Smart Break Detection in Mercedes Driving Simulator

Smart igus e-chains reliably transport energy, data and media in highly dynamic applications in the driving simulator

The Sindelfingen plant, with a history stretching back over a hundred years, is the Mercedes-Benz Group AG’s vehicle plant with the longest tradition and the competence center for the manufacture of vehicles in the global production network. This site is also home to one of the most modern driving simulators in the world – equipped with e-chains from igus.

The Sindelfingen plant is one of the German car manufacturer’s largest production and development facilities and employs around 35,000 people. As a pioneer in safety, the German premium manufacturer also plays a leading role in driving simulators. The company has been using moving driving simulators for 35 years. In 1985, the first self-developed driving simulator was put into operation in Berlin-Marienfelde. Fifteen years later, the Technology Center (MTC) in Sindelfingen saw the opening of the world’s most modern driving simulator at the time. Its key data: 2.2 MW of electric drive power, “22 tons of agility” and a total value of over 25 million euros. With a 360° screen, the fast electric drive and the twelve meter long rail for the “air-bearing movement”, the system is one of the most powerful in the automotive industry. The simulator is primarily used for testing and validating driving dynamics, operating and display concepts, vehicle assistants and autonomous driving. To ensure that all the necessary cables for the power supply, control system, network technology, as well as pneumatic and cooling water hoses are safely routed and protected, energy supply chains from igus are used.

High dynamics and enormous loads for the energy supply system

Energy chains act like an umbilical cord: they ensure the supply of energy, data and media and are constantly in motion. The vehicle’s control equipment is connected to the driving simulator’s computer control system via data lines. The computer calculates the car’s driving behavior over 1,000 times per second and issues the corresponding commands to the mechatronics. It moves the system at a maximum speed of ten meters per second (36 km/h). “In the energy chains used, 90 kilograms per meter are distributed over four chains. Each chain is 14.80 meters long and the travel distance is designed for 20 meters. We achieve an exceptional level of dynamics here, which puts enormous stress on the material – and yet we’ve had no issues for 10 years with just one system,” says Frank Schlögel, Head of the Engineering Projects and Assembly Services division at igus. To further increase system safety and availability, the team at the Technology Center decided to replace all the cables and, at the same time, install new P4.1 series energy chains including breakage monitoring. The advantage of the P4.1: Each link connection contains a bearing point for pivoting movement. This has now been equipped with maintenance-free plain bearings made from high-performance polymers, more than doubling the service life of the e-chain.

Everything from a single source

Once the decision was made, everything happened in quick succession. The existing P4 series profile rollers have been replaced by the latest generation e-chain P41.80 series. The old cables were replaced with new chainflex cables from igus, which meet all requirements for EMC safety as well as standards and regulations such as UL, VDE, CSA, Profibus, and more. As the existing guide trough was also specially manufactured and adapted to the tight installation space ten years ago and was still in very good condition, those responsible decided to replace only the damping profiles. In the new P41.80 system, the upper and lower run are offset one above the other. This ensures smoother running and ideal noise insulation. In addition to comb-like autoglide bars, the system also has tribologically optimized plastic rollers, which significantly increase the durability of the chains. “We can offer our customers everything from a single source — from project planning and delivery to installation and maintenance. That is, of course, a major advantage in a modernization project like this,” says Daniel Quick, Sales Manager West at igus.

Energy chains go smart: Breakage detection (EC.B) increases safety

To safely guide the weight of the cables, the e-chains used consist of multiple strands instead of the usual two. “With such dynamics, speed, and the size of the system, it’s crucial to carry out precise calculations to ensure the ideal weight distribution and even load on the strands. Our chain links are designed for demanding continuous operation. And if an unforeseen issue does occur during real-world operation — especially in such a highly dynamic application — we can detect it immediately. That’s exactly why we developed our unique EC.B breakage detection system,” explains Frank Schlögel. With this breakage detection, a cable is tensioned by the e-chain, which records any change in length and reports it to the EC.B sensor. This means that chain breakages are detected at an early stage and the system can be switched off automatically.

Summary

With the modernization of the driving simulator, igus has succeeded in further increasing system safety and availability, ensuring a high level of operational reliability. „The cooperation with the Mercedes-Benz Group was excellent and it was simply great fun to be able to support such a fantastic and exciting project from the very beginning. And, of course, it also makes me a little proud to ensure greater safety for such a renowned company”, concludes Frank Schlögel.