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Compact cable protection at high-speed on the dual-plane fluoroscope

Biomechanics research team relies on e-chain® in innovative fluoroscopy system

The Laboratory for Movement Biomechanics (LMB) at ETH Zurich is investigating the kinematics and kinetics of healthy, reconstructed and replaced joints. To this achieve this, it has developed a two-plane fluoroscope that can track highly dynamic human joint movements in 3D space and record high-resolution, biplanar X-ray images at high speeds. Two types of igus® energy chain are used to safely guide the many power and signal cables used in these high-accelerating imaging units during fluoroscopy.

Energy chains P4.1 and E4.1 in the two-level fluoroscope of the LMB

Profile

  • What was needed: energy chains for guiding the power and signaling cables both horizontally and vertically
  • Requirements: suitability for high accelerations and speeds, space-saving, low weight, long service life, minimal maintenance requirements
  • Industry: Medical technology, medical devices
  • Success for the customer: With P4 Series energy chains, the cables can be guided in the existing floor channels in a space-saving manner. Thanks to built-in profile rollers, these chains move with low friction even at high fill weights and speeds and require only a small amount of drive force. Our robust and easy-to-fill E4.1 e-chains® provide vertical cable routing. The modular design of both e-chain® series offers flexibility for future customization.

Application Overview

The bi‑planar mobile X‑ray system developed by the LMB is capable of tracking highly dynamic human joint movements in 3D space. By utilizing two overlapping image planes, the device overcomes out‑of‑plane errors, enabling accurate 3D registration of both implant and natural skeletal kinematics. Its design, featuring a separate image intensifier and image source, provides greater freedom of movement in both the horizontal and vertical directions.

This new technology broadens the foundation for understanding and monitoring degenerative changes in the musculoskeletal system, as well as evaluating the outcomes of orthopedic treatments and rehabilitation measures.

Problem

The development team was looking for suitable energy chains that would safely guide the many different power and signal cables of the motion track system. In order to accurately track the human knee during dynamic activities, the heavy carrier carriages for the imaging units have to accelerate rapidly. Finding energy chains that are suitable for such high accelerations was a challenge... especially in conjunction with the tight installation space. The chains had to be compact enough to fit into the 24 m long / 1.20 m wide / 0.15 m deep channels embedded in the laboratory floor.

Conditions for the horizontal | vertical axis:
Track length: 20 m | 1.5 m
Acceleration: ≥ 20 m/s² | ≥ 13 m/s²
Speed: ≥ 5.5 m/s | ≥ 2.5 m/s
Weight to be carried per unit: 500 kg | 150 kg
Cables to be transported: 7 power and 20 signal cables | 4 power and 14 signal cables

Solution

The team sought advice from our e-chain® experts in Switzerland and came up with a solution that met all requirements: E4.56 e-chains for the vertical movement and a double chain solution with P4.42 e-chains for the two horizontally travelling carriages. We have developed the P4 series for applications with very high fill weights and speeds. Because the P4 is equipped with profile rollers, the drive force for moving the e-chain® is reduced to less than 25% with quiet, low-vibration operation and a long service life. As a modular construction kit, the system also offers the LMB team a great deal of flexibility for future customizations.

The vertical chains belong to the E4.1 series, which is suitable for almost all applications. It is also robust, low-noise and modular. It is also quick to assemble and easy to open. If cables need to be replaced or added, this does not require a great deal of effort.

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Two-plane fluoroscope of the LMB, detail at the knee
Two-plane fluoroscope of the LMB, detail at the knee

The fluoroscope can be used to obtain key information about the kinematics and performance of a knee joint.

Two-level fluoroscope of the LMB, sketch
Two-level fluoroscope of the LMB, sketch

The imaging units travel along with the test person on a 20-meter-long track.

Two-level fluoroscope of the LMB being developed
Two-level fluoroscope of the LMB being developed

e-chains® from igus® are used to guide the many power and signal cables.

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