Receive long-lasting bearings in special dimensions for ergometers after just 4 days

• What was needed: iglide® P210 bearings
• Requirements: A durable and lubrication-free bearing that can withstand loads such as acceleration and heavy weight. The bearings were customized and required at short notice so that production could start quickly.
• Industry: medical equipment
• Success for the customer: Even with high loads, the bearings are extremely wear-resistant. In addition, they are rated highly due to their freedom from lubricants and maintenance as well as their long service life.

According to the Robert Koch Institute (RKI), cardiovascular diseases are the leading cause of death in Germany, accounting for around 40 percent of all fatalities. One of the most important examinations for diagnosing these conditions and monitoring treatment progress is the stress ECG. Medical ergometers are used for this purpose to provide controlled and reproducible physical stress for patients. Ergoline GmbH, based in Bitz near Albstadt, is the leading manufacturer of such ergometers and has already installed more than 60,000 units worldwide.

One of the company’s specialized devices is the ergoselect 1200 model. This reclining ergometer was developed specifically for dynamic stress echocardiography, a special cardiac examination method. The device’s inclination angle can be electrically adjusted between 0° and 45°, enabling detailed ultrasound examinations of the heart while the patient undergoes ergometric stress.

This adjustable height and tilt mechanism is precisely where Dominik Huber, Head of Design at ergoline, needed a reliable plain bearing solution. The bearings must be durable and capable of withstanding a wide range of loads, including acceleration forces and high patient weights. At the same time, they must meet strict hygiene requirements common in medical environments.

In addition, the project faced a tight production schedule. To bring the product to market on time, both manufacturing speed and cost efficiency were critical factors.

After consultation, the customer selected iglide® P210, which is well‑suited for pivoting movements on various shaft materials. It is extremely wear‑resistant, particularly for loads up to 20 MPa, and it also performs well under edge loads. Because it operates without external lubrication, the polymer bearing meets the strict hygiene requirements of medical technology. In the ergometer application, iglide® P210 provides maximum service life, as confirmed by the service‑life calculation offered through the igus online tool.

However, the standard catalogue bearings had too much bearing clearance, so an alternative solution was needed for the start of volume production.

To meet this requirement, we supplied custom‑machined iglide® P210 bearings. Thanks to our CNC production line for custom parts, we were able to manufacture the required plain bearings for ergoline in the exact geometry needed and deliver them within just four days. The cost was also significantly lower than expected.

The bearings proved successful both technically and economically. They are lightweight, corrosion‑free, and resistant to dust and dirt.

ergoline GmbH has been using our motion plastics for 13 years and has installed thousands of polymer bearings in its equipment. In other ergometer models as well, the company relies on additional igus solutions, including iglide® P210 bearings for the seat adjustment in the ergoselect 600 sitting ergometer.