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igus® inc.

PO BOX 14349

East Providence

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+1 800 521 2747
+1 401 438 7270
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System E2/000

igus® technologies and tricks

for long service life, high stability, ease of installation and modularity

Easily execute energy supply systems with the E2/000 energy chain system.
E2/000 - The standard for medium loads

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1... Pivots more than 210°

Good access, easy to fill, positive lock

Details of working principle

Dual lock

Special snap-open mechanism,

You can open the energy chain quickly and easily with the two-side flip-open crossbars. The crossbars pivot above 210° and remain firmly locked in place when closed.

igus® tested

Rip-off test

Perfect support

Crossbars pivot up to 210° and provide easy handling during filling of the energy chain. Maintenance is simple.

Application example

Quickly ready for use

Ready to install E2/000 supplied directly as a pre-assembled readychain® complete with guide plate for a glass processing machine.


2... High holding strength of crossbars

Prevents accidental opening during operation

... max. holding strength up to 200 lbs.
... can be quickly opened with screwdriver

Details of working principle

Dual lock

High retention force

Even after simple closure, the bracket ensures a secure fit in the energy chain. The bracket withstands the highest loads and prevents accidental opening of the energy chain in operation.

igus® tested

tensile test

Rip-off test

The maximum holding force of each crossbar is verified using practical pull-out tests. These tests are also preformed in oil and other liquids.

Application example

Plastic energy supply systems in this woodworking machine.

The E2/000 energy chain provides energy supply in the X and Y axis. Thanks to the snap-open and securely fitting crossbars, easy filling and high speeds are possible.


3... Opens in seconds

Helpful assembly tool

... from 33 to 2 seconds
... simple and quick opening of the energy chain

Details of working principle

Double, rectangular end stop-dog

Opens in seconds

Open and close long pieces of chain in one pass. With this tool, you can minimize the throughput times of your installation and assembly line.

igus® tested

Practical testing

The assembly time was tested with and without tools in the assembly line at the igus® factory

Application example

Chain opener in operation

Installation application. Available for all E2/000 energy chain sizes.


4...For long travels up to 492 feet

With guide troughs and as a roller energy chain

... low gliding coefficient 0.1 with E2/000 roller energy chains
... safely guided in guide troughs made of aluminum, steel or solid plastic

Details of working principle

Scale on crossbars

long travel distances up to 492 feet

Cost-effective E2/000 energy chains are suitable for long travels up to 492 feet, even in outdoor applications. Straight and reliable running is ensured by a guide trough. The optional use of rollers reduces the gliding coefficient.

igus® tested

lifetime testing at the igus® outdoor laboratory

The 3500R roller energy chain with corrosion-free "Guidelite" solid plastic trough was tested in ice and snow.

Application example

E2/000 roller energy chain in a "Guidelite" solid plastic guide trough in an irrigation system.

Implement up to 492 feet of travel quickly and inexpensively as a modular solution with a "Guidelite" solid plastic guide trough.


5... Modular and combinable

Available as a half and fully enclosed Energy Tube

... lid swung open on both sides
... snap open in the inner radius and available in many sizes

Details of working principle

Few parts

Modular and combinable

The E2/000 can be delivered as an Energy Tube enclosed on one or two sides. Swivelable to either right or left in the inner radius.

igus® tested

Unsupported in the lower run (FLU) test with the 3480 model

Test 2397:1.85 lbs/f additional load for 4.26 ft unsupported Energy Tube without backing is easy for the igus® 3480.075.125.0

Application example

E2/000 tube in a leather cutting machine

In this newly designed leather cutting machine, E2/000 energy chains were used to enable the cutting head to work faster and with more flexability.


6... Hinged extension bracket

Simple enlargement of the interior

... snap-open either in the inner or outer radius, pivoted open
... suitable for hoses with a diameter up 3.14 inches (80 mm)

Details of working principle

Hinged covers

Hinged extension bracket

By the use of extension brackets the interior of the energy chain is greatly enlarged so that even large suction hoses are safely guided. Existing systems can also be enlarged easily, inexpensively and compactly.

igus® tested

More volume

The inner space can be enlarged by up to 48%. It can also be divided with special separators which, like all separators, are cable-friendly and without edges.

Application example

Large hose diameter

Voluminous yet lightweight suction hoses are used in a woodworking machine to save space and cost.


7... Large pin/hole connection

Long service life and easy installation

.. accelerations of 33 f/s² and more
... travels over 492 feet possible

Details of working principle

Large pin/bore connection

Large pin/bore connection

Large pin/hole connections with tight tolerance provide a high push and/or pull force absorption. Due to the tight tolerances and almost complete zero backlash, very high accelerations can be achieved with very little wear.

igus® tested

igus tested

Tensile test with Zwick material test equipment

We test every energy supply system with a "tweak testing machine" at the igus® laboratory for pull force to provide reliable specifications on the maximum possible travel and also to get achievable acceleration values.
 

Application example

Long cycle life

On a 92 foot travel with a narrow installation space of only 8 inches, the series 2500 energy chain braves external weather conditions such as rain and wind in continuous operation 24 hours, 365 days.


8... Good protection against dirt and chips, even against hot chips

For the protection of your cable

... hot chips up to 1562°F cannot burn into it ...
extremely tight and still easy to open

Details of working principle

For the protection of your cable

For the protection of your cable

igus® Energy Tubes to protect cables and hoses have been successfully used applications with hot chips for almost 20 years. Dust, dirt, oil, aggressive environments, humidity, cold and heat do not affect the rugged plastic energy supply systems. The optional HT material makes hot chips just bounce off - no burn-in possible.

igus® tested

Quantity (g) of burnt-in chips depending on the temperature

Test:20 g hot chips (392 to 1562°F) applied on different materials. The graph shows which chip quantity was burnt-in. igumid HT tested best up to 1562°C.

Application example

Chip-proof in high temperatures

High-temperature Energy Tube inside the machine guides and protects the cables in the hot chip area.


9... Cable-friendly plastic crossbars

For even higher service life of the cables through rounded design

... Cables have the longest durability with plastic crossbars
... no plastic deformation with external impact force

Details of working principle

Cable friendly polymer crossbars

Cable friendly polymer crossbars

Smooth, cable-friendly inner contour and rounded crossbars provide for a long service life of the cables and hoses. The combination of the tribo-optimized plastic of the crossbars with the jacket material of the cables proves to be the best matching pair for the service life of cables in testing.

igus® tested

Wear and tear tested

Cable wear in plastic crossbars: Jacket materials of different materials show the best wear results in plastic crossbars. Moreover, compared to aluminum crossbars, these are not subject to plastic deformation with external impact force.

Application example

Low-abrasion operation

For SATO's utting systems, igus® provides reliable energy supply systems on demand: Regardless of high speeds, long travels, movements in all directions or design-oriented colorings, the pipes and hoses are guided gently.


10... 950 chainflex® cables from stock

... No cutting costs, no minimum quantities …
chainflex® works or your money back

Details of working principle

Wear pad

Variety in cables

Flexible cables in energy chains or in robots require special features to survive many cycles, high speeds and accelerations as well as more demanding environmental conditions. EMC safety and the compliance with norms and guidelines such as NFPA 79, UL, CSA, VDE, Interbus and Profibus are also a necessary requirement today.

igus® tested

igus tested

Complex tests of all Chainflex® cables in moving operation

All chainflex® cables are always tested in practice. This means in the energy chain or in motion, such as here in the igus® climate chamber at -40°F.

Application example

application example

Reliable function in all axes

In this CNC multi-spindle lathe, every single working position must be securely supplied with media, energy and signals. High freedom of movement in all axes require a high durability and reliability of the cables.


11... Cable-friendly interior separation

For higher service life due to rounded base

... nearly half the cable wear ...
less parts, more possibilities

Details of working principle

Cable friendly polymer crossbars

Cable friendly polymer crossbars

Smooth, cable-friendly and rounded contours ensure a long life for the cables and hoses. In addition, a better and more cable-friendly interior separation can now be implemented with less standardized parts.

igus® tested

Wear tests

With the new rounded separators, the wear of the cables could be almost halved.
 
Test 3748:Separator 301 compared to new version 45.1 The matching pair of plastic and jacket material also turns out to be the best here.

Application example

Tight filling

Here the rounded plastic crossbars assist in increasing the service life of cables


12... Double stop system

For maximum force absorption and thus high stability for large unsupported lengths

... max. unsupported additional load possible up to 8.75 lbs/ft
... max. unsupported lengths (FLB) 9.84 ft (+25% with the optional XXL material)

Details of working principle

Double, rectangular end stop-dog

Double, rectangular end stop-dog

More than two stop-dogs cannot be, or can barely be synchronized. Due to a rectangular shape, the force distribution is much better than in a round stop-dog (surface pressure formula, p = F/A).

igus® tested

Fracture test at the igus® laboratory

We test every energy supply system with a "tweak testing machine" at the igus® laboratory for compressive/breaking strength to provide reliable specifications on maximum additional load and unsupported length.

Application example

E2/000 series hanging in the lift of the PostTower, Bonn.

Strong air drafts and the fill weight in the hanging installation requires a stable and reliable structure of the energy chain.


13... Sound brake

Dampens noise of the stop-dog and rolling

... minimum noise level 42 dB(A)
... many series certified by TÜV Rheinland

Details of working principle

Brake mechanism

Brake mechanism

Simple principle, but extremely effective. A wedge-shaped contour in the energy chain stop-dog dampens the stop-dog noise of the energy chain.

igus® tested

Noise test

igus® tests energy chains for noise emissions in the igus® laboratory. Many series are also checked by TÜV. The quietest igus® energy chains start at a noise level of 33 dB (A).
 
Test 4381:Series 1400 with an average sound level of 42 dB(A), measured with different radii at 3.28 ft/s.

Application example

Quiet, fast, flying high

IMA Klessmann GmbH uses E2/000 in combination with the igus® Guidelok Slimline "F" guide system to provide absolute operational reliability even at high speeds and accelerations. The noise brake in the energy chain and the stable grip in the trough guarantees a significant noise reduction.


14... Side wear pads

Long service life, even for applications that are turned sideways

... longer service life in side-mounted, rotating applications
... safe vertical guiding even at high lateral accelerations with the Guidelok system

Details of working principle

Wear allowance

Side wear pads

Longer service life with high stressing capacity due to the standard lateral wear pads in igus® E2/000 energy chains.

igus® tested

Abrasion tests at the igus® laboratory.

The service life of the energy chains is tested in endurance tests.

Application example

CNC grinding machine

Installation turned 90° with Series 2500


15... Strain relief of electrical cables

Space reducing and reliable Chainfix program

... Three times higher tensile strength of igus® Chainfix clamps ...
also safe in oil, coolants, waters

Details of working principle

Wear allowance

Strain relief

Strain relief systems from igus® were specifically developed for the use in energy chains and dynamic applications. The combination of chainflex® cable materials and plastic components of the Chainfix strain relief system from igus® are designed for high cable durability and maximum holding force.

igus® tested

The tensile strength of the igus® Chainfix clamp is more than three times as high as a conventional strain relief system.

Application example

Media, data and control cables are reliably and securely strain-relieved in this ready-to-install readychain® system for machine tools.


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