Flexible cable routing for friction stir welding machines

Profile

• What was needed: twisterband HD, R4.1 series e-tubes, chainflex cables
• Requirements: Very small installation space, low maintenance, requires rotation of +/-720°, 24/7 operation
• Industry: Machine tools
• Success for the Customer: The twisterband HD and R4.1 e-tube solution delivered reliable 24/7 operation and ±720° rotational movement in a compact space resulting in improved uptime and dependable performance for Grenzebach’s friction stir welding systems.

The friction stir welding (FSW) process can be used to create media-tight connections, for example when welding heat exchangers and coolers. Since the material is welded in the plastic area, there is no structural change as in thermal welding. This makes FSW ideal for the production of battery trays for electric vehicles. This is how the process works: A wear-resistant, rotating tool is immersed in the material to be joined. This creates frictional heat, which makes the metal malleable. The two workpieces are stirred and compacted by the forward movement of the tool along the seam, so that a firm connection is created.

Since the tool has to dip in and out of the material with every seam, the welding process should take place with as little interruption as possible. For some components, this requires a high degree of mobility of the welding head, for example when the FSW system applies meandering sealing welds to a component the size of an A4 sheet of paper. The welding head must then rotate at least 360° several times within 60 seconds, along with start-up and shut-down movements and contours within the component. This ultimately requires a rotation of +/-720 degrees within a very small installation space – a challenge for the energy supply system.

Two twisterband HD systems were directly coupled with R4.1 series e-chains and chainflex cables to create a robust and reliable energy supply solution. Up to nine chainflex cables, along with cooling, sensor, servo, and encoder lines, were routed through R4.28 series energy chains and the TBHD.30 twisterband HD to accommodate the welding head's extensive rotational movements.

The twisterband HD is a compact, spiral-shaped e-chain® designed specifically for continuous rotary motion, supporting up to 20 revolutions around its own axis. It enables rotational movements of up to 7,000° horizontally and 3,000° vertically, even in confined spaces and at speeds of up to 180°/s. The system provides reliable, uninterrupted guidance of power, media, and data cables while minimizing space requirements.

In the HD version, the chain links are connected using a bolt-and-hook design, creating a defined bend radius while increasing system stability. Engineered for continuous 24/7 operation, the solution delivers low-maintenance, low-wear performance and allowed for fast and straightforward replacement when service is required.