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Control cables for energy chains


People think control cables are boring, but they keep industry running worldwide. The control cable is the quintessential cable and usually has one green/yellow core for earth and many black cores for the signals. The special number of cores is due to the typical strand structure of the past. Cores used to be distributed in layers, so a certain number of cores was specified. Today, there are more robust ways of stranding. Since the cable handles signals from the usual alternating current network, it is normally designed in the 300V/500V voltage class. A shielded variant of this cable is also available if EMC conditions call for it.
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We rely on cores wound in bundles.

Starting at 12 cores, our control cables have a special mechanical design for long service life in motion. We install so-called cores wound in bundles with short pitch lengths.  

But what exactly are cores wound in bundles? 

The number of bundles into which the cores are wound depends on the number of cores. These bundles are then stranded in turn. This method is necessary to absorb the pull/push forces which occur during movement. These forces arise when the cable moves around a curve (radius). The cores are compressed in the inner radius and stretched in the outer radius. We developed the cores-wound-in-bundles design to ensure that these forces do not put too much strain on the cores, since a core thus continually changes its position in the cable, balancing out the forces. It is especially important for preventing the so-called corkscrew effect, which often occurs on long travels. 


Seven reasons for our chainflex cable

In the course of cable developments over the past few decades, seven principles have evolved that ensure a high-quality, long-lasting cable in an e-chain. At igus, we call these findings the "seven reasons". 
Seven reasons

Here you have the opportunity to experience the CF6 control cable as a virtual, three-dimensional model


Application example: chainflex control cable with cores wound in bundles

Cables in a forklift - a special challenge

For us, a very exotic application is rolling up and down on plastic rollers on a forklift mast. Tension is maintained on the cable so that it does not jump off the roller when the vehicle starts moving. Deflection with these rollers also puts the stranding under extreme strain. A customer who performed very conscientious testing discovered years ago that this can lead to problems. We were allowed to take part in the customer's tests with our products, and we showed that our cores-wound-in-bundles solution relieves forces on the cores. Years later, corkscrews and broken wires in the cable in this application have long been forgotten. Facing challenges that your cable cannot currently handle can be a first step to finding a solution with us.


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The terms "Apiro", "AutoChain", "CFRIP", "chainflex", "chainge", "chains for cranes", "ConProtect", "cradle-chain", "CTD", "drygear", "drylin", "dryspin", "dry-tech", "dryway", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-loop", "energy chain", "energy chain systems", "enjoyneering", "e-skin", "e-spool", "fixflex", "flizz", "i.Cee", "ibow", "igear", "iglidur", "igubal", "igumid", "igus", "igus improves what moves", "igus:bike", "igusGO", "igutex", "iguverse", "iguversum", "kineKIT", "kopla", "manus", "motion plastics", "motion polymers", "motionary", "plastics for longer life", "print2mold", "Rawbot", "RBTX", "readycable", "readychain", "ReBeL", "ReCyycle", "reguse", "robolink", "Rohbot", "savfe", "speedigus", "superwise", "take the dryway", "tribofilament", "triflex", "twisterchain", "when it moves, igus improves", "xirodur", "xiros" and "yes" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries. This is a non-exhaustive list of trademarks (e.g. pending trademark applications or registered trademarks) of igus GmbH or affiliated companies of igus in Germany, the European Union, the USA and/or other countries or jurisdictions.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsubishi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention on this website. The products offered by igus® are those of igus® GmbH