Plastics improve machine performance and reliability

Engineered plastics from German polymer manufacturer igus continue to revolutionise mechanical systems across various industries worldwide with a pledge to “Improve what moves” by replacing moving steel components with polymer equivalents.

The igus range of polymer bearings, spindles and energy chain cable management systems have revolutionised machines in the lifting, agricultural, manufacturing and a host of other industries and is steadily being introduced to machines in other industries to improve performance and longevity.

Managing director of igus South Africa says its range is known for their lightweight, durability and lubrication-free operation and have become indispensable in improving machine efficiency, reliability and longevity. From complex robotic systems to heavy-duty industrial machinery, the benefits of motion plastics by igus are vast and diverse and offer significant advantages in design and performance.

“One of the standout features of our motion plastics is the tribological self-lubricating properties, which eliminate the need for external lubrication. This not only reduces maintenance costs but also prevents environmental contamination caused by leaking oils or greases. In industries like food processing or pharmaceuticals, where hygiene is paramount, these components offer an invaluable advantage by ensuring clean and oil-free operations.

“Our bearings, linear guides and bushings provide smooth and frictionless motion without the need for continuous maintenance, translating to reduced downtime and extended machine lifespan. They are also designed to withstand the most demanding environments such as extreme temperatures, chemicals, dirt or high levels of moisture Here they perform reliably under stress and unlike traditional metal parts, which can corrode, seize or wear down in these conditions, igus polymers are resistant to corrosion and wear, making them ideal for use in outdoor equipment or in areas with high exposure to the elements. For machines in industries like agriculture, mining, and construction, the robust nature of igus motion plastics ensures uninterrupted operation even in the harshest conditions.

“In industries such as automotive, aerospace and logistics, reducing the overall weight of components directly leads to improved energy consumption, faster operation speeds and lower operational costs.

In robotic systems, for example, using lightweight polymer bearings and gears improves the speed and precision of movements while decreasing the energy required to drive the motors. The reduction in mass not only increases efficiency but also reduces wear on other components of the machine, further extending its overall lifespan,” says Ian.

He explains that in addition to these components igus is also synonymous cable carriers designed to guide and protect cables, hoses and other conduits in constantly moving machinery. Its Echain carriers are engineered to ensure smooth, uninterrupted operation by preventing cables from twisting, tangling or wearing out due to continuous motion.

“Unlike traditional systems like festoons, cable reels or drag chains, which often have limitations in terms of movement range and can result in cable damage or failure, the igus e-chains provide flexible movement with minimal wear. They offer several advantages over these older systems, including greater design flexibility, lower maintenance requirements and improved longevity for cables. E-chains are extensively used in industries like robotics, automation and material handling.

Moreover, they eliminate the need for cumbersome, space-consuming cable loops seen in festoons or the mechanical limitations of cable reels, resulting in more compact, efficient, and reliable machine designs.

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Noise reduction for quieter operations

In addition to their performance and durability benefits, igus bearings and bushings contribute significantly to noise reduction in machinery. Traditional metal components can generate high levels of noise due to friction and vibrations especially in fast-moving or heavy-load applications. Polymer bearings however do not transmit nearly as much noise vibration as steel and operate with minimal friction which drastically reduces the amount of noise produced by machines.

This is especially beneficial in most industries where quieter operations are crucial for improving the working  environment and meeting ever stricter noise regulations. By integrating igus motion plastics, manufacturers can enhance the comfort and safety of workspaces while also improving machine performance.