Tips and tricks for using energy chains

Energy chains play a crucial role in modern automation technology. They protect and guide cables and hoses to ensure smooth and safe movement in machines and systems. To achieve optimal performance and a long service life for energy chains, it is important to observe a few key points.

Avoiding mistakes during selection and installation

  • Selecting the right energy chain: Selecting the right energy chain is the first step toward successful use. Make sure that the energy chain meets the requirements of your application. Consider factors such as the direction of movement, the required bending radii, and the load from cables and hoses. An incorrectly dimensioned energy chain can lead to increased wear or even failures.
  • Simulation of use: Before the energy chain is integrated into the machine, it can be useful to simulate the movements and loads. With the help of modern software tools, movement sequences, accelerations, and loads can be simulated so that potential problems can be identified and avoided at an early stage.
  • Avoid overloading: Energy chains should never be overloaded. Each chain has a specific load capacity that must not be exceeded. Overloading can lead to increased wear, noise, and, in the worst case, chain breakage. Ensure that all cables are laid neatly and evenly in the chain to ensure balanced load distribution.
  • Integration into the machine design: The energy chain should be taken into account as early as the planning phase of a machine. This means that space requirements, mounting points, and cable routes must be planned from the outset. Retrofitting can lead to compromises that impair the performance and service life of the energy chain.
  • Correct installation: The energy chain should be installed with the utmost care. Ensure that the chain runs in straight and even paths and that there is no twisting or kinking. Irregularities in the installation can put the chain under tension and significantly shorten its service life. In addition, cables within the energy chain should have sufficient freedom of movement to avoid unnecessary mechanical stress.

 

Optimization of performance and lifespan

  • Use of high-quality materials: The use of high-quality materials for the energy chain and the cables it carries can significantly extend its service life. Materials that are resistant to abrasion and chemicals offer greater resistance to the stresses of industrial environments.
  • Regular inspection: Even though many modern energy chains are maintenance-free, regular inspection can't hurt. Check the chains for signs of wear, cracks, or damage.
  • Adjusting speed and acceleration: The machine's movement parameters, such as speed and acceleration, should be set to match the load capacity of the energy chain. Excessive speeds or abrupt accelerations can increase mechanical stress and lead to premature wear.
  • Condition monitoring and sensor technology: The integration of sensors in energy chains enables continuous monitoring of their condition. Sensors can measure wear, temperature, vibrations, and other critical parameters in real time. This data helps to carry out maintenance work in a targeted manner and avoid unplanned downtime.
  • Automated maintenance systems: Automated maintenance systems can be used in modern industrial environments. These systems use sensor data to automatically perform maintenance tasks such as adjustments without the need for human intervention. Such systems can significantly extend the service life of energy chains and reduce operating costs.
  • Long-term forecasts for replacement: Through the continuous collection and analysis of operating data, precise forecasts can be made about when an energy chain is likely to need replacement. This makes it possible to order replacement parts in good time and carry out the replacement during planned downtimes.

Maintenance tips and troubleshooting

  • Regular inspection of cable routing: Regularly check that the cables in the energy chain are still correctly routed. Cables that become knotted or twisted in the chain can lead to increased wear and ultimately to failures. Ensure that the cables are free of tension and kinks.
  • Predictive maintenance: Rely on predictive maintenance to avoid unplanned downtime. Monitor the energy chain for signs of wear and replace components in good time before a failure occurs. Many modern energy chains offer the option of monitoring wear and tear and identifying maintenance requirements at an early stage.
  • Quick troubleshooting: If problems arise with the energy chain, quick troubleshooting is crucial to resume operation. Identify the cause of the problem—whether it is overload, incorrect installation, or wear—and take the appropriate measures. Keep spare parts on hand to minimize downtime.

LQ Group – The right partner for equipped energy chains

The LQ Group manufactures complete, ready-to-install energy chain solutions that are precisely tailored to your requirements. We support you in selecting and configuring the right energy chain to make your production more efficient.