The Wide World of Cable Carriers

EAST PROVIDENCE, R.I. – igus® announced the results of its worldwide cable carrier competition at this year’s Hanover show. The winners were awarded their prizes during a reception at the igus booth.

There were around 80 entries for the first Vector Awards two years ago, which was only open to European entrants. In contrast, this year more than 110 entries were submitted from all over the world: from China, India, Korea, and Singapore, to the USA, Canada and Brazil, and right across Europe.

The gold award and €5,000 prize money went to the Czech power supplier CEZ Group for the longest travel in the world ever to be accomplished with a plastic cable carrier: 2,018 feet in a lignite-fired power plant in Tušimice. A heavy-duty roller cable carrier system from igus’ 5050 RHD series is installed on the conveyer unit of the lignite excavator, which operates in extremely demanding conditions. Roller cable carriers, developed by igus for long distances, have been in use around the world for more than ten years.

CEZ Group says the robust system – which is also equipped with igus’ Chainflex® continuous-flex cables – makes a significant contribution to operational safety. System downtimes caused by cable breakage, for example, have been reduced to zero compared with before.

The jury awarded the silver Vector Award to the National Mineral Development Corp. Ltd. (NMDC) in Hyderabad, India. The state company belongs to the Ministry of Steel and carries out exploration work, among other things.

NMDC use a 61-feet long plastic cable carrier system with a rearward bending radius (RBR) on a bucket-wheel reclaimer in a steel mine. The reclaimer can rotate by +/- 180 degrees, while operating in an area that is difficult to access. The loads the cable carrier must withstand are enormous: the cables in the cable carrier alone weigh over 36 pounds per foot.

The heavy steel chain used previously in this application was damaged after just two years. According to NMDC, the igus cable-carrier system has been running reliably and with little maintenance and no downtime since its installation.

The bronze Vector Award and €1,000 prize money went to Rene Petsch, a design engineer from Deckel Maho Seebach GmbH. In this application, a traveling column milling machine underwent advanced development to make it more accurate, adaptable and economical than its predecessor. The rigid machine bed made from composite mineral and the symmetrical traveling column were to ensure improved precision.

To keep the design space compact, the Y and Z-axes of the machine use just one cable carrier: System E4.1 from igus. The E4.1 system ensures higher lateral stability, which was necessary due to the high lateral acceleration through the X-axis of 26 feet per second². The cable carrier was attached in an upright position with the run bent in at one side.

All the cable carriers applications submitted can be found on the competition website at www.vector-award.com. Video content is also available for certain entries.

The Vector competition was run in conjunction with the German Central Association for Electrical Engineering and Industry (ZVEI), the tooling laboratory (WZL) of the RWTH Aachen and TÜV Rhineland. The Vector Award is under the patronage of the Industrial Automation sector of the Hanover show.

igus
www.igus.com

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

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

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

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 lightweight multi-axis cable carrier provides low-cost alternative for robotic applications

EAST PROVIDENCE, R.I. – Igus® Inc. announced the availability of a new lightweight version of its Triflex® R multi-axis cable carrier. Triflex R is designed for use on automated robots and employs a pioneering ball-and-socket style design. Triflex R Light provides a low-cost alternative for robotic applications that don’t require a completely enclosed cable management system.

Unlike the standard Triflex R cable carrier, which is built with enclosed, two-segmented circular links connected by a ball on one link and a socket on the next, the links of Triflex R Light are a single segment. This leaves an opening between one link and the next, significantly lowering the weight and subsequently lowering the cost of the product.

Triflex R Light is reinforced by three fan-like supports that create three available compartments for cables and hoses, while standard Triflex R has an inner support that connects to the link in two places, creating two compartments, and also has dual guide channels for optional fiber rods.

Read more

Strain relief from igus defends against cable damage and system failure

EAST PROVIDENCE, R.I. – Igus® Inc., the industry-leading developer of Energy Chain Systems®, Chainflex® continuous-flex cables and iglide® plastic bearings, offers various strain relief elements for its comprehensive line of Energy Chain® cable carriers. Designed to house, protect and extend the service life of cables and hoses on automated machinery, Energy Chain is a lightweight, maintenance-free plastic housing that prevents cables from breaking, corkscrewing or tangling. Strain relief is an important element of any Energy Chain System, as it properly positions the cables in the cavity of the carrier. Energy Chain Systems, combined with appropriate strain relief elements, provide customers with an enhanced defense against cable damage.

Igus’ line of strain relief elements includes Chainfix clips, tiewraps, tiewrap plates and modular strain relief blocks. Customers requiring simple, space-saving strain relief can use a combination of plates and tiewraps. Every plate is equipped with a set of comb-like teeth. Using tiewraps, the cables are fastened to the teeth of the plate, which clips into the profile rail without the need for bolts or hardware. To save time, the plate can be directly integrated into the carrier’s mounting bracket.

For applications requiring more intense strain relief, igus offers the Chainfix clip, a modular snap-on device consisting of a series of top and bottom clamps. The unit accommodates cable diameters ranging from four to 24 millimeters and can be configured vertically enabling as many as three layers of cable to be strain relieved at once. Modular strain relief blocks—designed for small cables with diameters between 4.3 and 14 millimeters—also are available. With this option, customers eliminate the need for fastening hardware.

All of igus’ strain relief elements are compatible with almost any Energy Chain cable carrier such as System E4, designed for high-acceleration, high-speed applications and System E6 for extremely quiet operation. Custom-tailored options also are available. Energy Chain is used in numerous industries ranging from medical to farming to manufacturing. Energy Chain cable carriers are the perfect partner for Chainflex continuous-flex cables from igus. Chainflex cables are available in more than 700 sizes and styles. Contact igus for free samples and a free design consultation. Igus requires no minimum quantities on any order.

www.igus.com

Cable carriers minimize downtime costs

EAST PROVIDENCE, R.I. – GÜDEL Inc. uses reinforced plastic cable carriers from igus® across its range of automated systems—from multi-axis robots and press-transfer systems, to factory-automation equipment and gantry robots. The cable carriers guide and protect moving cables and hoses, helping to reduce the risk of cable failure and minimizing downtime for GÜDEL’s customers. GÜDEL supplies OEMs from many different industries, including the automotive and aerospace sectors. GÜDEL uses System E4/100 Energy Tubes, which feature hinged, snap-open lids for easy access to cables and hoses.

The robust plastic chains are completely resistant to harsh chemicals, hot flying debris, dirt and dust. They withstand high loads, fast accelerations and speeds, and can travel over long distances. This is key, as GÜDEL’s machines use up to 230 feet of Energy Tube at any one time and operate at speeds up to 23 feet per second. GÜDEL also uses igus’ modular System E4/4 Energy Chain® cable carriers, which have easily-removable crossbars so that cables and hoses can be replaced quickly, saving the customer both time and money.

System E4 cable carriers are suited to a wide range of demanding applications. “Energy Chain from igus is the only cable management system we use,” said Olivia DuRussel, mechanical design engineer for GÜDEL, “Energy Chain is featured in our catalog as the exclusive cable carrier used in all our designs.”

Contact igus at (800) 521-2747 or visit www.igus.com.

The Largest Plastic Cable Carrier in the World

The new Energy Chain® E4.350 is wear proof, maintenance free and resistant to seawater and mineral oil. It was developed for environmentally harsh situations such as those encountered on offshore oil-drilling platforms. E4.350 can move nearly 50 feet up and down, which guarantees any heavy hydraulic cables are protected and guided when a drilling rig is skidded on to an oil platform, or during a drilling head’s stroke.

It has an internal height of approximately 14 in. and a variable inner width of 8 in. to over 3 ft, giving a large internal capacity. Large cables and hoses with diameters up to around 12 in. are ably guided by the plastic chain, with loads possible in the region of 70 pounds per foot.

The cable carrier is made from high-performance plastics and is corrosion resistant. The chain also offers a weight saving over comparable steel alternatives. It will ultimately be available from stock.

The E4.350’s design ensures high torsional rigidity and stability. Thanks to the interlocking links and the large bolted joint between them, movement is smooth. The design also significantly increases lateral stability and prevents the cable carrier from coming apart.

Integrated sliding surfaces, larger wear surfaces and extra-strong stop-dogs guarantee a long service life. Center links increase stability further and make it possible to extend the width of the cable carrier almost without limitation. Additionally, special outer and inner links ensure a straight run and quick assembly, especially compared to steel alternatives. A comprehensive, easy-to-assemble, modular range of accessories includes internal cable separators and shelving options.

igus 
www.igus.com