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User report

Cables and energy chains for printed circuit board assembly: 17 million cycles per year

Precision in continuous operation: control and servo cables as well as e-chains extend maintenance intervals

With the "Speedmounter" PCB assembler, the name says it all. The special mounter of the automation company IPTE works at speeds of up to 300°/s, and in many companies in the computer and automotive industry in three-shift operation and around the clock. A new solution had to be found because cable problems in the past often led to restrictions in the availability of the systems under these conditions. By replacing with chainflex control and servo cables as well as type E2 energy chains, the maintenance intervals of the cable plate assembler could be significantly extended and production downtimes avoided.

Profile

Circuit board assembler By replacing the cable guidance with E2 energy chains and chainflex cables, the maintenance intervals of the special circuit board assembler "Speedmounter" could be significantly extended.

Problem

The Speedmounter is a fast machine that can assemble circuit boards with up to 12 components at a time. It moves its turret head at a speed of 300°/s, and each time it moves in 30° increments, it picks up 12 tools.Thus,the actual placement performance with this process is significantly higher than with all other machines worldwide.

The Speedmounter is a complex machine with high demands on its components. The focus is always on ensuring that the system is available and reliable. The individual assemblies must be reliable, and the suppliers of the parts used in the machines must also meet strict standards. As an ISO-certified company, IPTE carefully checks the quality and reliability of its suppliers.  

The company's emphasis on system availability is a direct result of the challenges they faced in the past with cable failures which have caused the machines to be unavailable, thus leading to downtime and production losses.
Learn more about chainflex cables

Solution

Various chainflex cables and energy chains are used in the "Speedmounter" today, all of which were specially developed for moving applications.
For the control cables, IPTE relies on the chainflex CF9 (unshielded) and CF10 (shielded), which with their minimum bend radius of 5xd allow use with tight radii in the smallest installation spaces. And they also take up little space in the energy chain. This is because a mechanically optimised TPE jacket material and the core insulation enable small outer diameters. And thanks to the gusset-filling extruded inner jacket, the cables retain their transmission properties even after many millions of double cycles. The control cables are supplemented by halogen-free, flame-retardant and UL-approved servo cables of the CF27 series for supplying the servo motors.
The cables are used in energy chains of the series E2 mini, E2 medium and E2/000. With the E2 medium, the stress is particularly high. The chain and cables follow around 17 million cycles per year. In order to avoid electrostatic charging in the printed circuit board assembly, all energy chains are delivered in a conductive ESD version.
Overall, the maintenance intervals could be significantly extended through the use of the energy chain systems and chainflex cables.
Find out more about E2 energy chains
Energy chains Safety even in reverse bend radius (RBR) applications.
Energy chains Limited space requires special solutions: E2 energy chain, here mounted on the side.

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Yap Han Song (Denis)

Product Manager for e-chain systems® ASEAN

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The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "igutex", "kineKIT", "manus", "motion plastics", "pikchain", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsubishi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention on this website. The products offered by igus® are those of igus® GmbH