Achieve energy efficiency with 60% less consumption
May 1st 2009 Energy chain systems not only transport energy,data and media to machines and systems.
They also influence their energy consumption costs.How much pull-push force, or driving
force, is required at a given speed to move an energy chain? How light or stable do energy
chains have to be for minimum energy to be consumed? Modern plastic energy chains and
'Chainflex' cables from igus, help in the design and operation of machines that are efficient
in terms of energy and cost
Energy consumption can be significantly
reduced by using the right materials
and the right design, as current tests at
the igus energy chain and cable laboratory
now show. For example: long travel distances
with high fill weights. If a roller energy chain is
used in place of a sliding application, friction
loss is reduced. Tests show that with the same
basic data (filling, chain length, speed and
acceleration) the friction factor can be reduced
from 0.3 to under 0.1. The result? Thanks to
the user of the roller energy chain, the drive
power was reduced by 37%
compared to the equivalent
sliding application.
Modern plastic
instead of steel
Such roller energy chains for
long distances developed by
igus have been in use
globally for more than ten
years now. A good example
is the 550m chain used in a
taconite mine in
Minnesota (USA); another
is the longest plastic energy
chain in the world so far, a
615m in the Czech lignite-fired
power plant Tusimice (pictured).Metal
chains are being replaced more and more
now by lighter and lubricant-free plastic
energy chains even in the toughest of
working conditions. The latest example is in
a steelworks in Isfahan (Iran), where dust,
lubricants and oils impaired the functional
ability of the heavy metal chain that had to
be pulled by the machine. Cables were
damaged by sharp chain edges and
permanent sun radiation.
Smaller, stronger and lighter
Alongside the reduction of the friction
coefficient there are further factors which
favour efficient energy management. Size
and weight, for example. Comparative tests
in the igus Technical Centre have proved that
17% drive power can be saved with smaller
energy chains which are as robust as larger
chains. A strong energy chain from the 'E4'
range was chosen. This is a comprehensive,
modular system that can be used in most
applications from 'side mounted' and
'hanging' applications, through to long travel
distances of over 200m.
Cables: Sheathing and insulating
'Chainflex' cables especially for energy chains
can help directly in reducing energy
consumption. According to the latest igus tests,
the use of high-grade sheathing and insulating
materials, depending on the combination of
cross-sections and cables used can, ultimately
save between 5 and 30% energy consumption.
The result is that the drive power requirements
can be reduced by around 17%.
Firstly, optimised sheathing materials,
matched to the energy chain application, can
achieve low abrasion resistance. Secondly,
high-quality sheathing materials can be
extruded with an extremely thin wall, which
saves up to 18% in weight compared with
conventional cables. Insulation materials
must also be considered.With high-quality
materials, significantly higher current
carrying capacity can be achieved with the
same core cross-section, or, the crosssections
can often be reduced without the
electric performance being diminished. This
again allows weight reductions of up to 30%. More articles from igus® Ireland: | 
