igus® tribopolymer research: friction, wear and mechatronics –
all tested in the igus® laboratory

Facts and figures of the igus® lab at a glance:igus® operates the largest laboratories of its industries with test facilities for energy chains, highly flexible cables, plastic bearing technology such as plain bearings, ball bearings, linear bearings, spindle drives, semi-finished products, piston rings etc.

29,600 sq. feet of Test labs

3,000 energy chain system tests annually on 180 plants: in-house climatic chamber, outdoor tests, noise chamber, up to 130 m travel, robot plants etc.

Two billion test cycles annually for highly flexible cables

One million electric measurement data sets annually

15,000 tribology tests (Friction and wear ) in 300 test facilities.

140 trillion test movements in the bearing business area


 
"plastics for longer life®" – that is our vision. For this reason we passionately develop products that extend the service life of their machines, eliminate maintenance work, thus reducing costs. And what's more, the longevity of all our products can be predicted online and delivered fast.
 
For this purpose, igus® operates the largest experimental and test laboratory for its industries. There beats the heart of the igus® innovation. In an area of 29,600 sq. feet we develop, test and verify single components or finished systems under real-world conditions. Solely with the objective of providing the best plastic product to our customers every time.
 
Focus of extensive experiments are push-pull forces, coefficients of friction, wear and abrasion and driving forces under the most varied speeds and loads. Furthermore, we test our components for effects in dirt, in the most varied weather conditions such as cold, or even in impacts and shocks. The aim is to continuously move up the limits of application.
 
In line with our core Tribo-polymers technology, 15,000 product tests are performed for the coefficients of friction, wear and abrasion alone. And this in more than 300 test facilities in parallel. In addition, 140 trillion test movements are performed for plain bearings, linear bearings and ball bearings and screw drives and robot joints.
 
In the business area of energy supply systems and permanently moving cables, the spectrum ranges from the test stands of the climate chamber, through linear test axes with different travels and accelerations, up to user-specific tests on six-axis robots and test stands for dynamic simulations such as bending cycles. Annually, 3,000 energy chain systems are tested, two billion test cycles for highly flexible cables are run and a million electrical measurement data sets are generated.
 
For some twenty years, igus® performs systematic chainflex® test series in its own test lab: Currently, 600 tests run in parallel for flexible cables. Beyond the standard norms, igus® has also created testing and manufacturing standards for chainflex® cables, which meet the actual requirements of cables for the constantly moving sector. On one hand, we constantly explore new manufacturing methods that help to optimize production costs; on the other hand, we are always working on improving materials that will ensure a still better interaction of the e-chain® with the cables.
 
All test results are documented and archived in the company's database. On this basis, the service life of our products are reliably calculated, new materials researched and products developed. In addition, our test results are incorporated into our online calculators.

Test lab bearings

Test lab bearings  
 

Test lab e-chains®

Test lab e-chains®  
 

Cleanroom tests

Cleanroom tests: Preliminary "cleanroom" test at the igus® lab

Cleanroom tests    

Test lab chainflex® high flexible cables

Test lab chainflex® high flexible cables  
 
Excerpt from tests

Test 2233 - CF5.10.25

Control cable CF5.10.25 survives more than 41 million double strokes with 25% lower bending.

Test 2233 - CF5.10.25    

Test 3089 - CFBUS.045

Bus cable CFBUS.045 has withstood more than 76 million double strokes in the endurance test.

Test 3089 - CFBUS.045    

Test 3105 - CFROBOT5.501

Robot FOC CFROBOT5.501 glass fiber cable withstands more than 28 million cycles at +/- 180°/ft torsion.

Test 3105 - CFROBOT5.501    

Test 3621 - CF98.05.04

Control cable CF98.05.04 survives more than 138 million double strokes at a radius of 18 mm (3.2 x d).

Test 3621 - CF98.05.04    

Test 4009 - CF THERMO. K001

Thermal compensation cable CFTHERMO.K001 lasts more than 97 million strokes at a 1.89 in (48 mm) radius.

Test 4009 - CF THERMO. K001    

Outdoor tests

Outdoor tests  
 
igus® inc.
PO Box 14349
East Providence
R.I. 02914

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