After weeks of retrofitting work at Cologne University of Applied Sciences, the small car set off on its round-the-world trip. Low-friction and dry running is the modern solution for a wide range of moving applications. To continuously improve its products, igus has been conducting research in this area for decades using its in-house test laboratory, the largest
in the sector. To demonstrate the capabilities of the carefully tested, innovative plastics technology, which has now been used millions of times, igus decided to fit a small car with iglidur components and send it on a strenuous round-the world trip along tarmac, gravel and mud tracks and roads across four continents. On the way, it will spread the company’s motto to the world:
‘plastics for longer life’. For its first point of call, the small car is in India, where it will be exhibited at the ‘Auto Expo’ trade fair. It will then continue to China and spend a month driving to various destinations around the country. Further Asian countries of Japan, South Korea and Taiwan will then follow before the car makes the crossing to America. On arrival, the plans include a coast-to-coast step straight through Canada and the USA. The route plan then returns to Europe, where several customers, trade fairs and igus offices will again be visited. Every stop and every kilometre can be experienced and tracked in detail at ‘blog.igus.de/iglidurontour’.
To prepare the car for this ambitious practical test, it first had to be retrofitted by a team from Cologne University of Applied Sciences under the leadership of Johannes Thomé and the igus bearing developer Michael Krug. The aim was to replace everything possible with igus plastics – in so far as technically feasible and permitted by TÜV regulations. The metal bearings on the brake pedal, windscreen wipers and window lift mechanism, along with the shift unit, seat console, handbrake and alternator were replaced with pure polymer bearings. Also replaced with the iglidur bearings was the throttle valve and the convertible roof. Many modules had to be disassembled and rebuilt to factory and functional specifications. Although standard plain bearings could often be used, in some cases CAD modules were needed to create carefully customised spare parts. The components were then milled or turned from iglidur bar stock. This involved the use of several of the 45 different iglidur catalogue materials. igus high-performance plastics were installed at a total of 56 bearing points. Attention was even paid to ensuring visual likeness, for example in the case of the seat locking mechanism. All modifications to the small car have now been successfully completed and the team of vehicle mechanics and plastic developers are thoroughly excited about sending their creation into the world.
More and more manufacturers are discovering the qualities of cost-effective, high-performance components made from tribopolymers. ‘Motion plastics’ are used in numerous modules, from seat and convertible roof systems through multi-link hinges and engine compartment components to undercarriage applications. This trend will become even greater in the future. This is because maintenance and corrosion-free polymer plain bearings that require no external lubrication, and weigh seven times less than metallic rolled bearings, speak for themselves. They are kind on both the environment and the pocket as they reduce production costs and offer a longer service life thanks to their wear resistance. In vehicle interiors, they are the ideal solution for dampening noise. At the same time, however, their robust structure and resilience make them equally predestined for ‘outdoor use’, which will be clearly manifested when they encounter the many weather conditions, altitude kilometres and road types along their journey. The range of potential uses has far from been
exhausted and perhaps the polymer-bearing-packed car’s demonstration triparound the world will inspire developers to come up with further new and exciting ideas and concepts.