Widely used in manufacturing, automation, packaging, mining, robotics and machine tool industries, energy chains are said to be fast replacing traditional festoon and cable reel systems. Polymer chains are designed to be low-maintenance and can handle multiple energy types, such as electrical, hydraulic, pneumatic, fibre optic and even auxiliary components such as hoses – all in a single solution.

Introduced in South Africa by German polymer manufacturer, igus, the innovative polymer chains act as a protective guide for cables and hoses, ensuring that they move in a defined, controlled path without tangling, twisting or wearing prematurely.

“Our e-chain cable carriers are increasingly being designed into new systems or retrofitting festoons and cable-reel systems in most industries. Our e-chains simply act as a moving conduit or a sort of spine that keeps the cable neat and always protected,” says igus South Africa MD Ian Hewat.

Hewat outlines the advantages of using igus energy chains when designing and building machines:

• Cable-friendly design: a smooth inner surface and controlled minimum bending radius based on cable specification helps protect cables and hoses from micro-abrasions and stress cracks.
• Modular, lightweight and strong: made from high-performance polymers, the chains are lighter than metal systems but still offer strength and stability. They can be extended, shortened or customised on site
• Multi-media integration: can simultaneously carry electric cables, pneumatic lines, hydraulic hoses and fibre-optic cables in the housing.
• Predictable service life and warranty: guaranteed service life and up to four-year warranty on igus chainflex cables.
• Low-friction, energy-efficient operation: self-lubricating plastic design reduces drag forces and offers minimal resistance.
• Maintenance-free operation: no greasing or lubrication needed, reducing downtime. Ideal for use in clean environments such as food processing or high-dust areas such as cement and mining operations.
• Quick configuration and customisation: free igus online configurators to help select, model and download energy chain setups.
• Intelligent condition monitoring: igus’s i.Sense smart plastics add-on sensors can be embedded to monitor wear, cable tension and chain motion.
• Space-saving and safe: cables and hoses can be neatly routed and contained, improving machine aesthetics and workplace safety.

The management of moving cables and hoses in machine building is critical to the operation and longevity of equipment and igus asserts that its e-chains are used in over 50 industries, across almost any moving cable application.