Bread packaging machine: avoid cable breaks with chainflex and smart plastics

• What was needed: Energy chains from the E4.1L series and extremely bend-resistant chainflex cables (control cables and measuring system cables), supplied as a harnessed readychain system, CF.Q i.Sense sensors, connector concept Module Connect, drylin W linear bearings
• Requirements: Minimum bend radius of only 63mm, highly bend-resistant cables, high loads of up to 80 double strokes per minute
• Industry: Packaging technology
• Success for the customer: The E4.1L is characterised by high force absorption and is used together with extremely bend-resistant chainflex cables. The i.Sense sensors with CF.Q module detect core breaks before they occur and help users save considerable costs due to downtime.

GHD Georg Hartmann Maschinenbau GmbH offers machines for slicing, packaging, sealing and grouping as well as for the transport and handling of baked goods and foodstuffs. From individual machines to customer-specific turnkey complete systems, the company supplies everything from a single source: planning, production, commissioning and service. On the basis of a very high level of vertical integration, customers appreciate the constant availability and first-class supply of spare parts and wear-resistant parts.
In a present-day packaging machine for industrial baked goods such astoast, the right energy supply components and linear technology for safe format adjustments had to be found. The automatic packaging machine GBK 440 offers the safe packaging and sealing of product bags in one operation. A wide variety of food formats can be packaged on the machine with the shortest possible cycle times. The speed can be varied according to your requirements and application. The machine is designed for up to an incredibly fast 80 cycles per minute, which is significantly more than one packaged unit per second.
The machine works with really high stroke rates in a relatively small installation space. Therefore, highly bend-resistant cables are required that must not exceed a bend radius of 63mm. In addition, we had to find a preventive warning system to avoid a possible cost-intensive breakdown of this machine with its high output.

To achieve exceptionally small bend radii, an energy chain from the E4.1L series was chosen, which is characterised by its high force absorption. This is complemented by extremely bend-resistant chainflex cables specifically designed for moving applications, such as chainflex control cables of the type CF10.UL.05.04 with a minimum bend radius of 5xd and the type CF9.03.04.INI. A chainflex measuring system cable of the type CF113.028.D with a minimum bend radius of 7.5xd, a 6mm pneumatic hose and two further CF9 sensor cables round off the range. The customer was provided with all cables including the chain as a ready-to-install and quality-tested complete readychain system.
The guarantee of a 36-month service life or ten million double strokes does not cover the high cycle rate of up to 80 double strokes per minute for the packaging machine. For this reason, the cables are supplemented by intelligent solutions for predictive maintenance. i.Sense sensors combined with a CF.Q module continuously monitor the condition of the cables. Beginning core ruptures are recognised due to changes in the electrical specifications. This is reported to the so-called icom module, which transmits the data to a cloud system.
In case of maintenance, a plug & play system had to be available. The Module Connect, a plug-in connector concept for connecting electrical cables, fibre optic cables and pneumatic hoses is used here. Thanks to its simple modular principle, a customised plug-in/disconnect point can be configured as a module - very easy with absolute plug-in safety.
Finally, a simple but reliable format adjustment was also required for the cross-feeder with a rotating device for half loaves. Thanks to linear technology from the drylin W modular system with a manual clamp, the cross-feeder can be positioned quickly in just a few steps.