Third week of remodelling

Now for the real thing!

Our car for “iglidur® on tour” shows us what’s ‘under the bonnet’!

Now that our car has disclosed its secrets the remodelling goes one step further! The bearings at the break pedal have already been replaced! Following you will find more novelties:

Now it is time to start dealing with the “starter”. This is used to not only start the engine but also generate electricity. In our car the “starter” is fixed to a shoulder bolt. Allowing the bolt to move enables radial- as well as axial movements to balance out vibrations. This ensures that the link which connects starter and crank shaft, is tensioned all times. The bolt, holding the starter, is fixed by two bearings. They enable the movements and are going to be replaced by igus® bearings.


The bold that carries the “starter”

Also the suspension strut is brought to focus. Its purpose is to prevent smashing our heads on the ceiling when going over a bump. More precisely we are going to examine the rolling bearing which is located above the suspension to ensure that the axis can be moved. As it is frequently in use it has to be able to endure pressure and friction over a long period of time.

This bearing is planned to be replaced with an igus® bearing which is specifically manufactured to endure pressures up to 11KN (which is about 2420 pounds)! Nevertheless there are two challenges with this bearing: The original bearing is of a different size which means we need to confirm if we still can use this special igus® standard-bearing or if one needs to be manufactured first. Furthermore, the suspension is screwed with the rolling bearing. Thus the igus bearing® has to be adapted. Will the suspension work afterwards or shall we already prepare ourselves to face a terrible headache?

The original bearing (right) and the possible igus® bearing (left).

Johannes Thomé is showing where the bearing is located

The throttle valve was examined too! Throttle valves are located in the air intake pipe of a car. Modern engines not only need fuel but the right mixture ratio of both fuel and air. The volume of air flow is determined by how fast we accelerate which is regulated by the throttle valve. It is placed on a shaft, which is moved by a small electric motor fitted inside our two bearings. They will be replaced by igus® bearings.

The throttle valve which is located on a shaft.

The handbrake

Last but not least the handbrake. The hand lever is connected to a module that is located on the car body. It is going to be investigated if the hand lever is connected through a replaceable bearing or just a metal bolt. This decides on whether we can fit an igus® bearing or not.

Conclusion: It comes to details but it still remains exciting!

Second week of remodelling

Our car for “iglidur® on tour” stripped off!

In the course of the next weeks the car will be totally dismantled.

During the first step it will be lifted so that the engine can be lowered and examined. This is done in order to check if we can replace bearings in the “starter”. Simultaneously the modules that have been already dismantled are going to be examined closely too. In cooperation with the german Technical Control Board (TÜV), igus® employees investigated which parts are replaceable. Thus the question that arises is “How can they be replaced best?“

Some are absolutely no challenge for the specialists in the University of Applied Sciences. For instance the bearings at the break pedal. They can be easily substituted by igus® “standard bearings”.

On the contrary other parts offer surpises as well as challenges like for instance the convertible top:

A positive surprise: The convertible top contains steel bearings! They will be substituted by igus® plastic bearings which will be one of the many parts sent on a 100000km (approx. 62100 miles) journey! By doing this we are proving that we have confidence in our products and that our plastic bearings are on a par with steel bearings.

A challenge: Bearings in the convertible top are riveted and therefore can only be replaced forcefully. Furthermore those bearings, which are “guiding” the top, are an on-off production meaning that igus®-substitutes need to be manufactured! Will the convertible top still work? Will it still protect us from rain, mud and extraordinary weather conditions on this incredible long trip?

Also the “door window machanism” consists of revitet bearings. Will it still work after they had been removed? Is it also possible to recreate the sliding carriages and to adapt them to the giving System?

The mechanism for the door-window with riveted bearings

iglidur® on tour

First week of remodelling At least 21 countries in nine months! Our car for “iglidur® on tour” is going to drive not only on conventional roads but also on dirt roads along fields, mountains and forests to visit customers, branches and exhibitions. India, China, South Korea, Japan, USA, Canada, Brazil and almost all of Europe are destinations of this extraordinary tour.

In the Cologne University of Applied Sciences students are working under the instruction of Johannes Thome to get the car ready for the trip. Over the course of the next four weeks various parts and bearings in the car are going to be replaced by igus® parts which will be put on the test when travelling about 100000km. During the exhibition in Hannover in 2015 they are going to be removed again to demonstrate how they endured the tour.

Currently students have already removed the chassis to get access to the modules they work on. In the next step they analyse how certain bearings in the car could be replaced. For instance they exposed the front part to be able to deal with the linkage of the windscreen wipers and the steering gear. The rear chassis as well as the doors have been removed too. The bearings which are helping to lift and lower the window will be replaced by igus® bearings.


The chassis on the sides had been removed to work on the window opener

In the course of the next weeks the project will be accompanied to document how the car will be prepared for this unique adventure.

RoboThespian 2013 Manus award winner, entertains at the Consumer Electronics Show.

RoboThespian, designed by Engineered Arts Limited, is a life-sized humanoid robot designed for human interaction in a public place that can be used for multiple purposes from education to pure entertainment. The integration of 85 iglidur bearings, from igus, allow for the smooth human-like movements to flow throughout the body from head to toe. This contributes to a longer life for RoboThespians around the world. The low friction, small size and lightweight iglidur bearings complement the anodised aerospace grade aluminium components used throughout RoboThespian. To see the robot in action at the Consumer Electronics Show recently in Las Vegas, click here: http://www.bbc.co.uk/news/technology-25681228 For more information on igus bearings, visit the website on: http://bit.ly/1eKB7y9

Welcome to our Brand New Blog!

Firstly, we would like to thank all of our new and existing customers for their loyalty throughout 2013.

2014 will see some even bigger and better innovations from here at igus, and this blog is where you can stay ahead of the game on what these may be via regular updates.

Another way for you to be kept up to date is via our social media platforms such as Twitter, Facebook and LinkedIn, which can all be accessed easily via the buttons above. Feel free to talk to us on there or comment below, we will always get back to you!

Plastics for longer life!

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