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Ready For Direct Connection: Igus Hybrid Cable For New Motor Generation

Ready For Direct Connection: igus Hybrid Cable For New Motor Generation

In order to supply modern motors with energy and data, users need appropriate cables that function dependably even at high accelerations and on long travels. Especially for use in motion, igus has developed a hybrid cable that is offered as a drive solution for the new Bosch Rexroth motors. It combines energy and data cable in one and is therefore also suitable for compact installation spaces. igus offers the cable as a fully harnessed readycable that is accurate to the centimetre. This saves the user costs.

Ever smaller and more compact with an even higher output: such a trend is becoming increasingly apparent in the field of motor development. But not only the motor but also the cables used must meet the new requirements. Hybrid cables are one solution. They combine energy and data supply in one by integrating the encoder into the servo cable. This eliminates the need for cabling with a separate measuring system for the encoder. Especially for use in the energy chain, igus has now developed a new hybrid cable suitable for Bosch Rexroth MS2N and IndraDrive Mi motors. A halogen-free PUR outer jacket ensures oil resistance and increases the service life of the cable. The user receives the drive solution already fully harnessed with connector as the so-called readycable from igus.

“While other manufacturers on the market only offer cables in metre lengths, customers can order their solutions from us down to the centimetre. This way we avoid unnecessary waste or residual stock. As readycable, the cable can be connected directly to the machine. This saves additional harnessing and installation times”, explains Markus Hüffel, Product Manager readycable at igus GmbH.

readycable finder helps in product selection

All cables are tested and inspected under real conditions in the company’s own 3,800 square metre test laboratory. Tests have shown that the new hybrid cable with a bend radius of up to 10xd in the e-chain can safely withstand 10 million double strokes over the long term. Due to the realistic tests, igus is the only cable manufacturer in the world capable of providing a 36-month guarantee on its chainflex cables. In total, igus has over 4,200 drive cables suitable for 24 manufacturer standards in its readycable range.

For a quick selection of the suitable solution, with the readycable product finder igus offers a practical online tool. Simply enter the igus part number or the manufacturer, or select the name of the drive manufacturer from the menu; then click on the required cable type and the product finder will list all matching parts. An overview provides the different cable qualities such as outer jacket, bend radius, travel and price. The integrated service life calculator also determines the running time. One click is all it takes to order the matching cable in the desired length and have it delivered within 24 hours.

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“Ice Chain” Reduces Freeze Induced Downtime

“Ice Chain” Reduces Freeze Induced Downtime

In order to prevent freezing of the energy supply, such as on inclined lifts, igus has developed a new e-chain called the “ice-chain”. With injection-moulded raised contact points, the chance of freezing is significantly reduced along with the costs of downtime and maintenance.

Inclined lifts are used in a variety of places to transport people or goods. However, regardless of its purpose, inclined lifts always require long-lasting, trouble-free operational systems. A failure would usually cause high maintenance costs due to the its height and limited accessibility. These challenges are compounded when inclined lifts are used in adverse weather conditions, such as in passenger lifts in the mountains or in construction lifts outdoors. This is because in these scenarios, operations can only be continued after a complicated process of defrosting. Thus, concepts that prevent freezing of energy chains are needed to guarantee safety and reliability under these extreme conditions.

New Design Prevents Plant Failure

There is a risk of freezing especially in systems with energy chains that are rarely moved and igus’ freeze-resistant ice-chain is best suited for such purposes. The technology powering these chains are as simple as it is effective: two raised domes per chain link are injection-moulded onto the crossbars of the e-chain along the outer radius of the chain. As a result, the contact surface area, and thus the risk of freezing, is significantly reduced. The e-chain is still safe in the guide, but it touches with only a tiny surface area and does not stick. The domes applied on the crossbars by injection moulding optimise the climate behaviour of the ice-chain without diminishing the traditionally high strength of the e-chains. The rectangular stop-dog system, which distributes the forces evenly, and the strong pin/bore connection in the side links guarantee high strength, offering large payloads or fill weights. Since the domes have only a height of 1.8 millimetres, the installation height is only slightly larger. The ice-chain can therefore be easily integrated even in confined installation spaces.

Withstand Freezing Temperatures With e-chains And Chainflex Cables

Like all e-chains for outdoor use, the ice-chain is made of weatherproof and media-resistant high-performance plastics. The material igumid G can be used in applications down to -40°C. Together with chainflex cables optimised for continuous dynamic use in energy chains, the ice-chain reliably moves applications even in snow and ice. With jacket materials made of PUR or TPE, chainflex cables provide trouble-free service even at temperatures well below freezing over a very long period of time. And if temperatures down to -35°C should actually occur, a chainflex CF29 series servo cable will still reliably supply any drive system. As part of the igus ready-chain concept, the ice-chain is also available as a complete system fully equipped with pre-harnessed cables that can be quickly installed and connected.


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