Space-saving energy chains for complex movements in lighting system

Profile

• What was needed: Plastic energy chains E4.1 as Reverse Bend Radius rotating energy supply, energy chains in zig-zag system, which were supplied as pre-assembled cable guide (readychain)
• Requirements: For various movements in the X, Y and Z axes as well as for the rotation of the lamp frames, safe cable guides were needed that fit into a small installation space.
• Industry: Automotive industry
• Success for the customer: The high flexibility of the lighting system could be supported by the energy chains and this also at 36 metres travel distance as well as in rotation. In particular, the space-saving solution and the simultaneous safe guidance of energy and signal cables were decisive for the customer.

This lighting system can be flexibly moved in X, Y and Z direction. Various cable guidances are used here.

Problem

Well thought-out solutions are needed for the ideal illumination of test objects during crash tests. In order to align the light optimally for the high-speed camera shots in the crash area, Messring GmbH has developed a lighting system in which no less than eight nacelles can be moved independently of each other on two tracks in the X, Y and Z directions. On each nacelle there is a lamp frame, which in addition to the nacelle movement itself is rotated around the vertical and horizontal axis, or can be tilted. This always allows the right lighting from any angle. However, the high degree of flexibility, which is also reflected in the 36-m travel distance of the nacelles, poses a particular challenge to the guidance of the cables. The space in the lighting system is also limited, which is why a compact cable guidance system was sought. Due to the particular variety of movements, different concepts also had to be developed for the X, Y and Z travel directions.

Solution

The diverse and flexible movement possibilities offered by the lighting system are now supported by several of our energy chain systems. In addition to a heavy-duty and high tensile strength plastic E4.1 energy chain (E4.32 series) for reliable operation, an E4.21 is used as a rotating energy supply for free rotation of the lamp frame. Such a system can allow rotation angles of up to 900° and this at high travel speeds. For the movement of the lighting system on the Y-axis, the supplier relies on an energy chain in a zig-zag system. Typical for use in stage technology, the special design enables space-saving cable guidance that does not stress the cables in the application and guarantees the safe transmission of energy and signals over a long travel. While the compactness of the cable guidances in particular was crucial for the customer, the fast assembly also provided a major advantage. Because of the already pre-assembled readychain cable guidance, i.e. an energy chain already equipped with cables, a lot of time could be saved. The cooperation in defining the problem and finding the product was fast and uncomplicated.

Since the lamp frame should be able to perform a rotational movement, a rotating energy supply system was installed in a small installation space.

Since the energy chains were supplied pre-assembled as readychain systems, the manufacturer was able to save assembly time.