Custom 3D printed bearings in rope-free lift

Fast delivery despite complex geometries

With the innovative MULTI interchangeable system, Thyssenkrupp elevator (TKE) have designed a ropeless MULTI lift which has been specially created to guide lift cars as they travel vertically, horizontally and at an angle. The designs required some complicated geometry parts, as well as a short delivery time, so the manufacturing process of these parts needed to be flexible. The components were finally designed and manufactured using 3D printing in iglidur i3, a laser sintering material with excellent wear properties.

The 3D printed bearing gliders not only provided excellent sliding properties, the material chosen also ensured high strength, maintenance and lubrication-free operation, as well as demonstrating how additive manufacturing is an adaptable manufacturing method and can be for demanding applications.

Requirement, challenge and solution

Requirement

What was needed: Special plain bearing for the linear drive
Manufacturing process: Laser sintering
Requirements: Fast delivery, self-lubricating
Material: iglidur® i3
Industry: Building technology
Success through cooperation: Fast delivery despite complex structure, excellent sliding properties for the linear guide

The X-Changer moves the MULTI car in several directions and thus enables completely new connections for lifts in and even between buildings

Challenge

Due to the complicated structure and the need for delivery at short notice, TKE decided to have the necessary linear bearings made with additive manufacturing. A material was needed that could meet the high requirements of reliability and guiding characteristics for the linear drive.

Three of the twelve shafts of thyssenkrupp's test tower are reserved for testing the MULTI lift. Among other things, the iglidur® 3d printed bearing by igus® are used here

Solution

The special gliders made of iglidur® i3 were quickly printed and delivered using laser sintering. The high-performance plastic iglidur® i3 is characterised by particularly good mechanical values and high strength. Thanks to the incorporated solid lubricants, the components made of iglidur® i3 require no additional lubrication. This also makes them particularly wear-resistant and durable.

More detail on the application

The linear drive moves lift cars both vertically and horizontally - and even at an angle
Thyssenkrupp is one of the most progressive companies in the field of lift technologies and services. 160 years after the introduction of the lift, the company is breaking new ground in lift technology - with the ropeless MULTI lift system.

In the MULTI, several cabins travel up one shaft and down the other in a continuous loop - comparable to a vertical circular railway system. With a speed of 6 m/s, this system enables almost constant access to a lift car every 15-30 seconds. Thanks to MULTI's innovative interchangeable system, the linear drive and the guide rods can rotate through 90°. How does it work? By using linear motor technology that was once developed for the Transrapid magnetic levitation railway. This revolutionary drive moves lift cars both vertically and horizontally - and even at an angle.

Printed linear gliders made of iglidur® i3 - Reliable in use in the lift guide system
The ropeless lift is being tested in the 246-metre-high test tower at Thyssenkrupp in Rottweil, which is also home to the Group's German research and development centre.

Communication between and to the vehicles runs via antennas along the entire route. The antennas used for this communication are routed along a rail. The guidance is provided by the linear gliders printed by igus® from the self-lubricating SLS-plastic iglidur® i3.

iglidur® i3 is the plastic most frequently used for printing abrasion-resistant special parts - it impresses with its outstanding mechanical values and high strength. The laser sintering powder can be purchased for in-house processing or as a ready-printed component using a 3D printing service.

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