80% less working time thanks to readychain

• What was needed: energy chain of type E4.1L, energy chain of type E4/light, both designed as pre-assembled readychain®, chainflex® cable
• Requirements: As the machine takes up just seven square metres, the chains also had to fit into a small installation space. It also had to be assembled quickly.
• Industry: Machine tool construction
• Success for the customer: The pre-assembled chains save the customer 80% of the installation time. The first machine with the readychain® has been in operation 24 hours a day, six days a week for more than 18 months without any problems.

Internal, external and face turning as well as internal, external and face grinding: This is what the DVS UGrind from DVS Universal Grinding GmbH can do. The company specialises in hard-fine complete machining and has developed a machine that can be used universally for turning, measuring and grinding applications on external and internal surfaces in just one operation. The aim was to develop a simple and easy-to-operate machine that can also produce small quantities of workpieces cost-effectively and flexibly.
With the UGrind 800, small and medium series, such as hollow shafts for electric drives or brake discs, can be produced with high precision in just one clamping operation. The machine can be operated via a touchscreen control system without in-depth programming knowledge. Production, including measuring and finishing, is then carried out at the touch of a button, eliminating the need for active operator intervention.
The heart of the UGrind is the specially developed multifunctional head, which can be equipped with up to five tools depending on the application. The head has an action radius of 270 degrees (±2″). With the appropriate tools, the UGrind can carry out internal, external, face and taper grinding as well as various hard turning operations. A measuring probe checks the oversize and finished dimensions, eliminating the need for time-consuming and costly reworking. The multifunctional head can be individually configured for each user and can be quickly retrofitted. What's more, the end user does not have to purchase several machines, which take up valuable space in the factory.
Speaking of space: the system takes up just seven square metres. Accordingly, all components had to be optimally adapted to the installation space: for example, the energy supply, which ensures a reliable supply of cable, hose and hydraulics to the multifunctional head. At the same time, it had to be quick to install.

For the cable routing of energy and data, we offered the customer a ready-to-connect solution with a readychain® - a finished energy chain system. Whereas the machine specialist previously had to assemble individual chain links himself and laboriously pull them through with cable, this effort is now a thing of the past with our ready-made system. In total, the manufacturer can save 80 per cent of his working time. The energy supply contains servo and encoder cables from the chainflex® cable programme, as well as the hydraulics and hoses for coolant. All components are pre-assembled with the appropriate connectors. The cables and hoses are specially designed for use in the energy chain and tested under real conditions in our in-house 3,800 square metre laboratory. The customer receives a guarantee on the complete system.
DVS Universal Grinding GmbH currently offers the machine series in two sizes. The UGrind 800 for workpieces with centre widths of up to 1,200 millimetres and the UGrund 1500 for sizes of up to 1,800 millimetres. For the larger machine with the same functions, the chain system only had to be extended by three chain links. The readychain® system installed in the machines today consists of a total of three preassembled energy chains. In the z-axis, two lightweight energy chains of type E4.1L (E4.38L series) supply the multifunction head with cable and hose. They are quick to install and cost-effective at the same time. The x-axis uses an energy chain of type E4/light (series 14240), which is also very light and cost-effective. Thanks to the reduced thickness of the side links and a thinner crossbar, the chain offers a larger interior space for the cable. DVS Universal Grinding GmbH is also impressed by the quality of the energy chain systems. The first machine with the readychain® has been in operation 24 hours a day, six days a week at a customer's high-volume production facility for more than 18 months without any problems.