First Place Gold manus Award:
Kesmac Inc.
Ontario, Canada
Plastic Bearing: iglide R
Solution:
The iglide R flange bearings were used because of the direct size interchangeability to the bronze bushings. The iglide bearings were used to eliminate the need for greasing 14 grease points. This decreases the maintenance time required. Secondly, owners do not want grease falling onto the freshly cut grass, for environmental and cosmetic reasons. Using the igus bearings also deliminated the machining costs required for the grease nipples.
Technical advancement through the use of plastic bearings: Replacement of an existing solution
Economic impact of using plastic bearings:
Lower manufacturing costs and
reduced maintenance costs
Type of bearing: iglide R
Application:
The Kesmac 11 Gang Reel Mower has 14 pivot points with 28 bushings. The wings fold up for transportation and the lift arms pivot to lift the reels.
Problem:
A replacement for bronze bushings was required. Therefore a suitable direct replacement was necessary. Second, a bearing that would not require greasing was desirable. Thirdly, a bearing was required that could better withstand vibration during operation and transportation.
Second Place Silver manus Award:
Waters Corp.
Milford, Mass.
Plastic Bearing: DryLin N linear guide system
Solution:
A completely new design of this assembly was undertaken to address the following issues:
• Reliability: a new design mechanism featuring direct drive to the needle, eliminating two 3/8” diameter guide shafts within a yoke assembly.
• Service: easy installation and accessibility without removing the top cover of the instrument
• Cost: reduced parts count and leaner design
Technical advancement through the use of plastic bearings: Replacement of an existing solution
Enhancement of technical performance
Elimination of technical problems
Economic impact of using plastic bearings:
Increase in machine reliability
Lower manufacturing costs
Longer service life
Reduced maintenance costs
Higher Quality
Type of bearing: Drylin N linear guide system
Application:
The High Pressure Injector/Seal Pack subassembly in the Alliance HPLC separation system is the mechanism used to collect samples and deliver them into the flowing mobile phase for transport downstream. The assembly consists of a linear actuator stepper motor supported by a cast stage which is anchored to the chassis. The stepper motor is driven by a unipolar chopper drive circuit which turns a lead screw that drives a union along a linear guide. The union contains the injector needle and sample loop which is moved through the seal pack assembly that is mounted to the bottom of the Stage. The seal pack is comprised of an upper and lower seal housing which sandwich a seal body containing two high pressure seals. These high pressure seals are designed to separate and seal the mobile phase from the outside environment. There are two optical switches that are mounted on a bracket that is anchored at the top and side of the stage. A flag mounted between the union and the carriage of the linear guide passes through two interrupt switches when the needle is moved down or up.
The position of the needle in this assembly is determined by a combination of motor steps and the interrupt switches. The needle is required to move to four different positions during the injection cycle:
The upper interrupt switch is used to define the stream position of the needle cross port. The seal position and the vial position are determined by motor steps. There is another position called the “auto-add” position which is used when the needle has been retracted from the vial in-between “auto-add” sample draws. The lower switch is used to determine the position of the needle for the “auto-add” operations.
Problem:
The injector assembly in the Alliance product has been problematic over the past few years, exhibiting binding and loss of positioning, resulting in increased warrantee costs and customer down time.
Third Place Bronze manus Award:BC2A Design, Inc.
San Jose, Calif.
Plastic Bearing: iglide G300
Technical advancement through the use of plastic bearings:
Development of a new product
Economic impact of using plastic bearings:
Increase in machine reliability
Longer service life
Reduced maintenance costs
Higher Quality
Type of bearing: iglide G300
Application:
The iglide G300 bearings are used as the main bearings in a high- performance, dual pivot, road bicycle brake caliper for consumer and professional racing applications.
Problem:
Because the brakes are aimed at a top-end market niche, all components in the caliper assembly are made from the highest- quality materials available. As an example, the main arms of the brake calipers are CNC machined from high strength to weight ratio grade 5 titanium, FEA optimized for brake modulation and weight savings. The brakes are ridden under all weather conditions, including rain and dust. They have to function under the extreme demands made by top-level profession cyclists, as well as the consumer market.
Second to function, weight is the primary driver; all components have to be as lightweight as possible, every gram counts in the total weight. Because this is a low volume product, profit margins are inherently low and individual part cost is important.
Competitors use steel backed PTFE bearings in this type of application, but under extended use, the thin PTFE lining becomes saturated with road debris, severely limiting the bearings life and functionality.
Solution:
High-performance polymer-based bearings address both the performance and weight issues. Because the bearing surface of a polymer bearing is potentially much thicker than the thin steel-backed PTFE bearing surface, the polymer bearing is able to absorb a much greater amount of road debris before becoming saturated, extending the life of the bearing before a rebuild is required. Because the polymer-based bearing has a lower density than steel backed PTFE, it weighs approximately only one-third as much.
Working directly with igus representatives we were able to test several different iglide series bearings under varying real-world conditions. The iglide G300 bearing series, with it’s unique combination of low friction, long life, low weight and low cost, answered all of our concerns and is now used in both pivot points in the dual pivot caliper design. The brakes were most recently successfully raced at the San Francisco Grand Prix bike race, billed as “ America ’s Toughest Bike Race”.
History of manus
Manus was developed to uncover applications using plastic bearings in new and challenging ways to acheive superior technical and economical performance. It also aims to educate the industry on the merits of plastic as a viable material for use in machinery components and to showcase the multitude of ways plastic bearings can support the most complex or the most simple applications and every kind in between.
Last year, igus unveiled the first North American Plastic Bearing Design Contest. Contestants from across the United States and Canada competed to win various prizes. Applications ran the gamut from sports equipment, to medical devices and woodworking machinery. Check out manus 2004
The winning applications from 2004:
Two manus Contests have been held by igus Gmbh in Germany, one earlier this year and the other was the first-ever manus Contest held in 2003. The success of that endeavor led to the North American manus Contest in which more than 60 contestants took part. Igus UK followed up next with its own manus Contest late last year and now igus offices worldwide are planning manus contests as well.
Check back for updates on the next manus competition.
Congratulations to the winners and to all who participated! Those who didn't win this year are eligible to resubmit their application in any upcoming manus contests.
If you have questions or comments, please contact Farrah Phillipo, manus coordinator at (800) 521-2747 or via e-mail at fphillipo@igus.com.