Engineering Maintenance-free Motion Systems

What You’ll Learn

• The benefits and design considerations of lubrication-free plastic components for harsh industrial environments
• How igus’ continuous-flex cable carriers support rotational motion without slip rings
• The role of smart plastics with visual wear indicators in predictive maintenance
• Practical application contexts and material selection guidance for machine design engineers.

In the igus booth at Fabtech, Mike Patterson, director of sales, explained to Machine Design that the company’s portfolio focuses on eliminating lubrication to reduce maintenance and contamination risks. “All of our products are lubrication-free, plastic, injection molded,” he said. “We really want to get away from lubrication. We know what lubrication does to the environment and the maintenance those systems require.”

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Igus provides more than 50 engineered polymer materials tailored to a range of conditions: from dusty, hot environments to splash and contamination-prone areas. Patterson highlighted the availability of materials design specifically for sensitive applications: “We have food-grade materials, FDA-approved, for machines that handle food, and also some medical materials to meet hygiene requirements,” he said.

The polymers operate without grease or oil, simplifying machine upkeep and reducing contamination concerns. These plastics are also lightweight and cost-effective alternatives to metal components, he said.

Continuous Flex-cable Systems and Rotational Motion

The company’s electrical division designed cable carriers and continuous flex cables to withstand constant flexing and bending. Of particular note is their system for rotational motion. This eliminates the need for slip rings traditionally used in rotating machinery, reducing complexity and maintenance. The system combines torsion-resistant cables and specially engineered cable carriers for simultaneous linear and rotational movement with minimal backlash.

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To assist predictive maintenance, igus integrates color-changing wear indicators into some cable carrier systems. For instance, one pad runs on the chain itself and as it wears down it changes color from green to yellow at about 30% wear and then red when it's time to replace, Patterson said. This visual cue allows operators to plan maintenance before catastrophic failures occur especially important and abrasive environments such as welding or dusty factories.