Filling rules - cables and hoses in energy chains

How to fill cables and hoses in energy chains

The key advantage of our energy chain systems is their ability to safely accommodate various data cables and energy suppliers in one system. You can separate different media, such as maintaining minimum distances between bus and motor cables. Pneumatics, electrical cables, and hydraulics can be mixed in the same compartments. The quality and arrangement of each cable within the energy chain, as well as the space allowed, are crucial for the system's service life. Different separation options let you adapt energy chains to the specific needs of each application. This section provides detailed recommendations.

cables and hoses filling in cable chains

Cable diameter

Interior separation

Distribution rules

Filling rules | Round electrical cables

Filling rules | Pneumatic hoses

Filling rules | Flat cables

Filling rules | Hydraulic hoses

Strain relief

Maximum cable or hose diameter

The maximum cable or hose diameter should match the inner height of the energy chains and tubes, plus some extra space. For example, add 10% extra space for electrical cables and 20% for hydraulic hoses. Ensure there's enough space between each cable or hose. Depending on the type of cables, movement, and expected lifespan, you might need more space. In some cases, you can use less space. Please contact us.

Electrical cables require at least 10% clearance space all around, and hydraulic hoses require 20%.
The maximum cable/hose diameter is specified for each energy chain series on the relevant product page and in the relevant catalogue chapter.

Instructions for energy chain interior separation

Cables and hoses with different diameters should be laid separately using separators to prevent tangling. The height of a compartment with similar cables or hoses should not exceed one and a half times their diameter. Distribute the weight of cables and hoses evenly across the energy chain. Cables and hoses with different outer materials should not stick together and may need to be laid separately.

Configure the interior separation of an energy chain quickly and easily online

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Automatic energy chain filling with chainflex cables or freely defined cables
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Connection to our 3D CAD library
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Filling rules calculations

Cables and hoses should move freely without tensile force is exerted on the energy chain at the radius. For high-speed applications and many load cycles, do not stack cables or hoses without horizontal separation. Use these guidelines: travel speed over 0.5m/s and load cycles over 10,000 p.a. igus interior separation provides a safe solution for these cases.

Calculation Filling rule 1: d1 + d2 > 1.2 x hi

If d1 + d2 > 1.2 x inner height, no separation between the two cables/hoses is necessary. Two cables/hoses should never be left unguided on top of one another or be allowed to become tangled.

Calculation Filling rule 1: d1 + d2 ≤ 1.2 x hi

If d1 + d2 ≤ 1.2 x inner height, a vertical separator or a horizontal shelf must be used to reduce the inner height. This prevents d1 and d2 from tangling.

Clearance space calculation

Illustration showing the necessary clearance space around round electrical cables. For other cable types in %: electrical flat cables 10%, pneumatic hoses 5-10%, hydraulic hoses 20%, and media hoses 15-20%

Bend radius R

The bend radius of your energy chain depends on the thickest or stiffest cable or hose. Adjust the bend radius according to the manufacturer's recommendations. Choosing a larger radius than the minimum will extend the service life. Minimum bend radii are specified for normal temperatures, but other radii may be recommended.

Filling rules | Round electrical cables

For electrical cables, the round cable is a safe, modular, cost-effective solution for energy chain systems.

Distribution rules for round electrical cables

Installation and strain relief for round electrical cables

Lay cables straight without twisting. Do not uncoil cables from the top of the spool. Chainflex cables are ready for direct placement into the e-chain® without needing to be disconnected or laid out first.
Ensure each cable can move freely in the longitudinal direction.
Cables must move freely along the radius, especially when the upper run reaches its maximum length.
Use igus interior separators to prevent tangling when inserting cables or hoses of different diameters.
Cables and hoses with different jacket materials should not stick together and may need to be separated. All series of igus chainflex cables can be combined.
Round electrical cables need strain relief at both ends. In some cases, strain relief at the moving end of the energy chain is sufficient. A gap of 10-30 times the cable diameter between the end of the bend and the fixed point is recommended. Chainflex cables can have strain relief directly at the mounting bracket.

Filling rules | Pneumatic hoses

In principle, the rules for round cables also apply to pneumatic hoses. After consultation, they can be laid together more closely than the 10% clearance rule allows. This requires double-sided strain relief. For pneumatic hoses made of rubber, we recommend that the 10% clearance rule be strictly followed because these hoses tend to stick to each other and to other cables and hoses.

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Filling rules | Flat cables

It is especially important for flat cables to move freely at the bend radius. Two adjacent flat cables should be kept apart with separators. If two flat cables are laid on top of one another, we strongly recommend horizontal interior separation. Flat and round cables should be laid separately in the energy chain. There should be strain relief at both ends. Flat cables are only recommended to a limited extent for use in energy chains.

Filling rules | Hydraulic hoses

During planning, pay special attention to longitudinal and transverse expansion when the hoses are pressurised. We recommend energy chains with crossbars every link to distribute the force of the hoses over more crossbars. Sufficient room must be left (20% clearance). It is important for selected hoses to be sufficiently flexible (they must bend in the specified radius). The surface of the hoses must also be abrasion-resistant and able to glide. The igus interior separation elements minimise hose abrasion with their wide, smooth, rounded contact surfaces. Hoses with textile braiding are usually more flexible than those with steel wire braiding. Because lateral hydraulic hose movements within the energy chain can lead to increased abrasion in the hose material, hoses should be secured in position with vertical separators, and jamming must be avoided. Notch separators that snap into the crossbar, for example, keep the hoses firmly in place in the energy chain even if there is strong vibration and shocks.

Guidance for hydraulic hoses

Strain relief

Hydraulic hoses are most often stretched lengthwise during operation. This must be taken into account when strain relief is applied. More hose length can be factored in or strain relief implemented. In some cases, one-sided strain relief on the moving end can be tolerated.

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rollclip

In almost all cases, the broad, smooth, rounded contact surfaces of all igus energy chains/energy tubes are sufficient to protect hydraulic hoses from abrasion. In extreme cases, the rollclip can be subsequently installed. In the crossbar, the hoses come into contact with a series of plastic cylinders which rotate with them. Extreme cases include particularly soft jacket materials, particularly small bend radii, and highly dynamic loads. Our experience shows that over 95% of all applications can be solved without rollclips.