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Managing cables through linear and rotary movement
A new concept in energy chains has been developed to provide a combination of rotary and linear movement. Mark Simms got to see it in action to understand the problems it addresses. There are many new concepts that seem so obvious once you've seen them, that you wonder why nobody thought of it before. Certainly there are challenges to be addressed, but once you've overcome those then the leap to the next big idea is actually only a very small step. The trick is in identifying that new idea, spotting potential markets, and understanding the technical problems that it could solve. In its e-spool energy chain system, Igus has just such a concept and just such a problem solver. It combines rotary and linear cable management systems to provide end-to-end cable connection on a self-retracting spool. Eliminating the need for slip rings and enabling different media (power, data, air, etc) to be combined, the e-spool is a reliable and dynamic alternative to conventional cable management approaches in some applications, and to typical cable drum approaches in others. Central to the e-spool is the Igus twisterband rotating energy chain. The twisterband was developed to provide greater rotation (up to 7000 degrees in fact, depending on the number of layers) than could be achieved with existing cable management technologies. As an aside, the development of the twisterband is an interesting story. Igus had identified a need, and then set about looking at how it might be done. According to Andreas Hermey, head of Igus' design department, inspiration actually came from a coiled telephone cable. Several design steps and many prototypes later, the twisterband was born. It provided a simple alternative to the complex and expensive rotary solutions that were usually needed to implement rotary movements in the smallest spaces to safely guide power, data and media. Typical applications for the twisterband include robot arms, medical equipment, test equipment, aerospace, handling systems and more - anywhere that rotary unions are used. But one interesting application was a cable drum, to eliminate the need for slip rings. A slip ring is far from ideal in such applications. It can't accommodate fibre optic connections and pneumatic connections are very difficult to implement. Even in pure electrical connections, slip rings quickly wear and need regular replacement. But suppose you could combine a twisterband with a linear energy chain on a drum. That would address a whole raft of application requirements, providing a simple, robust and reliable alternative to conventional cable drum systems.End-to-end connectivity That's where the e-spool comes in - a next generation cable management system that provides reliable operation for a wide range of lifting applications. A standard Igus e-chain from the E2/000 series is routed via a spool, and a twisterband connects the spool with the shaft bracket, which serves as the interface to the permanently installed cables. Connection is end-to-end with no breaks and no need for slip rings. Cables for power, data, compressed air and fluids can be connected without interruption, and can be replaced or modified at any time. The chain is compactly wound up in its initial position and, thanks to an integrated return spring, the desired length and tension of the energy chain is always ensured. Early applications for the e-spool have clearly demonstrated its effectiveness, and Igus sees potential in many areas where space is limited and in lifting applications where users are looking for space-saving energy chains, such as lifting platforms, cherry pickers, sorting lines, mobile cranes, platform applications, assembly or process cranes with grippers, or lighting rigs in the theatre industry. In addition, users can save space associated with storing the chain, as it has a smaller footprint than traditional zig zag chains that might be used in some of these applications. Christian Barthen, global product manager for e-chains, comments: "We can have horizontal movement, vertical movement, and always have the chain return to its coiled position, which could be very important for applications where you don't want anything left in the direction of travel. Compared to zig zag applications, we can have much more dynamic movement: where a zig zag chain might allow a maximum speed of around 0.4m/sec, the e-spool offers deployment and retraction speeds up to 1m/sec." With many successful implementations under its belt, Igus has now standardised the e-spool as a catalogue product available in three lengths, offering 4m, 7m and 14m of travel, with two inner chain widths of 80mm and 125mm enabling many different media and diameter cables to be housed in one drum. The twisterband TB30 can hold cables with diameters up to 16mm, and cables can be routed on one or both sides of the spool depending on individual customer requirements. Igus director Justin Leonard comments: "We work closely with customers to develop innovative solutions, and the e-spool is yet another example. Robust and flexible, the e-spool energy chain is more durable than cable drums, and enables power, data and media cables to be combined in one compact, straightforward system.
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Pop-open e-chain provides easy access for cables
Flexible conduit
Wimbledon's centre court roof glides safely with energy chains
Easy assembly with readychain speed from igus
igus sales engineers now all CSCS Certified
Faster searching, faster assembly and faster purchasing of igus readycables
Han connectors with RFID technology offer added value
Harting enhances M12 connector family with "press and go" and outdoor versions
Protecting fully automated spectrometer for climate research
E2 micro e-chains are small, light and even stronger
Han Hood Link speeds cable-to-cable connection
Highly sensitive and really tough
Light e-chain solution for large hoses and cables
Pluggable feed-through housing eases cable installation in industrial environments
Latest energy chains and bearings solutions at ABTT 2014
Energy chain guide system, enclosed for safe operation, is now even bigger
Up to 36 month guarantee on igus chainlfex cables delivers predictable safety
Harting at Drives and Controls 2014
Connector family extended with robust M12 module for applications at up to 10 Gbit/s
High-temperature connectors function in environments up to 200°C
Readychain cables are always secure
Online technical data sheets now available for over 1,100 chainflex cables
Easy and sealed servo motor connections
Slimline M12 connector for gigabit Ethernet applications
Harting connector provides space-saving interface with field assembly
igus' energy chain is always delivered in less than 10 days and ready to install
Standard LC fibre-optic connector module added to Harting's Han-Modular series
Connectivity for the smart network infrastructure
Flexicon sponsors 'Best of British' MotoGP Team
Flexible conduits protect world's first intercontinental sea tunnel
Configuring a cable in less than 3 minutes? With igus you can
Power supply and encoder cable in a single-cable solution
Flexicon announces growing team
Igus exhibits compact readychain delivery system and fully-assembled linear drives at Southern Manufacturing
CFRIP from igus now extends to over 230 chainflex cable types
Wanted: innovative energy chain applications
Light weight and reliable system for a variety of robotic applications
Cables in less than 24 hours with Igus readycable
New e-spool energy chain variants provide robust solution for routing multiple cables in small spaces
Custom chainflex cables available in just three weeks
Quick and easy to install guide trough for long travels of energy chain
Quality, safety and expertise
Assembly tools dramatically cut energy chain installation time
New low cost roller energy chain and guiding trough
Open guide system for energy chains is simple yet effective
Circular connector range offers compact, customised solution including rapid locking for drive systems
Cables deliver high performance in specialist applications
igus NFPA 79-2012 compliant chainflex cables for dynamic applications
New Polyurethane Coated Blue Flexible Conduit offers Low Temperature Performance
Reduce cable strip back time by up to 50%
Electrically conductive energy chains available within 24 hours
Investigating distant galaxies with help from energy chain
Additions to extensive cable range
Fast fit flexible conduit fitting range extended
Increase energy efficiency with green energy chains
Industrial connector module offers high-voltage transmission with minimum space requirement
Flexicon on track for Innotrans
Secure cabling system based on Harting's Ha-VIS preLink technology
Custom bodies offer new flexibility for M12 circuit board connectors
New additions to Han-Modular industrial connector system
Cost-effective emergency stop safety mechanism for cable management
Cutting cable stripping time in half
Cost-effective, flexible linear guide rail requires no maintenance
A critical decision: cables for dynamic applications
Easily import igus chainflex flexible cables into EPLAN
Tightly sealed with igus RX energy tubes
New design of energy chain is up to 37% lighter
Energy chains supply power on 117m ride
igus c-chain for continuous movement
Guide trough assembly made simple with igus
Why you need an igus energy chain
Why you need igus chainflex cables
Taking plastics offshore
Assembly tools for opening and closing energy chains in one go
Energy Chain guide system for vertical movement eliminates need for troughs
Quiet and reliable cable carrying for distances up to 800m
Pre-assembled Energy Chain system delivered and installed onsite
Control cables for energy chains now available ex-stock with 600V rating according to UL
Faster without wasted movements
An active retraction mechanism is now available for the ROBOTRAX
CC-Link-compatible cable for energy chains from igus
Universal bus fibre optic cable allows tight bend radius without compromising attenuation characteristics
First GigE cable for energy chains
Innovations in energy and data supply for robots
Nine advantages for the price of one
Profile roller energy chain P4 for fast, quiet movement
RWTH Aachen tests vibration behaviour of energy chains
The largest plastic energy chain in the world
Triflex RS for compact cable guidance
Sturdiness and flexibility in the same chain system
Cable protection on the world's highest railway
Cable carriers key at Bournemouth auditorium
Cables for dynamic applications