Energy supply systems for long travels
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 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
Recommended energy chains for long travels
NEW: drive-chain
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NEW: Roller e-chain P4HD.56R
The new heavy-duty rol e-chain® meets all the relevant requirements for container cranes of the next and future generations. Longer paths, higher dynamics, short load cycles, zero failures.
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NEW: Complete iSet solutions
Now you can save time and money with our complete energy chain set. No need to spend lots of time looking for the right energy chain series and relevant accessories.
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E4.1 series
For almost any application
- Inner height: 30–800mm
- Suitable for demanding applications
- Undercut design for high lateral stability
- Outer and inner side links for quick assembly
E4.1 series overview
E4/4HD series
High fill weight with long travels
- Inner height: 5680mm
- High stability
- Ideal for heavy duty applications
- Crossbars every link
E4/4 series overview
P4.1 series
Friction kept to a minimum, twice the service life
- Inner height: 56 to 80mm
- Travel distances of 800 m and more are possible
- Speeds of up to >5m/s
- Smart wear monitoring possible
P4.1 series overview
P4 series
rol e-chain profile
- Inner height: 32 to 42mm
- Travel distances of 800 m and more are possible
- Speeds of up to >10m/s
- Fill weights up to 7kg/m
P4 series overview
rol e-chain
Rolling instead of gliding
- Inner height: 3280mm
- 75% less drive power
- Speeds of up to 6m/s possible
- Uniform roller resistance
rol e-chain overview
autoglide
Self-guiding without guide troughs
- Inner height: 3280mm
- 75% less drive power
- Speeds of up to 6 m/s possible
- Uniform roller resistance
autoglide
Where are energy chain systems used?
Travel: 615m
Further information on the longest travel
Speeds: up to 10m/s
Further information on high travel speeds
High loads: 100kg/m
Further information on high loads
Efficiency: 57% less energy
Technical details on energy efficiency
Quiet operation
Energy chains are especially quiet and abrasion-resistant at high speeds and with large fill weights.
Further information on noise test
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.
Further information on dirt & dust
Temperatures
Energy systems by igus for long travels work reliably at high temperatures in steel works.
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.
Further information on acids and chemicals
Your application not listed?
Contact us by filling in the form with some basic information. Our experts will contact you as soon as possible.
Submit project enquiry now!
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
Energy chain systems instead of busbars
Energy chain systems instead of busbars
Energy chains systems instead of festooning
Energy chains systems instead of festooning
From support to installation
Engineering projects & special solutions
Installation and aftersales service
Other products for long travels
Submit enquiry
chainflex® cables for long travels
Motor cable CFCRANE
- For highest voltages and outputs
- Flame-retardant
- UV resistance: High
- Oil resistance: Oil-resistant (based on DIN EN 60811-2-1)
CFCRANE motor cable
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
CF300.UL.D motor cable
CFLG.LB fibre optic cable
- For heaviest duty applications with 5xd
- Outer jacket: TPE
- gliding application (horizontal) of 400m or more
- UV resistance
CFLG.LB fibre optic cable
Other systems for long travels
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
- Use position information from the application for other purposes
Sensors for smart energy chains
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
Steel guide trough
Condition monitoring i.Sense
- 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
Condition monitoring system i.Sense
Harnessed energy chain systems
- 95% less harnessing time
- Reduce assembly time
- Plug & play solutions, e.g. for the bulk goods technology
Harnessed energy chain systems
plane-chain
- Very compact structure
- Fail-safe and maintenance-free
- Fully protected by enclosure
- For high speeds
plane-chain
i.Cee Wonderbox
- Non-contact system monitoring
- Predictive service life information for each individual chain link
- Space-saving external mounting on the fixed end
2022 smart plastics news: i.Cee wonderbox
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
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
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
