Caring for your cables

Cables are really the lifelines of any machine. They supply the power, data, etc. to the right components, and without them, nothing works. So why let cables take the abuse of rubbing, tangling, pulling, and bending when you can protect them easily with a cable carrier system?

Cable carriers guide and protect the cables and hoses on moving machinery. They prevent tangling and damage from debris or contact with the machine itself. Using cable carriers can extend the service life of both your cables, and the machine itself. Any application that involved moving machines and repetitive motion will benefit from a cable carrier system. They’re used on applications ranging from machine tools, automated robots, in cleanrooms, and on ship-to-shore cranes.

igus has it’s own line of cable carriers, called Energy Chain Systems. They are made entirely of plastic, so they are light in weight, and they are also maintenance-free and resistant to corrosion and wear. Plastic Energy Chains can replace metal or steel carriers in almost any application. They are available in a wide variety of sizes and styles; from micro-chains for very small applications, E-Z Chains for quick assembly, special chains for very low noise and vibrations, and even fully enclosed tubes for applications with flying debris, and multi-axis carriers for robotic applications.

Cable carriers are often forgotten in the design process – but shouldn’t be!! The cable carrier is a crucial part of any machine’s design, and should be considered early on in the design stages. They can be implemented to move in a variety of ways, most commonly in a horizontal, unsupported run with a short travel length. (See image below Left) In an application like this, the upper span of the carrier operates without touching the lower run throughout the entire length of travel. The maximum length that can be unsupported is different for each application, but an unsupported application will have the longest service life.

In the travel length is too long to be unsupported, the cable carrier can run on itself in a gliding fashion (See image below Right). Just a note- in a gliding application like this, a guide trough and glide bar should be used.


Choosing the Perfect Cable Carrier

There is a huge variety of cable carriers available, but which one would be best for your application? Follow these guidelines to choose the best fit your your application.

1. Gather Your Data

Before jumping to purchase and install a cable carrier on your machine, its necessary to gather all the technical data first. This includes your application’s length of travel, what cables or hoses you’re planning on installing in the carrier as well as their weight, and environmental factors like debris, heat, chemicals, speed, or acceleration.

2. Find the largest cable/hose in the system

The first question any cable carrier manufacturer will ask when you’re planning your carrier system is “What’s the largest hose or cable in your machine?” This will determine the minimum size of the carrier. To the diameter of the cable or hose, we add space to ensure proper clearance – 10% for cables and 20% for hoses – and the result is the minimum dimensions for the inner height of your carrier.


3. Style, style, style

The next decision is about what style carrier would work best in your application. Its recommended that you choose a carrier that snaps open whenever possible, allowing easier access to cables at any point along the carrier. If debris or other external conditions can be an issue, tube style carriers replace the link crossbars with lids, for a fully protected system. This is especially useful in applications where woodchips, metal shavings or other debris may be present. igus has created cable carriers with special features like split crossbars, zipper-like closure systems, or hinged crossbars. These are all styles that allow for easy installation and replacement of cables and hoses as needed, minimizing assembly and disassembly time. Carriers are also available for heavy-duty applications with long travels, using hinged crossbars that open from either side for flexible access as needed.

4. Consider the Environment

The environmental conditions of an application are a good way to determine what style of cable carrier to use. If debris is present, like woodchips or metal shavings, or if the carrier is operating in a contaminated area, an enclosed tube is your best bet. An open crossbar carrier system is great for easy inspection and replacement of cables in applications where this is a common occurrence. You should also consider whether the application is underwater or comes into contact with liquids or chemicals.

5. Bend Radius

All cable carriers have a predetermined radius stopping point on each link. When several links are assembled these points restrict the carrier from fully pivoting, forming a curve loop or minimum bend radius. Cable carriers have several bend radii to choose from, and the manufacturers typically suggest a minimum bend radius. Generally, the rule is 8-10 times the outer diameter of the largest cable or hose in the system. The larger the bend radius, the less stree placed on the cables, and the longer the service life will be. Just a note: the bend radius is measured from the center of the curve loop to the center of the pivot pin on the side link – don’t get confused and measure the overall curve height!

6. Cable and Hose Package

Since the purpose of a cable carrier system is to ensure that cables bend properly, then it is imperative to install the conduits correctly! To ensure the best possible service life in your machine, its recommended to used cables that have been specifically designed to use in a cable carrier, like igus’ Chainflex continuous-flex cables.   Special features like a strain-relieving core and  special jacket and shield designs ensure that these cables will be able to complete millions of cycles without failure in continually-moving machines.

7. Cable carrier length

To determine how long your cable carrier needs to be, first determine the position of the fixed end of the carrier. Ideally (and most cost effectively,) the fixed end should be positioned at the center of travel. This requires the least amount of carrier to move the necessary distance.

8. Acceleration and Inertia

It’s essential to ensure that the cable carrier you choose is strong enough to support your application. If it isn’t, the results can be devastating – a carrier can literally be snapped in two if the overload is great enough. To make sure your carrier selection will do the job, use the following formula to determine the force required to keep your application up and running:

First, determine the acceleration force. This is the force required to keep the carrier moving once it’s started.

Acceleration force (lb) = Total Weight lb (carrier and fill) x Acceleration ft/sec2

Then determine the push force, or the force required to get the carrier moving and overcome inertia.

    Push Force (lb) = Total Weight x COF
    Once these two values are determined, calculate the force of the application by adding them together: Acceleration force + Push force = Force required.

The force must be less than the maximum force for the cable carrier selected. Carrier manufacturers typically don’t publish the maximum force allowance for their products, but igus technicians will calculate the force your application requires, and help you select the best carrier to meet these requirements.

9. Accessories

A variety of accessories are available to further facilitate the energy supply system for your machine, including:

Interior separators and shelves to properly align cables and prevent friction, tangles or corkscrewing. These are available in horizontal or vertical layouts (See above image).

Mounting brackets, which are almost always needed to attach the carrier to the machine. Plastic or steel brackets are available in one-piece designs for small carriers. Others have aluminum bushings in the bracket to prevent damage when tightening bolts. These can either pivot for most applications, or lock into place for vertical or side-mounted gliding applications.

Guide troughs are available for long applications, and for even longer travels, available rollers can be used.

Extender crossbars are available is oversized conduits are needed.

Strain relief is a common way to keep cables in position at either end of the carrier. Sometimes, strain relief is only needed on one side, and other times both side should be relieved. Strain relief can be made up of rails, clamps, or wraps. Imporper strain relief is a very common cause for failure, and while it may seem insignificant, can often make or break the success of an application.

To learn more about igus’ Energy Chain cable carrier systems, visit the E-chain page at

First days in Shanghai

Welcome to the land of dragons. Well, I haven’t seen any dragons… yet. Nonetheless, some of Shanghai’s skyscrapers –especially the Shanghai Tower at about 2067 feet tall- are as impressive as a dragon would be. My first thoughts when arriving here was just “Wow!!”

This city is incredibly modern. Starting with our trip from the airport on a highway much more modern than any I’ve seen in Germany, everything looked on the cutting edge. Still, despite some of the ‘wow-effect’ skyscrapers, I can’t tell you much about Shanghai; I haven’t had time to discover the city yet, but as soon as  I do I’ll report it to you.  

So far, I can only say that Shanghai reminds me of New York City, surely owed to the stunning skyline. I think the skyline would look much better with a small orange car in front of it, don’t you think?

Well, speaking of the car, customs has cleared it, but we are still waiting on driving approval. While waiting, we brought the car to the shop to get the fluids replaced – they all had to be emptied at the airport in Bangalore on our way out of India.

During the inspection, we learned that the car’s automatic transmission for the car’s gear shift was not working anymore. It’s annoying, but it won’t disrupt our immediate tour plans as the car is semi-automatic, which means we can drive it in manual, as well.

By the way, we have a planned route through China of about 3,700 miles. We’re planning on going from Shanghai to Beijing, to the Great Wall of China, and back to Shanghai. This is just a tentative plan for now, and there are dozens of stops at customers and other spots along the way. All in all we’ll be traveling China for about 3 weeks.

 On Monday, the official press conference launching the Chinese tour was held. James Mao, CEO of igus China opened the conference with a speech, before Mark Poensgen gave information about iglide bearings, Fred Lu gave a presentation of iglide bearings for automobiles, and Dirk Tietz gave an overview of the retrofit process. Dirk also introduced me as the driver, and I followed with an overview of our trip through India.

After all that, the program was topped off with some traditional Chinese musicians, and the unveiling of the car.


The conference was very successful – 57 journalists from 45 different journals attended, and seemed like they couldn’t wait to see the car that would be traveling through their country over the next 3 weeks.

Even though we couldn’t take the car with us, we went to visit our first customers the next day. Our Chinese colleagues surprised us with a “show truck” to take along for exhibitions. I can imagine that both the car and the truck together will be quite impressive! Even without the orange iglide car, we saw more than 250 visitors in only half a day from Johnson Controls! They specialize in manufacturing car components including seats and batteries.

Right now, I’m on my way to the Chinese driving administration. I hope today we will finally get the permission that we need to get on the road and explore China! I’ll keep you up to date!


Auto Expo Special

We had our first day at the Auto Expo in New Delhi yesterday.  This event is not only the biggest auto show in India, but the second largest in the world!!  It’s held every-other year, this year, at two different venues!  There is the motor show, and the component show.  igus has TWO(!!) booths at the component show, one inside a hall, showing our products, and other outside, demonstrating the iglide car and discussing our world tour.

The outside booth is a little “funkier” than inside; it aims to engage as many people as possible, though the car is attraction enough! In addition to the iglide car, we have a racing game, and a big screen with some funny video clips, and a game to test your knowledge about the car and applications of our bearings inside it. 

All in all, the first day was a success, but not without its problems. We not only had a leaky pipe to contend with in our indoor booth, but a cable fire outside!!! Despite the technical problems, we were able to get everything sorted and running properly. During the day, we got a lot of inquiries, and a lot of new potential customers!  Because I was outside most of the day with the car, I can’t say how busy it was inside, but where I was, anyway, we had a huge crowd. In addition to the interested passersby and new and old customers, we had press visiting the car, including reporters from the “Times of India,” one of the nation’s largest newspapers.

I’ll keep you guys up to date on our next adventure.

Til’ then,


Page 3 of 3123