronze nuts, metal recirculating ball bearing guides and brass components with plastic parts. However, the results of the tests they carried out were so impressive that these concerns quickly disappeared.Dynamic Devices then began to gradually replace more and more plain bearings and nuts with igus components. They even went so far as to make design changes to convert the entire bearing technology to igus products.

In addition to plain bearings, e.g. made from the all-rounder material iglidur J, the training robots also contain dryspin lead screw nuts and trapezoidal lead screws, drylin W linear guides, shafts and our small easy chain energy chains for secure cable guidance.

The iglidur plain bearings and dryspin lead screw nuts are made from wear-resistant high-performance polymers and are therefore 100% free from lubrication and maintenance. Two lead screw systems with a linear guide are used for the seat adjustment and additional safety precautions. Hard-anodised aluminium is the rail material for the drylin W profile guides, which ensures the best friction and wear results. The absence of lubrication makes the profile guide system extremely resistant to dirt. Thanks to its cleanliness, it is also suitable for applications in clean and hygienic environments such as hospitals and rehabilitation centres.

In addition to standard products, ddrobotec also received nuts, guides and lead screws, which igus manufactured according to the customer's individual requirements.