The load capacity of energy chains
Energy chains, also known as energy guide chains or cable drag chains, are indispensable in numerous industrial applications for safely guiding and protecting cables, wires, and hoses. To ensure that they can perform their task effectively, it is crucial to understand the basics of energy chain load capacity. This article provides a comprehensive overview of this important topic.
What are energy chains?
Energy chains consist of interconnected links or arches and are designed to allow movement in various directions and dimensions while protecting the media carried within them from external influences and mechanical stress.
- Energy chains from LQ Group are used in a wide range of industries, including:
- Manufacturing automation: Energy chains are used in production facilities and assembly lines to organize and protect the cabling of robots, machines, and other automated equipment.
- Machine tools: In metalworking and other industrial applications, energy chains are used to accompany the movement of machine tools and protect the cables and lines running inside them.
- Material transport: Energy chains are used in conveyor belts, cranes, and other transport systems to ensure media guidance and protection.
The design of energy chains makes it easy to install or remove the media they carry, which facilitates maintenance and repair work. They are available in various sizes and materials to meet the requirements of the respective application.
Why is resilience important?
The resilience of energy chains refers to their ability to withstand the mechanical and thermal stresses required in an application. It is crucial to ensure that energy chains do not fail or become damaged prematurely, which can lead to production downtime and costly repairs.
Factors that influence resilience
- Speed and acceleration: Fast movements and sudden accelerations generate additional forces in the energy chain. The load capacity must take these dynamics into account.
- Weight of the guided media: Cables, lines, and hoses have a weight that must be carried by the energy chain. This weight is an important factor in load capacity calculations.
- Bending angle: The tighter the bending angle of the energy chain, the greater the load on the links and fasteners. Energy chains should be designed to withstand these bends without wear.
- Environmental conditions: The environment in which the energy chain is used can affect its load capacity. Factors such as humidity, temperature, chemicals, and dirt must be taken into account.
Load calculations and tests
Load calculations and tests are essential steps in the development, manufacture, and use of energy chains in industrial applications. They serve to ensure that the energy chains can withstand the loads and requirements of their specific tasks and operate safely and reliably. Here are some important aspects related to load calculations and tests for energy chains:
Simulations and software tools
Engineers often use specialized software tools to perform stress simulations. These tools make it possible to model and analyze the stress on the energy chain under various operating conditions.
Physical tests
Physical tests are crucial for verifying the actual performance of the energy chain. Prototypes of the energy chains are tested under real or simulated conditions to evaluate their resilience, service life, and safety.
Norms and standards
The load calculations and tests should comply with the applicable norms and standards. In Europe, these include DIN EN 50597 and the ISO standards, for example. In the USA, UL (Underwriters Laboratories) standards may be relevant.
Safety factors
Safety factors are incorporated into load calculations and tests to ensure that the energy chains operate safely even under unforeseen conditions. These safety factors may vary depending on the application.
Meeting extreme requirements Heavy-duty energy chains for demanding applications
Even in the most demanding industrial applications, where extreme loads, extremely high or low temperatures, aggressive chemicals, and high speeds are the norm, there is one crucial component that is indispensable: heavy-duty energy chains.
The challenges in such demanding environments are manifold. High loads, whether from the weight of heavy cables and wires or from rapid acceleration and movement, are omnipresent. Extreme temperatures in the steel industry or in food processing put a strain on conventional materials and designs. In chemical plants and laboratories, energy chains must be resistant to aggressive chemicals and acids. And in robotics and CNC machines, fast movements and high speeds are required.
Heavy-duty energy chains have been developed to meet these challenges. They feature robust materials, including high-strength plastics and metal alloys that will not fail even under extreme conditions. The special design of these chains is such that they can withstand high loads, temperature fluctuations, and chemical influences. Some heavy-duty energy chains have self-lubricating joints that reduce maintenance and extend service life. In addition, they provide effective coverage to prevent the ingress of dirt, dust, and foreign objects, which further increases the service life of the energy chain.