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Long travels with energy supply systems

Long travels of 1,000 metres and more

It is a great challenge for operators of sewage plants, waste incineration plants, cranes, power plants or mines to guide data, energy and hydraulics safely on long travels. High speeds combined with a high fill weight often pose problems for energy supply systems such as motor cable drums, busbars or festoonings.
 
Energy chain systems by igus can be moved without problems on travels of up to 1,000 metres and more at a speed of 10m/s and with 50kg/m fill weight. As guide of highly flexible chainflex cables and hoses, energy chains can be guided smoothly and with low friction in long travels through guide troughs and enclosures. Both in- and outdoors, they energy chain systems by igus have been successfully used for more than 20 years in over 30,000 gliding long travels.
 
The igus Project Engineering Team will assist you with the sizing, design, project management, installation and commissioning on site. For the intelligent monitoring of the state of your system, igus isense sensors and monitoring modules can be used to measure the abrasion of the energy chain, push/pull forces and accelerations as well as to perform real-time monitoring.

 

Download "Long travel" assembly manual


Things you should pay attention to when installing a gliding application.
In this assembly manual, we will show you how to correctly install a long-travel energy supply system yourself and optimise service life.


Download now!

Where are energy chain systems used?

Travel: 615m

Travel: 615m  

The longest plastic energy chain in the world with 615m travel from igus has been in operation without failure for ten years.

Speeds: up to 10m/s

Speeds: up to 10m/s  

Profile roller chains of the series P4 are characterised by high speed, smooth operation and safe energy supply, and are used in gantry loaders.

High loads: 100kg/m

High loads: 100kg/m  

Energy chain system despite enormous fill weight of more than 100kg/m in a sludge treatment plant.

Efficiency: 57% less energy

Efficiency: 57% less energy  

With igus rol e-chains the required drive cable is reduced by 57%. The roller energy supply withstands the high acceleration and speed on a permanent basis.

Quiet operation

Quiet operation  

Energy chains are especially quiet and abrasion-resistant at high speeds and with large fill weights.

Dirt & dust

Dirt & dust  

Extreme dirt and dust exposure do not affect the energy chain systems. For several years now, they have reliably supplied conveyor units and stockpiling equipment with energy, data and media.

Temperatures

Temperatures  

Energy systems by igus for long travels work reliably at high temperatures in steel works.

Acids and chemicals

Acids and chemicals  

Energy chain and plastic trough made from chemically-resistant plastic withstand exposure to hydrochloric acid and have been in operation at a hot dip galvanising plant for years.

Your application not listed?

Project enquiry  

Contact us by filling in the form with some basic information. Our experts will contact you as soon as possible.


Submit project enquiry now!

Tušimice

Tušimice: The longest plastic energy chain in the world with 615m travel in operation without failure since 2007 - supplied by igus®.

 

Your benefits at a glance

e-chains provide great benefits for long travels

  • Long travels of 1,000 metres and more
  • All media, such as electrical, hydraulic and pneumatic energy as well as digital signals (electrical or optical), and liquid media can operate side by side in the same system
  • No unnecessary interfaces
  • Fill weights of up to 100 kg/m
  • Service life of ten years and more with energy chains and cables
  • Robust in all applications such as those involving exposure to wind, weather, dirt, chemicals and bulk materials
  • Quick installation and retrofitting of cables and hoses

System comparison

Energy chain systems instead of festooning, motor cable drums and busbars

Energy chain systems instead of motor cable drums

Energy chain systems instead of motor cable drums  

No slip ring on long travels. Guide all media safely in one system. Travels up to 1,000m.

Energy chain systems instead of busbars

Energy chain systems instead of busbars  

Guide data, energy, fluids and air fail-safe in one energy chain system. For narrow compact spaces and fast movement in lanes.  

Energy chains systems instead of festooning

Energy chains systems instead of festooning  

Guide cables and energy chains in a protected and safe way in wind and fluctuating temperatures. That way, downtimes can be reduced.

From support to installation

Engineering projects & special solutions

Engineering projects & special solutions  

From the first sketch to installation and on-site commissioning. We use igus low-maintenance e-chains, fail-safe chainflex cables and standardised modules that are quickly adapted to your application to convert an existing plant.

Installation and aftersales service

Installation and aftersales service  

We will take care of the installation. Clearly calculable assembly costs and at request a service contract for the entire energy supply by igus.

Suitable products for long travels

Energy chains for long travels

e-chains® P4.1 series

e-chain® P4.1  

  • Long travels of up to 800m and more
  • High fill weight of up to 30kg/m
  • Speeds of up to 10m/s possible
  • Longer service life due to maintenance-free tribo-polymer plain bearings

e-chains® series 4040RHD/5050RHD

e-chains® series 4040RHD/5050RHD  

  • Travels of up to 1000 metres and longer 
  • Cable loads of up to 50kg/m
  • Speeds of up to 6m/s possible
  • Various roller types for optimum application adaption

e-chains® series 4040R/5050R

e-chains® series 4040R/5050R  

  • Travels of up to 600m
  • Fill weights of up to 13kg/m
  • Speeds of up to 3m/s possible
  • Very wide gliding surface, low wear

chainflex® cables for long travels

Motor cable CFCRANE

Motor cable CFCRANE  

  • For highest voltages and outputs
  • Flame-retardant
  • UV resistance: High
  • Oil resistance: Oil-resistant (based on DIN EN 60811-2-1) 

Motor cable CF300.UL.D

Motor cable CF300.UL.D  

  • For very heavy duty applications 
  • Gliding applications from 400 m and more
  • Indoor and outdoor applications, UV resistant
  • UV resistance: High 

CFLG.LB fibre optic cable

CFLG.LB fibre optic cable  

  • For heaviest duty applications with 5xd
  • Outer jacket: TPE
  • gliding application (horizontal) of 400m or more
  • UV resistance

Other systems for long travels

Sensor for position-sensitive push/pull force measurement EC. PP

Sensor for position-sensitive push/pull force measurement EC. PP  

  • Integrates a positioning system into e-chain
  • Supplies information on position-dependent push/pull forces
  • Position information from the application can be used for other purposes

Steel guide trough

Steel guide trough  

  • Huge range available for almost all e-chains®
  • Very simple, modular assembly
  • Very strong and tough steel guide trough for applications in tough environments

Condition monitoring push/pull detection system

Condition monitoring push/pull detection system  

  • Safe shut-down or alarm signal in the event of a fault
  • The plant shuts down when the force is exceeded
  • Custom programmable and event logging in the data memory

Harnessed energy chain systems

Harnessed energy chain systems  

  • 95% less harnessing time
  • Reduce assembly time
  • Plug & play solutions, e.g. for the bulk goods technology

plane-chain
 

plane-chain  

  • Very compact structure
  • Fail-safe and maintenance-free
  • Fully protected by enclosure
  • For high speeds

 

Download "Long travels" assembly manual!


Things you should pay attention to when installing a gliding application.
In this assembly manual, we will show you how to correctly install a long-travel energy supply system yourself and optimise service life.


Download now!

"Rise of chain", "Wind load" and "Long travels" test

igus® performs application-specific tests in the in-house laboratory for a long-lasting energy supply.

The rise of chain in long travels

The rise of chain in long travels  

The rise of the 5050R series e-chain® was tested in a travel of 200 m and a load of 7.5 kg/m.
 
Result: The energy chain of the 5050R series only rises when the thrust exceeds
8,000 N.
 
igus® solution: Guide troughs with rise guard keep the energy supply system safely in the trough.

Wind load in long travels

Wind load in long travels  

Issue: Does the wind speed of 55 mph affect the functionality of the 4040CR series e-chain®? 
 
Result: At the wind speed of 55 mph, only the guide trough was bent elastically.
 
igus® solution: High-strength "HD bottom clamp" prevents elastic deformation of the guide trough under wind load

Test "Long travels": Rol e-chain was tested on long travels up to 240m and at a speed of up to 8m/s

 

Further information