Experience reports and application examples

How energy chains prove their worth in practice

Experience reports and application examples – How energy chains prove themselves in practice

How do energy chains prove themselves in practice? In this article, we highlight experience reports from various industries and use specific application examples to show how energy chains demonstrate their strengths in real-world scenarios. From customized solutions in demanding environments to innovations that are shaping the future of industrial automation – find out how energy chains prove themselves in practice and what added value they offer.

Below you will find a case study that illustrates how energy chains are successfully used in different industries:

A leading automotive manufacturer faced the challenge of increasing the production speed of its assembly lines while minimizing unplanned downtime. The high speeds and continuous movements in production placed heavy strain on the cables and wires used, which in the past often led to malfunctions and costly production interruptions. To address this problem, the company decided to use particularly robust energy chains that were specially developed for the high loads in automotive production. These energy chains are characterized by their high stability and durability, which reliably protect the cables and wires. After integrating these energy chains, the automotive manufacturer was able to significantly increase production speed, as the machines could now operate smoothly and without unexpected interruptions. Downtime was significantly reduced, which not only increased efficiency but also lowered production costs. The success of this measure led to the standardization of the energy chain solution in other plants of the company.

In practice, energy chains have established themselves as indispensable components in numerous applications. They enable trouble-free energy and data transmission even under extreme conditions. Here are some practical examples that highlight the versatility of energy chains:

• Machine tools: In modern CNC machines, energy chains are used to reliably supply moving parts with power, data, and coolant without causing cable breaks or malfunctions.
• Crane systems: In harbor cranes, energy chains ensure safe and flexible guidance of power and control cables, which improves operating times and safety.
• Conveyor technology: In automated conveyor systems, energy chains enable continuous operation by reliably guiding cables and hoses, even at high speeds and in confined spaces.

Although energy chains offer many advantages, companies often face considerable challenges when integrating them into their systems. These range from extreme environmental conditions and high speeds to limited installation space. However, there are tailor-made solutions for every challenge:

Standard energy chains can fail in high-temperature applications, such as in foundries or glass factories.

Solution: Specially developed heat- and cold-resistant energy chains ensure that cables remain protected even at extreme temperatures.

In applications where machine components are exposed to extreme acceleration and speeds, stable cable routing is essential.

Solution: Lightweight but high-strength energy chains made of special plastics or metals that can handle high dynamics without wear.

In many machines, space for cables and wires is very limited.

Solution: Compact energy chains that can be optimally integrated into tight spaces thanks to their slim design, without restricting freedom of movement.