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.

New lubrication free linear guide from igus for greater sliding precision

The drylin T guide as a heavy-duty version with adjustable clearance will be presented by the motion plastics specialist from Cologne at Motek in Stuttgart. This new product provides users with more precision during linear movement, even in very rough environments. The HD version with stainless-steel cover is also suitable for heavy loads in dirty surroundings and is insensitive to impacts.

Dirt, adhesive residue or mud are all factors that can influence the running of a linear guide system. In order to counter this, igus GmbH from Cologne has developed a heavy-duty version of the drylin T linear guide. This is now also available with adjustable clearance in order to achieve greater adjusting precision even in difficult environments. The heavy-duty guide carriages TW-12-20 can be adjusted seamlessly in the bearing clearance. This is very easy to do with an allen key As the plastic sliding elements made of the self lubricated material iglidur J are integrated into the carriage in such a way that they cannot be lost, they can be easily removed from the rail and pushed back on for assembly purposes. The complete linear guide causes little friction and is wear-resistant. Particles cannot stick to the carriage and impair running as no lubricant of any kind is necessary. Both the rail made of hard-anodised aluminium as well as the carriage made of anodised aluminium with a stainless-steel cover are corrosion resistant.

Interesting alternative to roller guides

In addition, this carriage simultaneously ensures easy and robust linear guidance. It is insensitive to impacts and can tolerate high loads of up to 740 kilograms and is therefore ideal for difficult extreme applications. The low weight and the compactness of the system allow easy and uncomplicated assembly. The range of floating bearing versions offered reduces assembly and alignment times drastically.

Due to the qualities of the system, namely its load bearing capacity, the absence of lubricants and its resistance to the influence of surroundings, the drylin T HD is an attractive product for many different branches of industry. Uses in the wood industry, for welding equipment or for equipment construction are just some examples. The possibility of manual clearance adjustment, however, offers great potential for a wide range of applications. As the drylin T HD was deliberately designed to have the same dimensions as classical roller guides, the retrofitting of existing installations is possible without difficulty.

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The drylin T HD linear bearing guide with freely adjustable bearing clearance and hard-anodised aluminium rail for low-friction and low-maintenance running even under difficult conditions. (Source: igus GmbH)

For more information please visit: http://www.igus.in/wpck/1994/drylin_w?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, Journal Bearings etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

The new R2.40 plastic energy tube from igus which is Compact and chip-repellent design

Chip-resistant energy chains, so-called energy tubes, offer cables protection from external influences in dirty environments or inside processing areas. Constructed on the basis of the cost-effective E2-principle (two parts per chain link) made of tribologically optimised plastics from igus, the chip-proof energy tubes of the R2 series also offer, in addition to the advantages of lubricant and maintenance free operation, protection from external dirt accumulation and flying chips. At the Motek igus will present the energy tube in a new size with 40 millimetres inner height to a specialist audience. This can be opened both along the outer radius (R2.40) and in the inner radius (R2i.40), allowing users to choose an option that is the easiest for them when filling the cables and hoses. The lids can be snapped open in either direction and need not be completely removed for filling the tube.

Gentle design for cables and easy on the ear

The contours of the lid of the R2.40 energy tube are smooth and their curvature and tight manufacturing tolerances guarantee that chips do not accumulate between the stop dogs. Smooth inner contours of the energy tube and rounded latching separators made of the same material also protect the cables. The integrated grid design also ensures a firm hold of the interior separation, even in side-mounted applications. With an integrated brake on the individual chain links, the chain runs audibly quieter. Less vibrations means more precise work on the workpiece. With the double stop dogs, the energy tube can absorb high fill weights and can even master long unsupported lengths. The universal mounting brackets of the R2.40 moreover ensure chip protection and also provide comprehensive options for internal strain relief.

The energy tube R2.40 (left) protects moving cables from chips, dust and dirt even in small installation spaces. Like the larger R2.75 (right), it is very easy to open and saves a lot of installation time. (Source: igus GmbH)

Know more about Cable Duct, Track and Applications with E-Chain® at http://www.igus.in/wpck/default.aspx?PageNr=1762&CL=IN-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, Cable Connectors  etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Novel energy supply systems sought: fifth vector award started

Energy chain systems possible areas of use are now vast in scope. They withstand saltwater on ships and oil rigs, prevent the ingress of persistent dust and dirt in materials handling systems or, certified to ISO Class 1, are used in clinically sterile cleanrooms. In order to find the most innovative and novel system in the world, the motion plastics specialist, igus, invites submissions for the vector award every two years. The starting signal was given at this year's Motek exhibition. Users can submit their entries online and present their constructions to the jury with short texts, photos and videos. The winners stand to receive prizes of up to 5,000 euros; the official prize-award ceremony will take place at the Hannover Messe in April 2016.

Every two years, inventive and creative applications for energy supply solutions are honoured with the "vector award", which was initiated by igus. This year is no exception and the official phase for the submission of entries for the prize-award ceremony in 2016 begins at Motek. A jury of experts with representatives from science and technical associations as well as from the specialist press will judge the applications and choose the winners from among the participants. "Even for us, it is sometimes still surprising and exciting to see where and how customers use our e-chainsystems", explained Harald Nehring, responsible for e-chainsystems at igus GmbH. "We therefore want to use this competition to honour new ways of using our products and the innovation of design engineers."

The vector award comes with prizes of up to 5,000 euros. Anyone who has novel or challenging applications with energy chains is invited to take part in the competition, irrespective of what branch of industry they come from. The deadline for entries is 26 February 2016. More information on the conditions of participation is available at www.vector-award.eu. This website also contains an overview of the 195 participants from 28 different countries who took part in the last vector award in 2014 as well as a list of other competitors and winners of the last competition. Here, the variety of submissions from previous years is shown.

Know more about Bearings, Bushings, Anti Friction Bearings at http://www.igus.in/default.asp?PAGE=IGLIDUR&C=IN&L=en

"The vector award promotes new ways of using energy chain systems and honours the courage of the design engineers as well." (source: igus GmbH)

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.

Small effort, big result! Igus launches Roll energy chain systems up to 100 metres easily by hand

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With the readychain rolling rack, one person can unreel a ready assembled energy chain system with lengths up to 100 metres. (Source: igus GmbH)

With the new readychain rolling rack the motion plastics specialist igus shows how even heavy, harnessed e-chainsystems can be unreeled by just one person allowing  assembly time and costs to be significantly reduced. The complete solution can be used for energy chain systems up to 100 metres in length, for example for gantry cranes.

igus offers reliable, tested energy chains and cables for use in chains as well ready assembled systemsknown as readychains. Especially for long travels, such systems not only saves time in assembly, but primarily offer predictable reliability as well. Customers can rest assured that they are getting a preassembled complete system in which all components are matched to one another for the movement. The new rolling rack now makes the transport and installation of these readychains even easier. The ready assembled chain is rolled up on a drum, which is then mounted on a steel rack. The rolling rack can be easily transported by a forklift to the desired location, and can be unreeled there by just one person. Moreover, transport rollers are available, which make the positioning of the e-chain on the application yet easier. The rolling rack is reusable and as a system is individually adaptable to chain type and reel size.

igus expands its transport system series

With the readychain rolling rack, igus expands its range of clever transport solutions even further. This transport frame readychain rack ensures a safe and quick assembly of the energy chain systems on the machine. If modifications to the machine become necessary, such as attachment of subsequent components, these can be performed at any time due to the modular design of the rack. In this way, the process costs in the prototype phase can be reduced by up to 80 percent, and up to 50 percent over the entire assembly process. Where the application has space constraints, the use of readychain rack light offers an edge length of just 40 millimetres. The light transport rack is so slim that the energy supply system can be used in even small applications, precisely fitting to the machine. The readychain rack is also available as an intelligent readychain rack with rotating traversing units and can be electrically or mechanically positioned on the machine interface.

You can see how easily the readychain rolling rack works here:

https://youtu.be/Fee9bb9IuIA

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igus provides transport systems for readychains, which simplify installation and reduce costs: readychain rack, intelligent rack, readychain rack light, rolling rack (left to right) (Source: igus GmbH)

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, cable carrier etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.

Twice the service life, same price: igus presents new plastic ball bearings

With the xiros S180 ball bearings, the Cologne-based motion plastics specialist is launching a new series of polymer ball bearings on the market and will present them at the 2015 Motek. The universal bearings have a very low wear, are FDA compliant, have twice the service life compared to the all-rounder xiros B180, and are available at the same price.

xiros plastic ball bearings from igus offer a versatile alternative to metallic solutions. Due to the lubricant-free operation and low weight of the bearing, they are ideal for demanding applications in which these criteria are crucial. As an autumn release in 2015, igus presents the new black material xirodur S180 and offers three installation sizes of the new xiros S180 series. "The ball bearings are available in the dimensions according to DIN 625 for single row deep groove ball bearings 608 with eight millimetre inner diameter, 6000 with ten millimetre inner diameter and 6003 with 17 millimetre inner diameter," explains Marcus Semsroth, head of the xiros polymer ball bearings division. Other sizes are already being planned. The ball bearings consisting of inner race, outer race and the cage that holds the balls made of stainless steel 1.4401, are completely made of the new material, which is manufactured in state-of-the-art injection moulding process. They are also FDA compliant and can therefore be used in all applications involving unpackaged foodstuffs.

Better features, same price

The new material xirodur S180 has properties similar to the known white all-rounder material xirodur B180. "We can offer the new black material xirodur S180 to our customers at the same price as xirodur B180, although it has an even longer service life," promises Marcus Semsroth. Like all other xirodur materials made of friction-optimised high-performance plastics, these cost-effective xirodur B180 and S180 xirodur series are distinguished by their freedom from maintenance and corrosion, high chemical resistance and the low price. The new xiros ball bearings of the xiros S180 series, like the other series, are available from stock at igus and delivered from 24 hours.

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Twice the service life at the same price is promised by the new lubricant-free all-rounder xiros S180 series.  (Source: igus GmbH)

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, cable carrier etc. which enable them to serve the whole industrial establishments in India from a small work shop to huge industrial establishments.