Measuring system cables for large scale machining centres

Werkzeugmaschinenfabrik WALDRICH COBURG GmbH relies on the latest generation of control systems for its highly complex systems.
The complete machining of large components such as diesel engines, turbines, generators or ship propellers means that the respective machining centres are becoming ever larger. This also has an impact on the machine technology. The machine tool manufacturer of these highly complex systems always relies on the latest generation of control systems. A special overall solution with a measuring system cable has been developed for them, which transmits the signals reliably over very long distances and ensures high machine availability.

Problem

WALDRICH COBURG is one of the world's leading suppliers of large machine tools. The highest quality standards and consistent customer-orientation are the guiding principles of the machine manufacturer. Milling machines in horizontal and vertical design, vertical lathes and grinding machines are manufactured at the Coburg site.
WALDRICH COBURG's customers often use the machines for 20-30 years or longer, and availability levels of at least 95% are often required. For this reason, all components must function perfectly under all circumstances. These circumstances mean a particularly high requirement profile for the cable routing in the application.
In addition, the cables must be able to withstand the continuous movement in the energy chain and the sometimes harsh environmental conditions of metalworking without damage. Thomas Bischoff explains: "Cables and connectors must be robust and fulfil the mechanical, electrical and chemical requirements. They must also be easy to process in production without the need to purchase additional special tools. We also wanted to use the familiar cable and connector material wherever possible to avoid any problems during the changeover.

Solution

For many years, energy chain and chainflex® cable from igus® have been used in the large machining centres. In smaller series of portal machining centres, the company also relies on pre-assembled energy supply systems, which are marketed under the name readychain®. One reason for the decision: The manufacturer's customers like to use the machines for many years longer than expected and demand consistently high availability. "For this reason, all components must function flawlessly under all circumstances," says the Group Manager, summarising the high requirement profile. "And here we have had the best experience over the years with chainflex® cables from igus®."
In 2010, the specialist for large machining centres decided to switch to a new control technology in its machines, which also required new measuring system cables. Due to positive experiences in the past, chainflex®-cable CF113.028.D was chosen.
CF113.D-cable have a PUR-jacket. With regard to use in energy chains, they offer an optimised stranding and shielding structure for a longer service life. In addition to being halogen-free and flame-retardant, it fulfils other important criteria of machine tool manufacturers, including UL and NFPA79.2012 approvals.

Energy chains

chainflex® cables

"Our customers often use the machines for 20-30 years or longer, and availability of at least 95% is often required. For this reason, all components must function flawlessly under all circumstances. And this is where we have had the best experience over the years with the chainflex® cables from igus®."

Dipl.-Ing. Thomas Bätz, Group Manager Electrical Design at WALDRICH COBURG GmbH

Diverse tests in advance
In order to be able to present a solution, it is not just about the functionality of a cable, but also about the number and quality of the individual connection points. A series of tests were set up in the company's own test laboratory in Cologne to find the optimised connection solution. The cables were then sent to the user, who connected them to an original control unit. Realistic machine loads were simulated here in order to test the cable concept found for its suitability for everyday use.

The great effort ultimately led to the desired result: today, the measuring system cables demonstrate their performance in all machining centres with the new control generation - even when retrofitting older machines. They have worked perfectly right from the start. A major advantage for the installation is that the familiar M23 round connectors can be used as standard components.

"The results are impressive. The durability and signal quality are right. A total cable length of 90 to 100 m can currently be realised without any problems, but 120 m is also conceivable," says Thomas Bätz. In addition, there are a maximum of five connection points. "With this connector/cable combination, we realise extremely low damping properties. They are many times lower than the original from the control unit manufacturer," adds Thomas Bischoff.

Complete stocks
measuring system cables are always matched to the respective measuring system of the various suppliers. They must function permanently. "Our requirements for robustness against external influences and stability have been met right from the start," emphasises Thomas Bischoff once again. "The prerequisite for this is the close and good cooperation in the development process."
WALDRICH COBURG relies exclusively on a wide variety of chainflex® cables in its own machining centres, which guarantee long machine running times. They must be available from stock. "We have not experienced any problems here either," concludes Thomas Bätz. "There are no bottlenecks, so we can react quickly if necessary."

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