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Energy chains with condition monitoring for driving simulators

Intelligent breakage monitoring in 22-ton automotive driving simulator

Smart igus® e-chain® reliably transport energy, data and media in highly dynamic applications
Moving driving simulators have been used in the German automotive industry for 35 years. The world's most modern driving simulator now boasts the following key data: 2.2 MW of electric drive power, "22 tonnes of agility" and a total value of over 25 million euros.

Description

What was needed: P4.1 roller chain, i.Sense EC.B for breakage monitoring
Requirements: high dynamics of up to 10 m/s as well as enormous load, safe guidance of power, data and other media in one, intelligent accident protection
Sector: Automotive industry
Success for the customer: Increase in system safety and availability; complete project realisation from a single source; smart early warning system

Problem

The simulator is primarily used for testing and validating driving dynamics, operating and display concepts, vehicle assistants and autonomous driving. The vehicle's control equipment is connected to the driving simulator's computer control system via data lines. The computer calculates the car's driving behavior over 1,000 times per second and issues the corresponding commands to the mechatronics. It moves the system at a maximum speed of ten meters per second (36 km/h). With a 360° screen, the fast electric drive and the twelve meter long rail for the “air-bearing movement”, the system is one of the most powerful in the automotive industry. All the necessary cables for the power supply, control system, network technology and pneumatic and cooling water hoses must be safely routed and protected. The most efficient solution was sought here.

Solution

Energy chains act like an umbilical cord: they ensure the supply of energy, data and media and are constantly in motion. In the energy chains used, 90 kilograms per meter are distributed over four chains. The length of each chain is 14.80 meters and the travel distance is designed for 20 meters. In order to further increase system safety and availability, those responsible decided to install new P4.1 series energy chains including intelligent breakage monitoring. Should an unforeseen problem arise in real operation, especially in such a highly dynamic application, this can be detected directly with the unique i.Sense EC.B breakage detection system from smart plastics. As a result, chain breakages are detected at an early stage and high accident costs for the entire system are avoided.

Overview rol e-chain P4.1 Overview condition monitoring EC.B Engineering & installation service

The cooperation with the Mercedes-Benz Group was excellent and it was simply great fun to be able to support such a fantastic and exciting project from the very beginning. And, of course, it also makes me a little proud to ensure greater safety for such a renowned company.

Frank Schlögel

Head of “Engineering Projects and Assembly Service”

The decisive added value

In the end, the latest generation of e-chain series P41.80 and new chainflex cables were used, which meet all EMC safety requirements as well as standards and directives such as UL, VDE, CSA, Profibus etc. As the existing guide trough was also specially manufactured and adapted to the tight installation space ten years ago and was still in very good condition, those responsible decided to replace only the damping profiles. In the new P41.80 system, the upper and lower run are offset one above the other. This ensures smoother running and ideal noise insulation. In addition to comb-like autoglide bars, the system also has tribologically optimized plastic rollers, which significantly increase the durability of the chains. With this solution, we were able to offer our customer everything from a single source: from project planning, delivery and installation through to maintenance.