RYDE, Australia - AussieJournal -- Every gram saved counts in aviation. Even slight weight reductions can reduce fuel consumption, increase reach and raise payload. Manufacturers of cargo aircraft are therefore constantly looking for ways to save weight, even with the smallest components. These include the ball transfer units over which containers slide on the cargo hold floor. While standard solutions often use comparatively heavy solid balls, igus is launching an alternative with its new xiros series ball transfer units. The hollow balls reduce weight by up to 49 per cent and work without lubrication, which decreases daily maintenance.

The new xiros ball transfer units consist of a housing made of high-performance plastic iglidur J350 and hollow stainless-steel balls. They are approved for air traffic and meet the FAA's fire protection requirements for aircraft interiors. Several hundred units are embedded in the cargo floor, creating a conveyor surface on which containers move easily in two dimensions. They are available now in three sizes, with ball diameters of 22mm, 25.4mm and 30mm.

High load capacity despite low weight

Hollow balls cut weight by up to 49 per cent. A solid stainless-steel 25.4mm ball weighs 87g; the hollow version weighs only 43g. With 500 ball transfer units, that saves around 22kg per aircraft. "Design engineers do not have to worry about a possible reduction in load capacity when they switch to our system," emphasises Marcus Semsroth, Head of Business Unit xiros Polymer Ball Bearings at igus. The permissible static load is 1,470N, roughly 150kg per unit, and in-house tests showed the units could carry up to four times that.

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Less daily maintenance thanks to lubrication-free design

Many conventional ball transfer units require lubrication, which can bind dust and dirt and impair smooth operation. With the igus solution, solid lubricants are integrated into the housing plastic. They are released during movement, allowing low-friction dry operation without external lubricants. This keeps the units clean and removes the need for relubrication. "With the new xiros ball transfer units, we are showing that lightweight design, high load capacity and freedom from lubrication can be combined," sums up Semsroth. "These are three decisive advantages for modern conveyor technology in the aerospace industry."

You can find more information about the xiros hollow ball transfer units here:
xiros® ball transfer units with hollow ball and iglidur® J350 housing, sliding (https://www.igus.com.au/product/xiros-btu-es-h)