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The evolution of the igus® rol e-chain®

igus rol e-chains shown in fast-forward mode over the last 20 years

The roller energy chain has been the tried-and-tested energy supply for long travels for about 20 years. Besides the successful design that distinguishes all of our linear energy chain systems, stainless steel rollers are added, which upgrade the energy chain to energy supply for heavy-duty applications. As the energy chain rolls and does not glide, it runs quietly and with low vibration. Wear is significantly lower than for designs without rollers, and the power needed for movement is also lower by as much as 57%.

More about the latest generation

10x longer service life for rol e-chains

More than 20 years of continuous improvement of the igus rol e-chains for long travels and less drive force

The evolution of the rol e-chain

Rol e-chain in crane systems

The first igus rol e-chain in Europe with a travel of 130 metres as the main way of supplying power to a crane system.

HD rol e-chain in STS cranes

Heavy-duty rol e-chain used for an STS crane. The "HD version" of the rol e-chain becomes the standard for STS crane applications and ship loaders/unloaders with long travels and high speeds, worldwide.

P4 rol e-chain in crane systems

As an addition to the rol e-chain product range, the P4 is for applications involving very high speeds (<240 m/min) and installations where noise is a very important factor. Where used: worldwide for STS crane systems, ASC cranes etc.

2018 - the expansion

P4.1 rol e-chain

The smart rol e-chain P4.1 supersedes the P4 and becomes an endurance runner. In the case of ASC cranes, the P4.1 enables the primary supply of power and data and operates at very high speeds (<300 m/min). Worldwide for STS crane systems, ASC cranes etc.

The most fascinating projects with igus rol e-chains

Lignite excavator

Lignite excavator

Travels of 615m and in operation without failure since 2008

Compared to previously installed festoon systems, the 5050RHD series e-chain systems® can now reduce the required cable lengths, save installation space and safely and reliably guide all media, such as water and energy. The 5050RHD series is used in the large lignite excavator in the Czech Republic.

Lignite excavator

Conveyor system in a mine

Conveyor system in a mine

Long travel of 550m under extreme conditions

The 5050HD series e-chain system and the CF35 chainflex motor cable were installed in a mine on the north coast of Lake Superior in Minnesota in October 2008. The travel is 550m.

Conveyor system in a mine

Conveyor systems

Conveyor systems

Energy supply under adverse environmental conditions since 2013

igus energy supply systems (rol e-chain type 5050RHD, chainflex cables and push/pull detection system) are used in conveyor systems.

Conveyor systems

Ship unloader

Ship unloader

Travel of 441m and in operation without failure since 2001

Series 5050R energy chains, CFCrane chainflex cables and fibre optic cables are used in ship unloaders at a modern coal-fired power plant in Malaysia. All energy chains are completely equipped with stainless steel guide troughs and withstand weather conditions.

BANG slab handling crane

Slab handling crane

Pre-assembled energy supply in hot, dusty environments

Based on the requirements for energy chains and cables in the BANG Kransysteme GmbH & Co. KG slab handling crane, igus technicians recommended a rol e-chain. It was designed and delivered as a Basic System Type 5050RHD pre-assembled readychain.

Slab handling crane

Ship-to-shore crane with readychain

Ship-to-shore crane

Safe, smart energy supply system in harsh environments

In the ship-to-shore crane's high-speed trolley drive, a rol e-chain was used for power and data transmission.
The system was entirely pre-assembled on the construction site, saving the customer a great deal of assembly time and largely eliminating assembly errors.

Ship-to-shore crane

Comparison of how rol e-chains evolved

E400R series

E400R series

1999

Due to rollers in the e-chain links, the coefficient of friction and therefore the drive energy needed for energy supply systems can be significantly reduced. Especially in the case of long travels of more than 100 metres, this is a decisive factor, which led to the success of the rol e-chains from igus.

4040RHD series

4040RHD series

2004

In the second development stage of the rol e-chains, the chain was strengthened at all important points. In the case of this "heavy-duty version", the pin/bore connection in particular was enlarged by 100% while the size of the contact surfaces was increased by more than 30%. As a result, the expected service life doubled compared to the preceding series.

System P4

System P4

2008

The P4 is a new development stage. It is characterised by the fact that it operates with considerably less noise and vibration due to the double-roller design, which increases the service life of the system. Due to
the same-sized pitch of standard links and roller links, the polygon effect was reduced as well.

System P4.1

System P4.1

2018

In the latest development stage of the igus rol e-chains, the use of maintenance-free, tribo-polymer plain bearings in the connection of the e-chain links also considerably lengthens the service life. As an option, they can also be fitted with the i.Sense condition monitoring system to reliably predict the expected service life of the system. Compared to the first rol e-chain, the expected service life has been more than trebled.

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Download a free case study

This case study illustrates how EMO B.V. is able to achieve over 375,000km on its STS cranes with igus chains for cranes®.

Go to the PDF download

Fail-safe even on long travels ... with igus chainflex cables

Largest product range with 1,354 cables types for motor, data, bus, and hybrid systems and much more. Specially developed for moving applications in e-chains.

CFCRANE.PUR motor cable

CF.CRANEPUR

The special cable at the standard rate

For maximum voltages and outputs
Flame-retardant
UV and oil resistance

DNV-GL and NEK cables

CF DNV-GL

Certified and resistant to mud and dirt

Unique in the world with DNV-GL approval
MUD-resistant according to NEK606
More than 370 certified products for all types of cables

CF310.UL single-core cable

CF price check

A variety of potential savings with single cores

First advantage: installation space reduction
Second advantage: cost reduction
Third advantage: longer service life

Further information

Brochure

Further e-chain applications

"The evolution of the rol e-chains" (PDF)

igus system guarantee

igus system guarantee

Every application is different. igus guarantee certificates are issued for your application on an individual basis. Ask for the igus guarantee: "Chain, Cable, Guarantee"

smart plastics

smart plastics brochure

Information brochure on i.Sense condition monitoring systems and i.Cee predictive maintenance systems.

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