See how assembly time can be reduced with E4.1L and what features this e-chain® offers E4.1L makes filling quick and easy. E4.1L even makes retrofitting cables much easier: individual cables can simply be taken out and new ones inserted without cables located above them having to be removed from the e-chain®.
... low weight
... optimised installation space
Due to narrower outer links and the geometry of the crossbars, an optimum ratio of inner to outer dimensions can be achieved. This is how useful space is obtained in the e-chain®.
Given the same installation space, several cables and hoses can be guided in the E4.1L.
...crossbars can be removed completely
...openable on one side for fast filling and closing
Thanks to their design, the crossbars can not only be removed from the E4.1L completely but can also be detached on one side. The crossbars thus remain attached to one side of the e-chain®, cables can be inserted or removed, and the e-chain® can be closed in the blink of an eye.
The crossbars can withstand high forces up to 450 N. Tested in test EW13-004
... reduce cable wear almost by half
... fewer parts, more possibilities
... flexibly adjustable
Smooth, cable-friendly and rounded contours ensure a long service life of the cable and hoses. With a few standardised parts, better and more cable-friendly interior separation is possible.
With the new rounded separators, the cable wear was reduced almost by half.
Test 3.748:Separator 301 versus new version 45.1. In this case as well, the combination of plastic and jacket material is shown to be the best choice.
In this application, rounded crossbars help to increase service life in plastics machining equipment.
... noise level from 33 dB(A) possible, 44 dB(A) with igus® E4 series measured
... many series certified by the TÜV (Technical Inspectorate) Rheinland
The principle is simple but extremely effective. A wedge-shaped contour in the e-chain® stop-dog dampens the impact noises.
We test igus® e-chains® for noise emissions in our own laboratory. Many series are also checked by the TÜV. The noise levels of igus® e-chains® are between 33 db(A) and 46 dB(A), for example.
Test 4.381:E4.32 with operating noises under
44 db(A) stop-dog noise, at 1 m/s
If the unrolling noise has to be reduced even further, the optional dampening pads can help. They enable a reduction of up to 5 dB(A).
... max. fill weight unsupported up to 600 kg/m possible
... max. unsupported lengths (FLB) 7.0 m (+25% with the optional XXL material)
More than two stop-dogs are very difficult or impossible to synchronise Due to a rectangular geometry, the distribution of force is considerably better than in the case of a round stop-dog (formula for surface pressure, p=F/A). The complete E4.1L product range has the double, rectangular stop-dog.
We test every energy supply product
for pressure and breaking force with the help
of a Zwick testing machine in the igus® laboratory
in order to be able to provide reliable
information on the maximum fill weight
and unsupported length.
The double rectangular stop-dogs and the undercut design principle of the e-chain® ensure high lateral stability and optimum cable protection even in the case of an upright e-chain®.
... pull/push forces up to 7,000 N possible
... fill weights up to 600 kg/m and more possible
Due to the offset stop-dogs, the force is directed through three points, namely the two stop-dogs and the large pin, instead of the force being absorbed centrally. This reduces the load on the individual elements, the pin and dog-stops to around 1/3.
The maximum load over a period of 96 hrs is tested. The photo shows an E4.1 with the optional material "XXL", which enables the maximum unsupported length to be increased even more by +25% to approx. 8 m.
... travel of more than 600 m possible
... acceleration of 10 m/s² and more
Close tolerances and large pin/hole connections ensure high push/pull force absorption. Due to the tight tolerances and the resulting almost complete absence of clearance, extremely high accelerations can be achieved and wear is also reduced.
We test every energy supply system for tensile strength in the igus® laboratory with the help of a Zwick testing machine in order to obtain reliable information on the maximum possible travel and the possible acceleration values.
Test 3.992:A tensile force of more than 30.000 N is possible
In this example, an E4.1L is being used in a palletising machine for drinks crates. Due to the rapid movements of the machine, it is especially important that the chain is designed for high speeds and stability.
... alternating inner and outer links provide straight run
... precise parallelism of the e-chain® bands ensures durability
In an alternating sequence, inner and outer links interlock with each other, as a result of which the run of the e-chain® is especially straight. This enables the e-chain® to move very easily and, at the same time, enhances the durability of the product.
The inner and outer link principle is tested in all E4.1L e-chains
This e-chain® is guided in a guide trough that only has minimal clearances. This is enabled by the very straight run of the E4.1L and prevents wear on the side of the e-chain®.
... fill weights of 7.7 kg/m on 2 m unsupported
... ideal for laterally rolling applications or high torsional forces
Interlocking chain links ensure a very high degree of torsional rigidity of the e-chain® and long unsupported lengths even in the case of laterally rolling applications.
Here we also test each system for maximum load bearing capacity so that reliable information on the service life can be provided in our online service life calculator.
Test 4.099:2 m E4 e-chain® with a 7.7 kg/m fill weight
An E4.1L e-tube in a sideways position in an automatic welding machine can be seen. It protects cables against flying sparks and, thanks to the undercut design, is also extremely stable for uses where it is in a sideways position.
... acceleration of up to 784 m/s²
... same materials
A few parts that are made of one material and guarantee the smallest possible clearance are especially important for high rates of acceleration. A uniform material is the ideal solution in the case of expansion or shrinkage caused by temperature differences.
Speeds up to 10 m/s and more are continuously tested in the igus® laboratory in order to meet the highest requirements.
Extremely high accelerations of up to 784 m/s² require an exactly tailored and clearance-free energy supply system. A few parts ensure this.
... wear pads on the sides ensure a long service life
... an important criterion especially in the case of applications where it is turned 90°
... an operating distance of 10,000 km and more is guaranteed
The wear pads on the sides of the E4.1 ensure that this e-chain® also withstands heavy levels of stress and also has a long service life.
In endurance tests, the service life of the e-chains® in an abrasion test and when the travels are long is tested. Every e-chain® can complete a total travel distance of at least 10.000 km and often much more
Due to the wear pads, large circle diameters with high fill weights are possible. In this crane head, the laterally rolling e-chain® performs a 400° turn.
... cables with plastic crossbars last longest
... no structural deformation when force is applied from outside
Smooth, cable-friendly inner contour and rounded crossbars ensure a long service life of cables and hoses. In tests, the combination of the Tribo-optimised plastic of the crossbars on the one hand, and the jacket material of the cables on the other, is found to result in the longest cable service life.
Cable wear on plastic crossbars: Jacket made of a wide variety of materials show the best wear results with plastic crossbars. Moreover, compared to aluminium crossbars, they cannot be structurally deformed when force is applied from outside.
Of course, wear plays a large role in such rough applications as well, such as here in a coal excavator. In this context, hydraulic cables, among other things, are routed in the e-chain® and a failure can be extremely expensive.
... makes it easy to insert interior separation elements that can be locked in at 5 mm intervals
... absolutely even, no wear of the cables due to scaling
Scalable crossbars are standard for all E4 models. This makes pre-configuration with interior separation elements easier and shortens the assembly time. The separators with catch-tabs can be placed in the crossbar in 5 mm increments and will reliably hold in place (approximately. 25 kg holding strength of the separator in locking position). Spacers are not necessary for laterally rolling applications.
We conduct long-term tests on all chainflex® cables for wear, and service life in continuously moving use. We also test customer-specific cables in order to predict the system service life.
Cables guided safely and reliably in an E4.1L e-chain® that has been turned 90°. The interaction of energy chain material and jacket material is a decisive factor when it comes to service life.
... extender crossbar for hoses with a Ø of up to 300 mm
A variety of extras make the E4.1L system very flexible and are available from stock. For example, there are extender crossbars for holding hoses with a Ø of up to 300 mm or different noise-dampening options.
Due to the additional extension link, widths of up to 2000 mm are possible.
... hot chips up to 850°C cannot burn into it
... extremely impermeable design and yet easy to open
igus® energy-tubes have been used successfully for protection against chips for almost 20 years. Dust, dirt, oil, aggressive environments, moisture, low temperatures and high temperatures have no effect on the robust plastic energy supply systems. Chips thatare up to 850 °C hot simply bounce off the optional HT material - they cannot burn into the material.
In the test, 20 g of hot chips (200 to 850 °C) was brought into contact with different materials. The graphic shows the amount of chips that have burned into the material. The test winner is igumid HT with hot chips up to 850 °C
Safe protection against hot chips is provided by the energy-tube in the case of this gantry milling machine used to make tram points. In spite of the enormous amount of chips produced as well as the high temperatures, the milling machine could operate without any problems thanks to the igus® e-tube.
...enables extra cable guidance at a later time
...easy to extend with the help of TUBs
TUBs can be fastened to the side of the E4.1L so that corrugated tubes can be guided parallel to the energy chain. They have a feature that makes it easy to fit PMA clips.
The clip feature on the side of the E4.1L makes it easy to clip in corrugated tubes so that they can be guided safely alongside the e-chain®.
The TUB extension is used wherever additional cables have to be guided retroactively. The parallel guidance of corrugated tubes is especially popular in mechanical engineering.
...an e-chain® for solutions with or without pretension
...no corrective thermal processing necessary, available from stock
An e-chain® with camber can quickly be made into an NC version by simply turning the outer links. NC versions are only needed in the case of very special applications such as in hanging installations or where space is restricted.
Products for special applications such as this storage and retrieval equipment are also tested. For example, the guidelok slimline F system, which prevents the e-chains® from swinging out in storage and retrieval equipment.
Especially in hanging installations or where space is restricted, an e-chain® without camber is the first choice. Thanks to its outstanding stability, the E4.1L is the ideal solution for such applications.
... suitable for hoses with an outer diameter of up to 137 mm ...
The E4.1L can be supplemented with extender crossbars, which increase the size of the interior of the e-chain®. The crossbars can be mounted in different ways: from one or both sides, alternating with normal crossbars and combinations of all these options.
In the case of this woodworking and sandwich processing machine, the e-chain® was fitted with extender crossbars to hold the suction hose for wood chip removal. The extender crossbars hold the hose securely in the energy supply system and are openable.
... easily accessible from above or below
... with a better seal than many competing products and nevertheless easy to open
The lids of the close E4.1L e-tubes can be opened easily and removed completely. This makes it easy to insert cables and the e-tubes can also be closed with a very tight seal.
Test> Most impermeable igus® e-tubes IP tested:
In the igus® laboratory, the impermeability of e-tubes is tested under extreme conditions. In this way, a method of maximum cable protection can be developed and the stop-dogs remains completely free of chips.
The example shows an e-tube in use in a machine, where it is intended to protect cables from chips and dirt as soon as the machine starts operating. The e-tube is nevertheless easy to open when new cables have to be inserted or old ones replaced.
... protection against chips up to the front edge of the e-tube
... can be retrofitted with integrated C profile for the installation of a tension relief system
... universal connection
Can be retrofitted and are highly impermeable. Mounted on the front, the impermeable plastic-and-metal mounting bracket (KMA) keeps dirt and chips away, thus providing ideal protection for the cables.
With the impermeable KMA, the last "gap" in applications in the working environment of machine tools has been closed. The chip-proof plastic-and-metal mounting brackets have integrated C-rails and protect the cables right up to the front end of the e-chain® and, at the same time, enable strain relief (with the help of CFX strain relief clamps).
At the front, the e-chain® in this example is flanged on and protected all round with a KMA element.
... three times greater tensile strength in igus® chainfix clamps
... also resistant to oil, coolant and water
Strain relief systems from igus® have been specially developed for use in e-chains® and dynamic applications. The combination of chainflex® cable materials and touching plastic components of the chainfix strain relief systems is designed for durability of the cables and maximum holding strength.
The tensile strength of the igus® chainfix clamp is more than three times greater than that of commercially available strain relief systems.
Reliable and safe strain relief for media, data and control cables provided with this ready-to-install readychain® system for machine tools.
...material and undercut design ensure permanent electric conductivity.
The igumid ESD material guarantees long-lasting and maintenance-free conductivity over many years due to the additives it contains. In order to ensure this, each component of the e-chain® must be completely conductive throughout.
The igumid ESD material has been tested with over 10 million cycles in the igus® technical center and thus fulfils extremely high requirements. The continuous end-to.end conductivity is measured in all e-chains® with ESD material. Only products that pass the test are given a test seal and shipped to customers.
... From 1 metre, no cutting charges, no minimum quantities
... chainflex® works or money back
... 36 month guarantee
Flexible cables in energy chains or robots need special characteristics to last through many cycles, high speeds and accelerations, as well as demanding environmental conditions. Electromagnetic compatibility and compliance with standards and guidelines such as NFPA 79, UL, CSA, VDE, Inter- and Profibus are also taken for granted today. The igus® chainflex® product range contains the appropriate cables for very different applications.
All chainflex® cables are always tested under realistic conditions. Fitted in an e-chain® as well as in motion, like here in the igus® climate chamber at -40°C.
In this automatic CNC multiple-spindle lathe, every single working position has to be reliably supplied with media, energy and signals. Outstanding freedom of movement on all axes requires considerable cable durability and reliability.