Energy chain installation guide

Energy chain applications are commonly horizontal, but they also offer some very useful solutions for guiding and protecting cables in vertical motions.

The two most common types of configuration are hanging or standing (there is a third, which is less conventional, and involves a ‘zig-zig’ arrangement). Since these configurations are all very different, it is also important to consider the unique design attributes of each.

Vertical standing

Vertical standing configurations are often used in pick-and-place applications. Generally these will be shorter travel lengths. The most important factors to consider in a vertical standing application are how the cables are laid in the cable carrier and how they are secured at the end points. When installing the cables, it is crucial that they can bend freely and are strained relieved at both ends. 

Another important factor to remember is that mounting brackets must be attached so that the cable carrier does not bow outwards. Locking mounting brackets are available for almost every style and size of energy chain from igus. In vertical standing applications in particular, locking “KMA” style mounting brackets are highly recommended because they can be attached flush to the machine. 

If lateral acceleration occurs, the energy chain should also be supported along the outer radius. For taller standing applications, it is generally recommended that a minimum of the first three links on the outer radius be supported. For extreme heights and weights, it is advisable for the entire distance of the energy chain to be supported.

igus engineers are at hand to assist with the many aspects of your application, including advice on loads, stroke heights, bending radii and energy chain types, and wherever possible more cost-effective solutions may be recommended – such as, using an energy chain that combines vertical and horizontal movements. 

Vertical hanging 

Vertical hanging energy chains are often used with storage and retrieval systems, because they can easily achieve the longer travel lengths required, than can be achieved in standing mode. This is due to gravity acting to the system stable. In this type of application, an igus energy chain can be used to house the different types of moving cables and hoses used on the system, while at the same time preventing them from becoming caught on shelf parts or protruding pallets. 

As with vertical standing, the two most important factors in a vertical hanging application are how the cables are laid in the cable carrier and how they are secured at the end points. 

When hanging the cables, it is crucial that they bear their own weight so that the energy chain does not have to do so. It is also important to secure the cables at both end points and use interior separators to keep the cables from tangling. 

A traditional igus energy chain with camber is suitable for a hanging application if enough space is available. However, most storage and retrieval systems have to operate in narrow aisles and so an energy chain without camber (pretension) will deliver the best performance because it will operate within a smaller space. If the space restrictions are rigid, this “no-camber” or “NC” version should always be used. igus engineers are always available to help with more information on Energy Chain solutions without camber. 

If the application involves vertical motion without lateral acceleration, the energy chain can be installed without lateral support. If there is lateral acceleration, the energy chain should be guided laterally.

Partial guidance is also an option, however, at minimum it has to cover the area where the energy chain might sway. As lateral acceleration can occur in two directions, lateral guidance must be installed accordingly. Also, keep in mind that additional guidance along the side of the energy chain helps increase its stability. 

In these situations, the use of locking mounting brackets will help increase the performance of the energy chain system. In restricted spaces, other custom-designed solutions are available from igus. Secure strain relief and clear separation of the cables are absolute musts, while remembering that cables must be able to move freely and bear their own weight. 

Zig-zag 

For applications with strict space constraints, a less conventional configuration known as ‘zig-zag’ can be used. This type of installation is very common for lifts, where a variety of cables (eg power, AV etc) need to be housed and protected.

igus energy chains can simply be reversed at any point to allow the system to fold over in a controlled way. This can be done several times to form a ‘zig-zag” style application, which is compact when stowed. It is important once again to ensure good cable separation, and strain relieving in this orientation because of the various moving joints.  Also, it is recommended that the system has a basket built to control and contain the energy chain while it is stowed. igus can provide a standard metal basket solution for any ‘zig -zag’ energy chain system, which also makes installation of the system very simple.