chainflex®

..cables...

chainflex® cables...tested and lasts...

plastics for longer life®...

www.chainflex.eu

for use in energy chain systems®...

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7 basic rules for a good cable for use in e-chains®

The tricks and ingenious features of the chainflex® design… and why we feel so confident about this design

chainflex® lasts ... in dynamic applications ...

4. stranding with short pitch length

2. optimized strand wire

1. strain-relieving centre element

3. high-quality core insulation

5. gusset-filled extruded inner jacket

6. shielding with optimized shield braiding angle

7. abrasion-resistant outer jacket, pressure extruded

In over 2 billion test cycles per year in igus® own chain-flex® test lab (1750 m²) we have been gaining a unique level of knowledge of cables in the area of e-chains®. This is what our rules for extremely long-lasting cables are based on.

chainflex® is uniqueFrom the customer‘s point of view, a flexible energy supply system only needs to function properly. How-ever, this demand presupposes the perfect operation of all components, including the cables being used in this system. And this is exactly where problems came up in the early 1980s. In extreme cases, failures caused by „corkscrews“ and core ruptures brought the entire production pro-cess to a standstill and resulted in high costsigus® was the first company to develop complete e-chainsystems®. chainflex® cables and e-chains® are tested and optimized in conjunction. Based on the increasing know-how gained since 1989 and on the very sophisticated series of tests that have been conducted since then, design principles were and are still being created that help prevent machine downtimes in factories throughout the world today.

chainflex® are the special cables for energy chain systems®

More sophisticated applications with high number of cycles, speeds and accelerations, as well as adver-se environmental conditions require reliable cables in the energy supply system. A high EMC safety and the compliance of standards and regulations such as UL, CSA or VDE is necessary.A reliable function of bus properties in the area of Pro-fibus, Profinet or Ethernet are required.. Ultimately, our customers expect a consistent res-ponse to different forms of movement, because they require the same electrical characteristics in both long linear chains and small torsional movements.It is our mission to guarantee this worldwide and non-stop

Richard HaberingGlobal Product Manager chainflex®

Phone: +49-2203 9649-9806Email rhabering@igus.de

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igus® cable range for all movements and electrical requirements

1030 chainflex® types ... Available from stock...

Control cables Bending radii up to 4 x d Shielded or unschielded Jacket materials: PVC, PUR, TPE

Data cables For travels up to 400 m Optimized shields with high cover Jacket materials: PVC, PUR, TPE

Bus cable Profibus, Profinet, CAN-Bus, Ethernet, CAT6, USB… Jacket materials: PVC, PUR, TPE UL- and NFPA79 approval

Fiber optical cables Bending radii up to 5 x d Plastic and glass fibers Jacket materials: PUR, TPE

Measuring system cables For high dynamics For 20 drive manufacturers Jacket materials: PVC, PUR, TPE

Servo cables Abrasion-optimized With inner-jacket for high dynamics Jacket materials: PVC, PUR

Motor cables Shielded and unshielded For extreme applications Jacket materials: PVC, TPE

Torsion-resistant cables ± 180° at 3 mill./m With UL and CSA Jacket materials: PUR, TPE

Special cables Cables with high tensile strength With special approvals for the rail sector Jacket materials: PUR, TPE

igus® delivery service

Ordered today, delivered tomorrowThe igus® delivery service: from 24h or todayThe goods leave igus® within 24 hrs. On request we can deliver via express or special delivery.

From stock No minimum order value No minimum order quantity No cutting costs Delivery and consultation daily from 7-20 h and Saturdays from 8-12 h!

Order tracking in the Internet Invoices and confirmations by post, fax, or email “Round-the-clock” emergency service DIN EN ISO 9001:2008

75% of all cables can be delivered from stock with UL

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Your chainflex®. in 3 minutes. from 300 m. in 3 weeks..Process-oriented solutions

Online selection and configurationsFind, configure and order chainflex® cables easily at www.chainflex.de

Use the product finder to find all relevant chainflex® cables specifi-cally for your application.

igus.eu/quickcable

With the special cable configurator, individual cables from 300 m can be ordered in 3 minutes and deli-vered within 3 weeks at daily upda-ted prices.

igus.eu/eu/ccc

Calculate the service life of your chainflex® cable with the QuickLife service life predictor.

igus.eu/cf-lifetime

Calculation of the copper surchar-ge updated daily.

igus.eu/eu/ccc

chainflex® online shop: Select and order highly flexible cables for ener-gy supply systems directly online.

igus.eu/eu/chainflexshop

We will find the right cable for your application

Desired cable in 3 minutes with the chainflex® custom cable configuratorCreate the required cable for your e-chain® with the chainflex® custom cable ... configured in only 3 minutes ... from 300 m ... delivered in 3 weeks!Based on the new production system “chainflex® SFP”, igus® can now produce and deliver an almost “endless” variety of individual special cables for the customer within short time and in tested igus® quality.Thereby, igus® combines the tested chainflex® quality with the individual requirements of their customers in the over 1,750 m² large igus® lab.This is called “chainflex® CC”, CC denoting „custom cable“.The new online tool thereby offers the option to select

the cable type the structure the shield the jacket material the color and the individual printing. igus.eu/eu/ccc

We will be glad to visit you for a personal dis-cussion and advise you about your customized application on site.

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1,750 m2 lab... more than 700 cable tests... 2 bill. test cycles... Reliability through practical experience...

Media tests: Test of durability of chemical interferences in motion

Test for combined movements: Simulation of complex movements in robotic applications

Frost test of cables and e-chains® at -40°CRotation tests: Ambitious chain applications with small radii

Special design for special solutionsQuality Assurance: Continous batch testing to ensure the quality level

igus® lab and development...

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Linear movements in short and long travels

Test of servo cables

Permanent batch test

Direct comparison with competitors

Long-term tests

Travels up to 12.6 m in the interior, up to 120 m in the outdoor area

Variable speed and acceleration

Continuous monitoring

Torsion cables in standardized tests

Uniform setup for objective assessment

± 180°/m

10 test setups at the same time

Up to 50 test cables

Shield testing and optimization

igus® lab and development...

Constant load test in the smallest radii

Serial test of twisterband solutions

CFLG.2LB.50/125 tested with 70.4 mill. strokes at 4.35 x d

CFROBOT5.501 27 mill. ± 180°/m

CF98.05.04 in a radius of 18 mm 138,6 mill. strokes

Torsional movements

CF9.03.04.INI 4 cables with > 1.2 mill. cycles with 3,000°

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Reliability in your application

Special chain setups

Service life statements for special chain movements

Reliability for the series

Fault analysis of existing designs

Optimization of the cable routing

Torsional movements without chain guide

Torsion in machine feedthroughs

Combined motions

Combination of various media

Reliability through optimization with plain bearing guides

Automatic measuring

Permanent measuring

Automatic

Reliably

High-speed application for millions of cycles

Abrasion tests

Optimization of braid designs

Service life guarantees

Ascertainment of maintenance intervals

Precise and detailed analysis of the cable parts

All components of a cable are indi-vidually taken apart and assessed

Documentation as photo

Measuring of elements

Analysis of fault patterns

Assessment up to wire strength

Tensile test up to 5,000 N

Roller test stand with variable loads

Test certificate for every test

Test-Report chainflex®

page 1 of 2 Test No.: 3105

QM-2-201-F/ Original CF D&T Ch. Mittelstedt/Versuch/11.10.2011 Copy 1 Test Lab For internal use only

The managing data show the results of the accomplished examinations. With all data it still acts neither around one or more warranties of certain characteristics around one or more warranties regarding the suitability of a product for a certain targeted application, since the examinations on laboratory conditions took place. The warranty of certain characteristics of the products and/or their suitability for a certain application requires writing in the confirmation of order. Finally we recommend user-specific measurements under genuine operating conditions.

Copy 2 Client

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Test Intention:

In test 3105 we want to investigate the lifespan of the new chainflex® LWL cable for torsion applications.

Client:

Name: Rainer Rössel Team: chainflex® Date: 24.09.2008

Order-Info:

Customer/ No.: igus® GmbH, Spicher Str.1a, 51147 Köln

Series / No: CFROBOT5.501 Installation type: ±180°

Customer test: Yes No Development test: Yes No

Technical data Target & Examination

e-chain® type: TRC.100.145.0 Cable length [m]: 50,0

e-chain® radius [mm]: 145 Target [cycles]: Lifespan Cycle [°/m]: ±180 Optical check:

Acceleration a [°/s]: 60 Function check:

Velocity v [m/s]: 0,5 Standard measuring:

Ambient temperature [°C]: approx. 25°C AutΩMeS:

Experimental setup (Sketch, Photo ...) Checklist for the experimental preparations

additional inscription/label at all wires strain reliefs at both ends of the chain correct electrical connection of all wires radius was marked at the cables and the energy chain

1. Construction:The following pictures show the test laboratory and test machine, the 10fach-Torsion“.

Elaborate analysis and documentation

igus® lab and development ...

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Cable assembly... harnessed e-chains®...Capacity for 600,000 assembled cables a year......more than 18,000 test programs...1,800 test adapters...

readycable® – in 24-48h or todayigus® offers more than 2240 harnessed cablesfor drive systems according to 20 differentmanufacturers. Professionally manufactured,100 % tested.

Servo, Power and Signal-/encoder cables No cutting costs, no minimum order quantity, no costs for packaging

Cable length according to customer requirements Smallest bending radii from 7.5 x d Reduce storage cost and increase cashflow igus.eu/readycable

QuickPin 2.0 connector-cable configurator– directly integrated in ePlanConfigure your cable online in only three minutes from over 1,030

chainflex® types and 3,500 connector components, order immediately and generate ePlan electric P8 macro.

igus.eu/quickpin

QuickFluid hose cable configuratorChoose from 28 types of hydraulic and industrial hoses, tubes and hose cables as well as a total of 200 fittings

and configure your individual hose cable in few minutes. igus.eu/quickfluid

Allen Bradley

B&R

Baumüller

Beckhoff

Berger Lahr

Control Techniques

Danaher Motion

ELAU

Fagor

Fanuc

Heidenhain

Jetter

Lenze

LTi DRiVES

NUM

Omron

Rexroth

SEW

Siemens

Stöber

Assembled energy supply systems, connectors and cables from igus® all from a single source

readychain® – Ready-to-fit assembled systems in 3-10 days700 systems per week in 11 readychain® compa-nies around the world – assembly-optmized and raise your cash-flow

Reduces your storage costs Cut your throughput times from days to hours Respond flexibly to order variations Utilize igus® manufacturing capacities and our know-how in cable assembly

Reduce the number of suppliers (one order, one invoice, one delivery)

One partner for minimal machine downtimes All readychain® components are subject to an extensive quality control and function testing readychain.eu

readychain® assembly rackSave 80% at prototyping. Assembly transport rack for ready-to-install energy supply systems.

readychain® „Basic“

readychain® „Standard“

readychain® „Premium“

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/ISO 9001 : 2008/90.000

/ISO/TS 16949 : 2009*In the sector of energy chains®* with cables and assembly as well as plastic plain bearings, igus® is certified according to DIN EN ISO 9001 : 2008 and ISO/TS 16949 : 2009*.

/20hOrdering and deliveries weekdays from 7.00 am to 8.00 pm, Saturday from 8.00 am to 12.00 pm. No minimum order quantities, no surcharges. Quick delivery. www.igus.eu Phone. +49-2203 9649-0 Fax -222

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MAT0072154.20 Issue 03/2013Subject to technical alterations *from 01/04/2013

Buy online – 24 hrs!More catalogs and brochures online – www.igus.eu/downloads

igus® GmbH Spicher Straße 1a 51147 Cologne GermanyPhone: +49-2203 9649-0 Fax +49-2203 9649-222info@igus.eu www.igus.deu www.chainflex.eu

®

/readyAsk for fully harnessed and preassembled readychains® – increase your cash-flow and profit immediately – www.readychain.eu