Linear Motion Tips allows engineering and manufacturing professionals to stay industry-current with linear motion component and linear cable carriers news and information. Our linear cable carriers articles below are produced by engineers and other industry experts. Read on to learn more about the latest innovations in linear motion components.

Cable Carrier Competition

EAST PROVIDENCE, R.I. – igus® is running its Vector® competition for a second time to reward challenging applications using cable carrier systems.

The first competition only accepted submissions from European companies, but the contest is open to entrants worldwide this time around. This gives North American cable-carrier users the chance to participate for the first time.

The winners of the Vector awards will be rewarded with cash prizes up to 5,000 Euros at the Hanover Fair from April 19th-23rd 2010, although entrants do not have to be at the awards ceremony to be eligible to win.

Entry forms and additional information can be found at www.vector-award.com. The final date for entries is February 28, 2010.

Cable carriers—also widely known as Energy Chains®, cable tracks, cable chains and drag chains—are the umbilical cord of modern machines and ensure the safe supply of energy, data and other media. Cable carriers are suitable for multi-purpose use in the crane and machine-tool industries, as well as in robotics, cleanrooms, material handling, and more.

igus
www.igus.com

Interconnect Motor Cables for Continuous-flex Applications

EAST PROVIDENCE, R.I. – Cable carrier expert, igus®, has developed a line of continuous-flex, interconnect motor cables harnessed in accordance with leading manufacturers, including Siemens, Indramat, Fanuc, and Allen Bradley. As with all Chainflex® cables, these interconnects are ideal for continuous-flexing applications in an Energy Chain® cable carrier.

The cables are available for drive, control, motor and robotic functions and come equipped with different cable connectors, including those with flying leads, adapter plugs and extensions.

igus’ entire line of Chainflex cables can handle tight bending radii in dynamic applications and are tested over millions of cycles in all types of conditions to ensure optimal performance.

igus
www.igus.com

Total Chip Protection for Machine Tools

EAST PROVIDENCE, R.I. – Metal chips can cause abrasion and wear in long travel, gliding cable carrier applications. To combat this, igus® has developed a horizontal guiding system called “Guidelok”, which is designed to keep the upper and lower cable carrier runs apart. The new solution is ideal for applications in the machine tool industry up to 164 feet.

Debris and chips can become trapped between a cable carrier’s upper and lower runs as they glide on top of one another. Guidelok’s design keeps the upper and lower runs separate via a spring-loaded roller support, which is pushed back as the cable carrier passes through, before snapping out again after the radius has passed. The upper run rests on the roller support and is not allowed to glide on the lower run.

The system not only works to reduce abrasion and wear caused by trapped chips and debris, but also offers a number of other advantages. The system means the cable carrier can support itself over a longer distance. This enables users to choose a smaller version for the given length, saving overall costs and reducing the required push-/pull driving force. Guidelok keeps the upper and lower runs of the cable carrier separate from one another, which helps to minimize friction and wear and thereby increases service life.

The horizontal Guidelok system is already being used successfully by one machine-tool manufacturer, who replaced a heavy steel chain with this solution. A more traditional solution would have allowed large metal chips to settle in the inner radius between the upper and lower runs of the cable carrier, which could have caused damage. In contrast, the new system is ideal for such applications. Guidelok is also lower cost than most steel chains or sophisticated gliding systems.

New Guidelok is designed to be modular—the side troughs are optional—and is currently available from igus North America with a three week lead time. A movie illustrating the new design can be found at www.igus.com/ApplicationCorner/ec_videos.asp. Alternatively, call 1-800-521-2747 or e-mail sales@igus.com for more information.

igus Inc.
www.igus.com

ESD Cable Carriers from KABELSCHLEPP

When manufacturing and processing electronic components, electrostatic discharge (ESD = ElectroStatic Discharge) presents a serious hazard for the sensitive electronics. In addition, the increasing miniaturization of semiconductor components means even greater sensitivity to ESD.

Even More Conductive! ESD cable carriers satisfy tomorrow´s requirements. Thanks to the new
ESD material KABELSCHLEPP cable carriers are now even more conductive and with a surface resistivity of ≤
105 ohms surpass by far the requirements contained in the ESD standard (DIN EN 61340)

Improved protection against electrostatic discharge is thus necessary for not only for the materials and tools used, but also for cable carriers However this can be achieved during handling and assembly only if the plastic cable carriers used have an even lower surface or volume resistivity.

To provide this, KABELSCHLEPP is relying on nanotechnology. The material used in the new ESD cable carriers incorporates carbon nanotubes (Baytubes® from Bayer MaterialScience). Carbon nanotubes are microscopically small tubular particles made of carbon. The carbon at-oms form a honeycomb-like structure. The electrical conductivity of such nanotubes is deter-mined by the details of this structure. The electrical conductivity is increased thanks to the graphite structure on the surface of the material created by the carbon nanotubes as a func-tional additive. So much for theory.

For the real world, this means: The new ESD cable carriers from KABELSCHLEPP are now even more conductive and with a surface resistivity of ≤ 105 ohms surpass by far the require-ments contained in the ESD standard (DIN EN 61340). Thanks to the large specific surface and the extremely even distribution of the carbon nanotubes in the carrier material, good conductiv-ity is also achieved at the contact points between the chain links and thus over the entire length of the carrier.

Additional benefits: As a consequence of modifying the fiber-reinforced material with nano-tubes, the stability of the cable carriers increases as well.

Whether in chip manufacturing, semiconductor production, manufacturing of electronic components or solar engineering, thanks to their low surface resistivity, the new ESD cable carriers from KABELSCHLEPP not only significantly reduce the risk of ESD, but also represent a useful investment with respect to future standards.

KABELSCHLEPP AMERICA
www.kabelschlepp.com

RX Energy Tube from igus

EAST PROVIDENCE, R.I. – igus® has now developed an energy tube especially for the machine-tool industry that is almost 100 percent chip-proof. The airtight, fully enclosed cable carrier ensures all debris simply falls off.

igus® is using the FABTECH show in November to launch the new-style “RX” energy tube, which has a specially designed, smooth domed exterior onto which debris—such as metal or wood chips—can not attach itself. Connecting parts are concealed on the interior to facilitate this. Comprehensive tests—including underwater experiments—have been carried out in igus®’ test laboratories which confirm the new energy tube is 100 percent airtight.

Despite this, the RX energy tube can be easily opened using a screwdriver to unscrew bolts integrated into the outer radius of each link. There is also a very large interior space for cables and hoses, which can be separated using vertical separators, and a horizontal shelf to safely route cables and hoses and thereby prevent abrasion. Both these features mean maintenance and machine downtimes are reduced to a minimum.

The new energy tube is well suited to short, self-supporting lengths inside tooling machines. The chip-proof cable carrier was also developed to be used in reverse bending radius (RBR) applications. The RX energy tube is available in a high-temperature version, made from the special, high-temperature material “igumid HT”. This version ensures that even red-hot chips up to 1,562 degrees Fahrenheit fall off the tube rather than melt onto it. The enclosed cable carriers can also be delivered as pre-assembled ReadyChains®; ready harnessed with cables, hoses, and internal separators, as required by the customer.

igus
www.igus.com

igus’ Rol-E-Chain Cable Carriers

EAST PROVIDENCE, R.I. – igus®’ Rol-E-Chain cable carriers have a unique design: built-in wheels to facilitate travel over long distances, such as on a crane. The wheels are integrated into the cable carrier’s side links and reduce friction dramatically, which makes longer travel, heavier load and faster speed applications possible.

The upper portion of a conventional cable carrier glides on the lower portion over longer distances. However, requirements for cable carriers in long travels have been increasing in recent years. Travels over thousands of feet present new challenges in crane construction, as do high travel speeds and cable loads up to 33.6 pounds per foot. As length of travel, load and speed increases, so does friction, which can lead to premature wear and load problems for a cable carrier.

This new-found need to expand the technical limits of cable carriers was behind the development of Rol-E-Chain. With its unique design, friction is decreased and travels over 2,600 feet are achieved easily at speeds up to 32.8 feet per second. Moreover, the drive power required to move the cable carrier is reduced by more than 25%. Rol-E-Chain is also resistant to applications involving harsh environmental conditions, such as thick dirt.

The cable-carrier design is ideal for applications on cranes, material handling devices, plasma cutters and high-speed transfer systems.

igus
www.igus.com/rol-echain.asp

This Cable Carrier Goes Only Where You Want it to Go

Because of its smooth, tubular design, “Triflex R”—‘R’ for ‘round,’ multi-axis cable carrier protects moving cables and hoses on 6 axis robots in demanding industrial environments, such as in automotive production plants or welding applications. 

The cable management system can move multi-dimensionally through all axes and can twist up to 380º per yard, making movement through complex configurations easy. The cable carrier glides around the exterior of the robot without getting caught up.

igus, Inc.
www.igus.com

New Cable Carrier for Cranes

EAST PROVIDENCE, R.I. – igus® has now launched a completely new generation of roller cable carriers. New “System P4″ was unveiled in the States at the IMTS show in September and is available on request. The new cable carrier has achieved speeds up to 23 feet per second over distances of 400 feet in igus’ outdoor testing facility. P4 is specially developed for indoor and outdoor cranes, as well as conveyor systems.

The need for ever-increasing speeds demands advancements in cable carrier technology. Similarly, cable carriers must operate smoothly and quietly because many ports are expanding and moving closer to residential areas. P4 is especially low noise and wear resistant at high speeds, even with loads up to 20 lbs/ft. In fact, thanks to the use of additional center links, there is practically no weight limit. Each link has the same short pitch, which means the cable carrier moves with minimal vibration in its radius. Plastic bridges and grooves along the surface of the cable carrier —a design from igus for long travels called ‘AUTO-GLIDE’ —mean the upper run of the P4 chain glides smoothly over the lower run.
The plastic rollers are firmly integrated into the sides of the cable carrier and do not rotate over one another, because the cable carrier’s upper and lower runs offset. This reduces wear and increases service life.

www.igus.com

igus’ T3 Cable Carrier

EAST PROVIDENCE, R.I. – igus®’ ‘T3’ cable carrier for applications involving very high speeds and accelerations was one product to catch the attention of visitors to IMTS. The lightweight cable carrier runs extremely smoothly with minimal vibrations and virtually no noise: 33 dB(A) with 26.5 dB(A) of background noise. The polymer side bands are injection-molded as one piece, reducing assembly times and increasing affordability for the customer.

T3 was developed primarily for applications in the electronics industry, but is suitable for measuring machines, high-speed handling systems, industrial printers, cleanrooms and linear motors. The T3 cable carrier is also available in a special-material version for ESD (electrostatic discharge) applications, for which its one-piece design is ideally suited.

www.igus.com

Continuous flex cables deliver longer life and better performance

EAST PROVIDENCE, R.I. – Igus® Inc.’s Chainflex® continuous-flex cables are designed for installation in Energy Chain® cable carriers to deliver longer life and better performance for automated machinery. Chainflex cables are ideal for demanding, high-flex applications where a robust energy supply system is critical.

Igus first developed Chainflex cables in 1988 with the goal of eliminating common cable failures such as corkscrewing, loss of continuity and insulation damage. The company pioneered a unique technique of cable construction in which the conductors are bundled rather than layered. The wires are twisted with a special pitch length and the resulting conductors are cabled into bundles. For large cross sections, this is done around a strain relief element. The conductor bundles then are cabled around a tension-proof center.

Bundling the conductors and eliminating multi-layers ensures a uniform bend radius across each conductor. Pulling and compressing forces balance one another around the high-tensile center cord that provides the necessary inner stability. As a result the cable core remains stable even under maximum bending stress.

Chainflex continuous-flex cables are available in more than 800 sizes and styles. The line ranges from power and control cables to air hoses data cables, servo cables and fiber optic cables. Igus performs more than 35 rigorous cable tests in all types of conditions, to ensure the elite performance of Chainflex.

www.igus.com

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