Dusting can be an annoying task. One can barely enjoy the spotless surfaces before the first specks of dust begin to collect again after cleaning. But the manufacturers of displays and semiconductors face more severe problems with it. Any tiny particle, even the one invisible to the naked eye, can damage electronic components. Therefore, the strictest cleanroom class - ISO Class 1 according to DIN 14644-1 - must contain no more than ten 0.1-micrometre (0.0001-millimetre) particles per cubic meter of ambient air. To achieve this level of purity, all suppliers of cleanroom production system components must meet the strictest requirements. In this lead, igus has developed the e-skin flat which is, a flat cable guidance system made of abrasion-optimised high-performance plastic that ensures reliable and particle-free guidance of power and data cables in moving production systems, and is thus suitable for ISO Class 1 as well.

Unique test setup: e-chain runs for 1.5 years in a dirty and dusty environment
"The e-skin flat cleanroom energy chain is ideal for robots and other automation systems in electronics production in such areas as semiconductors and display production," says Andreas Hermey, Development Manager for e-chain systems at igus. "It is so abrasion-resistant that contamination by airborne particles is no longer an issue." However, the intensity of the high-performance plastic's particle abrasion after long and intensive use has been unclear. To determine its details, igus launched a unique test setup. Part one of the experiment was conducted in igus's laboratory. The energy chain moved in an environment with normal levels of dust and dirt for around 1.5 years, during which it performed 60 million double strokes.

igus e-chain stays at the highest cleanroom class even after 60 million double strokes
igus conducted the second part of the experiment which took place in the cleanroom laboratory in Cologne, in cooperation with the Fraunhofer Institute for Manufacturing Engineering and Automation (IPA), also their development and certification partner for more than 17 years. The heart of the setup has three so-called laminar flow boxes equipped with high-performance filters that enable tests in uncontaminated air. The worn-out e-chain was in motion there for over 100 minutes. Sensors detected particle concentration in the surrounding air. "Even after 60 million double strokes, our e-skin flat e-chain still qualified for the highest cleanroom class. This finding offers cleanroom production facility operators additional confidence," Hermey shared the results.

Modular concept for flexible filling
Along with the extreme abrasion resistance, the e-skin flat comes with a modular design. If a profile into which cables have been fitted is defective, the user can just change that module. Many other solutions available in the market would require the entire system to be replaced. The module connection also allows individual profiles to be interlinked. The cable guidance system thus grows in line with requirements and ensures investment security. In combination with the specially harmonised chainflex CFCLEAN stranded structure, the complete system offers an especially high level of reliability, also having a globally recognised certification from the well-known US Underwriters Laboratories (UL) organisation. Finally, the cable guidance systems are 9dB (A) quieter and cost 20% less than standard ribbon cables.

igus GmbH develops and produces motion plastics. These lubrication-free, high-performance polymers improve technology and reduce costs wherever things move. The German-based company is market leader in energy supplies, highly flexible cables, plain and linear bearings as well as lead screw technology made of tribo-polymers.

For details, contact Kaushik R, Product Manager of igus® (India) Private Limited, Bangalore, on email: kramanujachar@igus.net, or visit www.igus.in