Now also in series production

Three in one go: Due to high demand, Igus is launching new rope pulleys, rollers, and drums as standard products, previously only available as custom-made items. Manufactured from high-performance plastics, these new components offer a cost-effective alternative to traditional metal counterparts in numerous applications. They are lubrication-free and dirt-resistant, durable and maintenance-free, as well as vibration-damping and quiet-running.

Designers frequently rely on dependable rope pulleys to create, for example, height-adjustable workstations, mobile medical devices, or compact lifting systems. "Traditionally, rope pulleys with lubricated ball bearings are used, but their susceptibility to contamination can make them a weak point in the system," says Lars Kleist, Development Engineer for Pulleys at Igus. The plastics specialist has therefore introduced an alternative: rope pulleys made of the high-performance plastic Iglidur JB. Their advantage: Thanks to integrated solid lubricants in the material, the pulleys run directly on the shaft without additional lubricants – dirt-resistant, maintenance-free, and durable.

Designers frequently rely on reliable rope pulleys to create, for example, height-adjustable workstations, mobile medical devices, or compact lifting systems. According to tests in the company's own laboratory, Iglidur JB is approximately four times more wear-resistant than POM pulleys. To minimize wear on the rope, Igus has also optimized the pulley's geometry. For example, a specially shaped groove base ensures that the rope makes contact across the entire surface. "This makes pulleys a component that designers no longer need to worry about once installed," says Lars Kleist. The maximum recommended surface pressure is 35 MPa. The pulleys are available immediately in three sizes for rope widths of 1 mm, 1.5 mm, and 3 mm.

High-performance plastic rollers for linear adjustments

Another new addition to the Igus product range is rollers made of the high-performance plastic iglidur J. They are suitable for linear adjustments, such as for closing machine doors, for movable control panels, or compact protective enclosures. Until now, lubricated metal ball bearing rollers have often been used for these applications. “Metal rollers have a high weight, which increases the drive forces on moving axles. They are also sensitive to dirt, can be prone to corrosion, and can damage guide rails under continuous load,” explains Lars Kleist.

In contrast, the new guide rollers made of the tribologically optimized and lubrication-free material Iglidur J are dirt-resistant, corrosion-free, and gentle on the rails – and are suitable for surface pressures of up to 10 MPa. According to laboratory tests, they are also approximately six times more wear-resistant than guide rollers made of POM. Previously only available as a special component, Igus is now launching them as a standard component due to increasing demand. They are currently available with outer diameters from 19 to 40 mm and can be directly exchanged for standard ball bearing rollers without any modifications to the design.

Polymer Bandages Minimize Running Noise and Wear

If designers still want to use metal rollers, Igus has found a way to extend the service life of guide rails with a simple modification. This is where new bands made of the high-performance polymer iglidur P360 come into play. Users can easily clamp their rollers into the bands in just a few steps. This means that metal no longer runs on metal, but on plastic. This protects the guide rail and consequently reduces maintenance work. "Our laboratory tests have proven that the bands made of iglidur P360 are up to three times more wear-resistant than conventional PA bands," says Lars Kleist. "The material is particularly cost-effective and resistant to impacts and shocks. Last but not least, it enables significantly quieter operation." The rollers are available with outer diameters from 19 to 48 mm.