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

Requirement, challenge and solution for the Mercedes automotive driving simulator

Requirement

The automotive manufacturer required a reliable energy supply system for one of the world's most advanced driving simulators. The application demanded the safe transmission of power, data, cooling water and pneumatic media within a highly dynamic environment operating at speeds of up to 10 m/s. Maximum system availability and operational safety were essential to support the continuous testing of vehicle dynamics, driver assistance systems and autonomous driving functions.

Challenge

The 22-ton driving simulator is subjected to extreme dynamic movements and continuous operation. The energy supply system needed to withstand high loads while protecting sensitive power and data cables over a travel distance of 20 metres. Any unexpected chain failure could result in costly downtime, disruption to vehicle testing programmes and potential damage to critical equipment. Early fault detection and long-term reliability were therefore key project requirements.

Solution

igus® supplied a complete cable management solution featuring P4.1 roller e-chains®, chainflex® cables and the i.Sense EC.B condition monitoring system. The robust energy chain system safely guides power, data and media through highly dynamic movements, while intelligent breakage monitoring continuously checks chain condition and alerts operators to potential issues before failures occur. The result is increased system safety, reduced unplanned downtime and a fully integrated solution delivered, installed and supported from a single source.

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.

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.