Material handling systems integrator Bastian Solutions has turned to high-performance lubrication-free motion plastics from igus to overcome operational challenges in its Ultra Blue robotic truck-loading system. The adoption of polymer components including plain bearings, linear guides, spherical ball joints, and slewing bearings enabled significant improvements in reliability, maintenance reduction, and performance consistency across demanding warehouse environments.
Robotic systems deployed in warehousing operations face harsh conditions including temperature fluctuations, dust accumulation, and constant high-impact loads. Traditional metal machine components—particularly bearings requiring external lubrication—prove vulnerable in these settings, leading to frequent maintenance intervals, unplanned downtime, and potential contamination issues.
Ultra Blue combines multiple capabilities into a single automated loading solution, moving boxes from warehouse floors directly into truck trailers. The system needed components capable of withstanding continuous, high-cycle operation in dynamic, debris-laden environments. Specific challenges included temperature swings from summer humidity to winter cold, presence of particles from corrugated boxes, and variable package conditions creating irregular loading dynamics.
Rather than continuing maintenance battles with conventional components, Bastian Solutions integrated a comprehensive suite of igus high-performance polymer products. Plain bearings operate within a four-bar linkage mechanism driven by cam profiles. Linear guides support the linkage mechanism while larger custom guides serve the conveyor section. Spherical ball joints connect conveyor sections that pivot relative to each other, and plain slewing bearings function as rear pivots in areas particularly prone to debris accumulation.
A key advantage across all igus components is their self-lubricating nature. Unlike metal bearings demanding regular lubrication, igus products incorporate solid lubricants embedded within high-performance plastic materials. This ensures adequate lubrication at all times without external maintenance, eliminating labor costs, lubricant procurement expenses, and contamination risks from grease attracting dirt and dust.
