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TV lift in motorhome moves reliably with smooth linear guide
- Sector: Motorhomes/caravans
- What was needed: A maintenance-free, vibration-resistant and durable motorised TV lift
- Requirements: Very limited installation space, no vibrations at a stroke of 500 millimetres despite the weight of around 7.5 kg of the 32-inch screen, long service life, maintenance-free, silent operation, vibration-resistant, easy installation
- Products used: drylin® W1040-guidance with the matching dryspin® threaded spindle
- Success for the customer: Achievement of ten times the required stroke, best price-performance ratio, easy installation thanks to single or double rail, best friction and wear results thanks to hard-anodised aluminium, extremely dirt-resistant thanks to no lubrication, suitable for applications in clean and hygienic environments
Zero complaint rate: Aluminium guide withstands more than 100,000 strokes
linear guides from igus® guarantee high quality standards in caravan construction and withstand harsh conditions
The enquiry from FAWO, Europe's largest distributor for caravan interior fittings, was demanding: the experts at CERES Entwicklungs & Produktions GmbH had to produce a maintenance-free, vibration-resistant and durable motorised TV lift. Many years of development expertise and high-quality design elements produced the desired result. In the meantime, 500 pieces of these vehicle components are produced every year, with linear guides from igus® playing a key role.
CERES Entwicklungs & Produktions GmbH in Ottensoos near Nuremberg was founded in 2012. Founder and CEO Werner Schuss sees his company as an interface between design and production: "The key to sometimes astounding results is to create synergies between different areas. Our affinity for design combined with our experience of what is feasible in terms of production technology creates added value for our customers." These can be found in medical technology, optics, precision engineering and electromechanics, plastics technology, IT and the automotive sector. In addition to well-known industrial customers such as Zeiss, Bosch, Hilti, IST Metz and Siemens, medium-sized and small companies are also among the clients. Schuss: "We develop our own products together with sales partners such as Hörmann, ISONO and FAWO. Depending on requirements, we produce initial and functional samples, small and pilot series of one to 1,000 pieces in the shortest possible time. We support product development from the initial idea through to series production."
FAWO, the European leader in caravan interiors, also commissioned a motorised TV lift for motorhome interiors. This is characterised by special requirements in terms of guidance: Firstly, there is only very limited installation space available behind the backrest of the corner bench. Secondly, with a stroke of 500 millimetres, there must be no vibrations when extended - despite the 32-inch screen weighing around 7.5 kilograms. Other marginal data from the specifications: service life of at least 10,000 strokes, maintenance-free, noiseless operation, vibration-resistant, simple installation.
Key purchasing decision: "Good from experience"
Against this background, CEO Werner Schuss found it easy to decide in favour of the corresponding guide system: "I know igus® very well and have done so since the 1980s. In the past, sliding bushes and energy chains have been used in various designs and devices. We were sure that the drylin® guide system would not cause us any stress with the TV lift." The drylin® W1040-guidance used together with the matching spindle achieves ten times the required stroke - at CERES, the tests were cancelled after 100,000 strokes.
drylin® W profile guides are a pre-assembled cost-effective system that is highly flexible. According to Werner Schuss, the price-performance ratio in particular played a decisive role: "The 'caravan' segment is extremely price-sensitive and there is massive cut-throat competition. Alternative guidance systems were significantly more expensive, heavy and also complex to handle." André Hock, technical sales consultant at igus®, accompanied the project and adds: "Single or double rails make installation very easy. Since hard-anodised aluminium is used as the rail material, we achieve the best friction and wear results."
In addition, the lack of lubrication makes the profile guide system extremely resistant to dirt and therefore also suitable for applications in clean and hygienic environments. drylin® W is also available in stainless steel or with manually adjustable bearing clearance for special applications.
Perfectly harmonised
The designers at CERES also supplemented the guidance with a spindle from the dryspin® programme. This is based on wear-resistant igus® high-performance polymers specially developed for screw drives. The spindle offers a high service life and efficiency. The efficiency is up to 82 per cent. In the case of CERES, the spindle pitch is 25 millimetres to ensure that the television can be retracted and extended as quickly as possible. This now takes just 15 to 17 seconds. Control electronics developed by CERES supply the lifting motor with 12V DC. At the same time, electromagnetic compatibility and mechanical safety aspects are taken into account.
A rounded tooth flank geometry reduces the contact area between the moving surfaces of the lead screw nut and spindle. As a result, dryspin® lead screw nuts move vibration-free and almost silently. Due to the larger distances between the individual threads, the thread adapts ideally to the specifications of the lubrication-free high-performance polymers.
Another technical detail: The proportion of tribologically optimised polymer in the threads can be increased by a factor of 1.3 for all sizes. More wear-resistant material and a higher degree of efficiency are decisive for a service life that is up to 5 times longer than standard geometries. The larger the spindle diameter, the greater the effect. In the case of CERES, this is 10 millimetres.
Facts, facts, facts
The corresponding values are the result of extensive testing in the igus® test laboratory in Cologne. André Hock from igus® explains: "Several hundred tests are set up and carried out on thread test benches every year. The results flow into various online tools. These are freely accessible on the igus® website and are used to determine the service life and the required torque."
For CERES CEO Schuss, the experience gained from previously implemented applications was also important: "The guidance is used in an aircraft reclining seat, for example. And after we had inspected a functional sample, the decision was clear." Especially as the currently dimensioned igus® components were used to install five times the required safety in the TV lift.
Another application is also being planned - a reversing camera is being considered, which also requires fast guidance for extending and retracting.
Products used
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dryspin® Screw drives in vehicles
5 reasons why dryspin® technology is used in automobiles
The dryspin® lead screw technology enables a simple and customised design of the lead screw nut and spindle according to the customer's requirements. Our experts will be happy to help you select the right thread drive and ensure short delivery times. The wide range of materials and absolute freedom from lubrication and maintenance mean that the lead screws can be used in almost any application in the automotive industry. They are ideally suited for small installation spaces and run almost noiselessly even under low drive torques. The uncomplicated system integration in your vehicle or assembly also speaks in favour of the cost-effective alternative to conventional metal screw drives.
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