E4.1L from igus - Low weight, easy assembly and cable-friendly design

Optimum use of installation space, light weight and high stability - these are just some of the benefits of the E4.1L energy chain from igus, which is now available in new heights and widths from stock. Compared to the E4.1, weight can be reduced by 30 percent, with this light version, meaning that the chain is well suited to highly dynamic applications. It was developed especially for unsupported applications; long gliding travels are also possible with the e-chain.

The E4.1L of the motion plastics specialist igus combines the strengths of different series of chains from igus and also has a design that is very kind to all the surfaces in contact with the cables. "Rounded edges of the crossbars and separators of the chain ensure a long service life of hoses and cables," explains Harald Nehring, authorised representative for e-chain systems at igus. "You can therefore call E4.1L an energy chain in which the moving cables feel at ease." In addition to the rounded surfaces that come in contact with cables, gridding and positioning scales are used for the best possible separation of the chain. Along with the easy assembly and high stability it displays its strengths especially in fast unsupported applications, such as in automation or in machine tools.

Technical tricks for design freedom

The simple snap-open mechanism of the crossbars in the outer and inner radius ensures a quick filling of the e-chain. The captive crossbars, which can be opened with a screwdriver, open by 115 degrees and latch into final position. If necessary, they can even be removed completely, placed again and closed by simply pressing in. The patented positive-fit tongue and groove of the chain links and the double stop dogs with large stop surfaces that allow a high degree of stability were carried over from the heavy duty E4.1 chain. Here a 'brake' also ensures a lower rolling noise and a very smooth chain travel. Due to the variable mounting of the outer links, the chain can be installed either with or without camber. This is a decisive advantage especially in limited installation space, such as in machine tools.

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Due to the modular design, the E4.1L energy chain can be adapted to any specific application. As an open standard version for cable routing, with brackets for hoses, or enclosed in a chip-resistant tube in a guide trough – just three of many customising options. (Source: igus GmbH)

"Perhaps the best e-chain in the world"

Compared to E4.1, the application-oriented design of the E4.1 L could save so much mass that the chain is about 30 percent lighter. This brings an additional advantage: "In this way, users save not only a lot of drive power," says Harald Nehring. "It can also accommodate more hoses and cables in a given space envelope – all these advantages perhaps make the E4.1L the best e-chain in the world." The energy chain is now available from stock in more interior heights between 31 and 64 millimetres and new widths, as well as fully enclosed options for the protection against chips. As for the open energy chain, igus also has an ESD version and even a high-temperature option for the enclosed energy tube.

For more information please visit: http://www.igus.in/energychains?C=IN&L=en

About igus® India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® Spherical Bearings Plain Bearings and Bushing Accessories etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

igus introduces Industry 4.0 for trouble-free motion with smart plastics

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smart plastics eliminate unplanned downtimes of machineries: The intelligent drylin linear guide, the intelligent energy chain and the intelligent cable monitor themselves permanently and make predictivemaintenance and replacement possible. (Source: igus GmbH)

Motion plastics, high-performance plastics for motion, defy rain, salt, extreme temperatures, are resistant to oil or chemicals, are lighter, more dynamic, more energy efficient and yet cost effective. At the Hannover Messe, igus now shows the next step – intelligent "smart plastics" for Industry 4.0. Their goal: to make predictive maintenance even easier and thus reduce costs in the factory of the future.

Today they are used worldwide, high-performance plastics for moving applications. In everyday life, in kitchen machines, bicycles or shower cubicles as well as in industrial environments, such as machine tools or in crane facilities. igus is able to make accurate statements about the service life of motion plastics, thanks to the extensive tests in the 2,750 m² testing lab,  The test results are incorporated into the online tools which are also available as a mobile app. At the Hannover Messe igus now goes a step further, and in Hall 17 presents smart plastics; intelligent plastics solutions that ensure additional reliability in the factory of the future.

Smart plastics detect conditions in operation

The networked smart plastics expand the possibilities for so-called predictive maintenance and increase the plant availability for the customer. Intelligent drylin linear guides as well as the intelligent energy chains and the intelligent cables constantly monitor themselves and provide early warning of failure. The range named isense consists of different sensors and monitoring modules. By networking with the igus communication module (ICOM), a direct integration with the customer's infrastructure takes place.

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Through isense the smart e-chain, cable and linear guide communicate with the customer and inform them about their condition and potential maintenance dates. Optionally isense can be connected to the igus data centre to automate and optimise maintenance processes. (Source: igus GmbH)

Automated maintenance saves time and money

isense is capable of monitoring the service life of the e-chain, cable or linear guide. Through continuous distance measurements and the calculations using the parameters of the system as well as the thousands of test data from the test laboratory, it is possible to also reliably predict the smooth functioning in real operation. If measured values are exceeded, the intelligent products indicate the remaining term of use early, which enables a timely maintenance and replacement. Optionally isense can be connected to the igus data centre, thereby opening up more digital options: customised service life calculation and optimisation of business processes. These include maintenance commissioning or spare parts ordering. In this way, the electronic intelligence lowers maintenance costs even further and increases plant availability. The products will be available to customers for testing after the Hannover Messe.

For more information please visit: http://www.igus.in/iglidur?C=IN&L=en

About igus® India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® Spherical Bearings Plain Bearings and Bushing Accessories etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.
E-ChainSystems® & ReadyChains®

Press Contact:

Harish Booshan

Product Manager

igus (India) Private Limited

36/1, Sy. No. 17/3

Euro School Road,

Dodda Nekkundi Industrial Area - 2nd Stage

Mahadevapura Post

Bangalore - 560048

Phone : +91-80-49127809 (Direct)

Visit us on www.igus.in

Detectable plastics from igus for maximum safety in foods

In the food and packaging industry, the highest safety standards apply. To protect consumers, food must be free of contaminants of any kind. As part of its ball and spherical bearing series, igus offers plastic products that are lubricant-free and at the same time, detectable. This guarantees that no lubricants and no plastics enter the production chain during operation or in the event of a system failure.

In the plants of the food and packaging industry, metal detectors are now an industry standard. They detect any metallic conductive particles derived from the production environment. Subsequently, the products can be sorted out as soon as possible. But how can plastic particles be traced? That was the question that developers at Cologne-based motion plastics specialist igus asked themselves. The solution was finally the development of a special high-performance plastic, which can easily be traced with standard metal detection methods. The material is used today in selected products in the igubal series, which includes rod end bearings and clevis joints, flange bearings, spherical bearings and pillow block bearings. Both the housing and the spherical balls are made of the detectable plastic. This characteristic is sought after in other areas of bearing technology. For example, xiros M180 is a lightweight polymer ball bearing, whose material is also detectable.

Freedom from lubrication ensures additional safety

In addition, these high-performance polymers do not require external lubrication. "A central point in the production process of the food and packaging industry is the avoidance of contact of product and lubricants in the machine," points out Lars Braun, Industry Manager for Food and Packaging Technology at igus. A major contribution towards this is made by the lubrication-free and maintenance-free plain bearing materials from igus. Because, they precisely meet these requirements: materials like iglidur A181 or iglidur A350 need not be actively lubricated. Moreover they are compliant with the EC Directive 10/2011 and also with FDA specifications for repeated contact with food.

For more information please visit: http://www.igus.in/iglidur?C=IN&L=en

About igus India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® Spherical Bearings Plain Bearings and Bushing Accessories etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Cable reel for energy chains proves its worth on the stage

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Tests conducted in the 2,750 square metre test lab demonstrated the low noise emissions of the e-spool. Thus, the cable reel without slip ring qualified for low operation noise in the stage sector. (Source: igus GmbH)

The e-spool from igus, a cable reel for energy chains, has passed all the noise tests in the igus test laboratory with flying colours. This means it has distinguished itself as an ideal solution for applications in noise-sensitive areas, such as in stage engineering. With the space-saving e-spool, energy, media or fibre optic data cables can be run together in a single system, as it requires no slip ring.

The Cologne-based motion plastics specialist igus operates the largest testing laboratory in the industry with a floor area of 2,750 square metres, where all products have to pass various tests. There, more than 3,000 basic and user-specific tests are performed annually for energy chain systems alone in 180 test facilities under real conditions. These include tests at various temperatures and pressures, or even in contact with chemical substances. Tests are, for example, also conducted in the special noise chamber. It was here that the e-spool from igus was subjected to an intensive test for its noise emissions during operation. e-spool is an alternative to conventional cable reels for very tight radii and installation spaces. In the tests, the cable-friendly energy, data and media supply system of the latest generation has been proved extremely quiet. In particular the absence of slip rings minimises the noise development significantly in this special reel. An e-spool equipped with 'anti-vibration matting' was able to reach levels below 46dB (A) in these tests.

The tests in the igus test lab also proved the performance of the e-spool with respect to its service life. In addition to the noise emissions, this special insulated option was tested for compliance with the service life expectancy for a customer. This result was amazing: at full extension to twelve metres, the integrated return spring held the required tension of the pull-out e-chain at all times, and a maximum rotational movement of the used igus twisterband the e-spool has surpassed the required 24,000 double strokes by far, completely trouble-free. The twisterband works as the rotating link through which the cables are routed smoothly for the chain and which allows the rotation of the reel. igus offers e-spools with one or two twisterbands, depending on the number of cables to be routed. The achievable life is dependent on the application and execution of up to about one million movements. For the model with spring reel, the spring must be replaced after 75,000 double strokes. In the e-spool power with motor drive, that is not necessary.

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The igus twisterband is used in the e-spool: Thus rotations can be implemented economically and with low wear and low maintenance in a confined space, while reliably guiding energy, data and media. (Source: igus GmbH)

Suitable for noise-sensitive applications

The latest test results prove that the e-spool is ideal for use in noise-sensitive applications such as stage installations. Finally, moving stage elements must be moved as smoothly and quietly as possible, at the same time the energy supply system needs to be as compact as possible in order to manage with the limited space. Similarly, factories or logistics centres, where noise emission limits are increasingly becoming a norm, are suitable areas of its application. But there are even more features such as the strain relief of the cables, the variable guiding in all directions, as well as halogen-free components support the use of an e-spool. The latter is particularly important in order to achieve the required fire safety standards. For this purpose, igus offers the appropriate chainflex cables with TPE outer jacket for moving applications.

The e-spool energy supply system is available in standard catalogue sizes of four to 14 metres. For special projects which are either particularly compact or for very long extension lengths up to 50 metres, igus also offers customised special solutions. All components together according to customer requirements with completely pre-assembled cables and optional installation.

For more information please visit: http://www.igus.in/wpck/1764/productoverview_EC?C=IN&L=en

About igus India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® Spherical Bearings Plain Bearings and Bushing Accessories etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Local manus India: awards for exciting bearing applications

The global manus award ceremony was held for the seventh time at the Hannover Messe 2015. Developers from all over the world submitted 467 applications, demonstrating the creative potential when it comes to using polymer bearings. With 73 enteries India was the leading country with the highest number of participants. The three most exciting applications out of 73 Indian submissions received the "local manus India" award at the occasion of Auto Expo 2016. The golden manus with prize amount ₹1,00,000 was given to ATS ELGI. This company relies on lubrication-free polymer plain bearings from igus at its carwash underbody sprayer. A diagnostis screening device for breast cancer from Tuscano Equipments private Ltd won the silver manus (₹75,000). The bronze manus award (₹50,000) went to SRG Machines Pvt Ltd for egg sorting machines. 

Every two years, interesting applications using polymer plain bearings are chosen for the manus awards. These applications stand out due to their technical and economical efficiency as well as the creativity and boldness of the developer. The entries from all over the world demonstrate the diverse range of application possibilities for polymer plain bearings, from prototype to serial application. Most of the applications for the manus 2015 competition came from India. From these, the three most innovative applications were chosen in a local manus competition and the prizes were awarded during Auto Expo 2016 in New Delhi.

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The award winners of the local manus India. From left to right: Mr. Mihir Garware (3rd from left), Mr. V. Mahesh Kumar (4^th from left) and Mr. Sudhan Chandrasekaran (5^th from left). 

From carwash to medical device – the winners of the local manus India

The manufacturer ATS ELGI received the golden manus award. The company relies on robust iglidur bearings for the underbody washing system at its carwash. Since these polymer plain bearings do not corrode, downtimes at the carwash are reduced. Besides the self lubricating bearings eliminates the need to grease or maintain continually. A screening device from Tuscano Equipment for diaganosing breast cancer secured a second place. In this application, the thermal radiation of the breast is recorded and a thermal map is created.  Thanks to the installed iglidur PRT slewing ring bearings, linear slides SLW & ZLW, the machine runs smoothly with low noise. The bronze manus went to SRG Machines Pvt. Ltd. for egg sorting machines. These machnices segregate eggs into four different weight classes. A lubrication-free and dirt-resistant drylin N system from igus was installed here, which is resistant to corrosion and thus perfect for use in the machines. With this application, that ensured high hygiene standards by eliminating lubrication SRG Machines Pvt. Ltd. won the third place.

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The golden manus went to ATS ELGI from the Indian state of Tamil Nadu. The company reduces downtimes in its carwash by using robust iglidur P plain bearings in the underbody washing system (Source: igus GmbH)

At www.manus-award.com, you can find all information on the winners and all other applications from previous years.

About igus India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® spherical bearings, Journal Bearings etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

igus: The world leader in cables for energy chains after 25 years

With 100 million euros of revenue from cable sales over the last year, igus is maintaining its status as a world leader among cable manufacturers for moving applications in energy chains. Thanks to the industry's largest test laboratory in Cologne, Germany, now expanded to 2,750 square metres, the motion plastics specialist is the only supplier on the market able to offer a 36-month guarantee on all chainflex cables. Increasing industrial automation is prompting igus to make significant investments in innovation, reliability and fast delivery worldwide.

The motion plastics specialist igus revolutionised the cable design for moving applications in e-chains 25 years ago and has been offering motor, control and data cables for specialised moving applications in energy chains through the chainflex brand ever since. The use in energy chains requires specific cable designs to increase the cable's service life and, as a result, the service life of the application. In this area in particular, igus can draw on its experience as market leader for e-chains and on its expertise of more than 50 years with all things plastics-related. "As market leader for e-chains, the advantage at igus is that we develop both energy chains as well as cables. For this reason, we can test and offer both as a system," emphasises Frank Blase, CEO at igus GmbH. igus is having plenty of success in this area. The chainflex business area exceeded 100 million euros in revenue last year, which made up more than 20% of the total revenue at igus. In the Indian market alone, igus generated 250 million INR (3.5 million euros), which is an increase of approximately 25 percent over the revenue from cables in the previous year. The Cologne-based company has 1,040 cables to make up the widest product range on offer with respect to energy chain applications. Of these, no less than 3,200 drive cables at seven price points can be fabricated according to 22 manufacturer standards. Components such as energy chains and cables are fabricated at the Indian office in Bangalore. This ensures that local customers receive their orders more quickly. "The degree of automation in companies is continuously increasing, particularly due to Industry 4.0. At the same time, it is necessary to guarantee an interruption-free flow of data, media and energy," says Blase. "This really motivates us to invest significant resources in innovation, product reliability and fast, worldwide availability, to ensure that our customers receive the best possible ratio of price to reliability."

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With 100 million euros in revenue from cables, the largest cable selection for the e-chain and the industry's biggest test laboratory, igus is a leader among the field of cable manufacturers for moving applications. (Source: igus GmbH)

2,750 square metres of movement for innovation and reliability

Considerable investments are being made in the industry's largest test laboratory. Here, more than 70 cable test machines perform over two billion test cycles per year. On average, 650 cable tests are conducted simultaneously. New test rigs enable fast acceleration speeds of 15 m/s² over 50 metres; a new cryochamber now allows tests in temperatures as low as -40 °C. Thanks to new torsion attachments and the expansion of the outdoor installation for long travel paths, cable use can be simulated under real conditions. The overall area of the test laboratory increased by 1,000 square metres to a current total area of 2,750 square metres. Thanks to a multitude of tests, igus is the only manufacturer able to offer a 36-month guarantee for all chainflex cables, including torsion cables such as the world's first CAT7 cable for robotics. These tests also allow igus to provide exact specifications in its catalogue regarding bend radii, temperature ranges and service life for special use in the e-chain, in addition to the standard norms. The results from the test laboratory are also used for the five online tools for chainflex and three online tools for readycable. igus has invested significantly in the online area to allow customers to quickly determine the service life in moving applications and find, configure and order the most suitable cables for their particular application.

Worldwide local delivery according to the customer's needs

igus has considerably expanded its production and storage capacity in North America, Asia and Europe to ensure even faster delivery to its customers in local markets. A warehouse expansion is also in the works for the Indian market. With cable production on three continents and 14 storage and assembly centres worldwide, customers receive the exact cable needed for their production system from stock: single, individually cut cables, reeled piece goods, fabricated cables or ready-to-install energy chain systems. igus also offers on-site system installation service.

With increasing automation, quality becomes ever more important

The best possible reliability for the customer is also the goal of igus' unique quality assurance in the production area: 20% of any chainflex batch is always removed and checked for proper function at the test laboratory following an initial visual inspection. igus wants to offer the most affordable cable worldwide that is guaranteed to work every time. But, as Frank Blase emphasises, an affordable price is not everything. "Now and in future, affordable pricing will not be the sole concern of customers. Their primary concern is the quality and reliability of a cable, particularly as it relates to special movements in the energy chain. We consider ourselves the first point of contact for finding a solution for our customers and our 36-month guarantee makes it clear that chainflex lasts."

For more information please visit: http://www.igus.in/Chainflex

About igus India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® spherical bearings, Plain Bearings and Bushing Accessories etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Consistently high holding force guaranteed: Demountable angled joints from igus

The motion plastics specialist igus has combined the demountable igubal angled joint with the user-friendly "crimped" joining method. The advantages: customised lengths from 1 piece, easy assembly and disassembly, as well as high holding force up to 300 N, and completely free of lubricant and maintenance.

Angled joints made of tribologically optimised plastics are becoming increasingly popular, whether in the automotive, machinery or plant construction. Just like the low cost, low weight, corrosion resistance and long service life speak in favour of the igus angled joints. In addition, you can eliminate external lubrication with the use of an incorporated dry lubricant and they are therefore practically maintenance free. These positive features characterise the new demountable option as well. The iglidur RN 56 material has particularly good friction coefficients, low wear and robustness. The crucial factor is that the ball pin, which is made of galvanised steel, stainless steel or plastic, is always kept stable compared to the standard part, With the demountable angled joint the user has a component in variable lengths from 100 mm. which makes it suitable for demanding environments such as accessories for pneumatic cylinders and gas springs.

Easy installation and dismantling

Frequently, the user is faced with the task of mounting its angular joints quickly yet safely or demounted easily for maintenance. The process speed is a decisive cost factor because it determines the downtimes of the plant. The demountable angled joint is the ideal solution. A few seconds are enough to release the ball pin using a screwdriver. The cylindrical design of the articulated shaft with its recesses guarantees high mechanical safety during crimping. Even in the case of repeated dismantling, the holding force of the ball pin (M6) is not affected. Up to 300 N holding force is permanently ensured even after repeated opening and closing of the connection. Demountable angled joints are also available as an option with M5 and M6 female thread in combination with threaded rods in customised lengths from 80 mm.

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The angled joint made of lubrication and maintenance free high-performance plastic with ball pin is very easy to assemble and disassemble - with constant holding force up to 300N. It allows customised lengths and is available from a quantity of 1 piece. (Source: igus GmbH)

For more information please visit: http://www.igus.in/wpck/2510/productoverview_igubal?C=IN&L=en

About igus India

igus® operations in India started in the year 1998 with head quarters in Bangalore. igus offers widest range of products that includes polymer bearings, igubal® Spherical Bearings etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.