Easily filter the products according to properties such as material, dimensions or arrangement.
When you hear the word automation, everyone agrees: processes are required that are as precise, reliable and fast as possible, that can be cyclical and work around the clock. Without exception. Cable chain systems are an indispensable part of process automation, as almost every production site can find applications in which machine parts need to be continuously supplied with power, data or media, such as air and water. On this page, you will find out what exactly is meant by a cable chain, when it is used, which materials are available for cable chains, what arrangement and assembly options are available, and last but not least what you need to keep in mind when selecting the appropriate cable chain cables.
Find what you are looking for with our online tools!
For unassembled cable chains:
For assembled cable chains
What is a cable chain and what task does it perform?
A cable chain is a mechanical system that protects, carries and guides cables and media hoses in permanently moving machine applications.
The movements in the cable chain are performed in a controlled manner so that the forces permanently acting on the cable or the media hose do not cause premature damage or failure. Cables and media hoses are ultimately subjected to millions of bending movements along the travel distance in the cable chain.
So what are the main features of a cable chain?
It allows the electrical, optical, hydraulic or pneumatic connection between two points in linear movement in an easy and economical way. Certain cable chains enable rotations of up to 540° and can therefore also perform three-dimensional movements, as required in robotics applications.
It guides and supports the cables and hoses contained in a controlled manner, while observing the minimum permissible bending radius.
It provides mechanical protection for cables and hoses and even separates them from chemical environmental influences if they are enclosed with protective covers.
This not only reduces the number of maintenance intervals for cables and hoses, but also increases their service life.
How is a cable chain constructed?
A cable chain is made up of many interconnected chain links that are closed on both short sides. The size of the chain link is determined by the number and dimensions of the cables.
A single chain link consists of the following elements:
- Side band
- The individual sideband chain links are connected to each other with connecting pins.
- Frame stays are available in a wide range of variants. In addition to open variants, there are also those with protective covers made of plastic, aluminum, steel or even stainless steel to protect the cables from environmental conditions if necessary.
- Separators, on the other hand, ensure the correct positioning and separation of cables and hoses within the cable chain. They are attached vertically to the frame stay.
- Connecting elements: to ensure that the cable chain can be attached to the system or machine at both ends, connecting elements are used for a wide variety of mounting positions.
What advantages does a cable chain have compared to cable trolley systems?
Competitive advantages of the cable chains as compared to the traditional systems, like conductor bars and festoon suspensions and cable trolley systems are:
- they shine thanks to the ability to carry different kinds of utilities (power, signal and data cables as well as hydraulic and pneumatic hoses),
- they can be used unconditionally in critical environments where dust, moisture, chemicals and aggressive substances can be present in the atmosphere on a daily basis.
- They can withstand high speeds and accelerations.
- Cables can be installed, replaced or installed at a later date.
- Horizontal, as well as vertical, diagonal and circular travel distances are also possible.
- Maintenance work is easy to carry out, but it is generally less maintenance-intensive.
- They require a much lower media length for comparable travel distances, as the media are linear in the cable chain rather than sagging.
The cable chain follows the cable
What does that mean?
Cable chain serves for protection and guiding of flexible cables and hoses installed in a cable chain. For this reason, chains must always be designed in consideration of cable/hose protection requirements and not the other way around! The more precisely the cables/hoses/cable conduit to be used can be defined, the better.
How are cables arranged in the cable chain?
In order to ensure that the cable chain functions smoothly and to avoid any damage to the media, the cables and hoses to be guided, which are relevant for the chain size and composition of the components, should be thoroughly evaluated before selecting the cable chain.
To name just a few examples, make sure that:
- cables/hoses lie loosely next to each other in the chain chambers. They should be separated as much as possible using separators.
- Cables/hoses are installed symmetrically in terms of their weight and size. Those with greater diameters and weights on the outside, those with smaller diameters and weights on the inside. They can also be placed in descending size order from inside to outside. Avoid arranging the cables above one another without the use of a shelf.
- in one section only media with the same outer jacket is used to avoid unnecessary friction.
- defined clearance between the cable/conduit and the separator is guaranteed according to a medium so that the cables/conduits can move freely and allow the media to move relative to one another and to the cable chain.
Which cable for the cable chain?
Cables and hoses suitable for cable chains are sometimes flexed very strongly and continuously. As a result, they are permanently exposed to the stresses resulting from the bending movement in the cable chain. Unlike three-dimensional torsional movements, this bending movement is always linear and always in one direction.
The flexibility of a cable has a direct impact on its bending radius, which indicates how much a cable can be bent without impairing its functional capability.
The tighter the bending radius, the greater the stress on the cable and the more difficult it is to achieve the long service life required.
The requirements for the flexibility of cables and hoses can therefore be defined as follows
The conductors inside the cable should be at least fine-wire, i.e. correspond to conductor class 5.
The shorter the lay length, i.e. the core stranding, the more flexible the entire stranding assembly.
Of course, these should have met the cable chain requirements and the prevailing environmental conditions.
Cable chain cables only have more than 25 cores in exceptional cases. This prevents the risk of the many conductors being literally knotted and then breaking.
Ultimately, the cable chain must not only support its own weight, but also that of the cables and media hoses placed in it over a length of m (ft).
Find out more about the outstanding bending properties of highly flexible cables and wires for continuous motion applications.
What other factors are important when choosing a cable chain?
Many factors are of great importance when configuring cable chains. In addition to specifying the cable chain cables and considering your application environment, the length, speed, acceleration and operating time of the cable chain as well as the weight of the cables must also be determined.
It is also important to include the subsequent arrangement, the type of installation and the cable chain material in the planning.
You can find detailed information on this in our whitepaper
What chain configurations are possible?
Self-supporting arrangements are primarily suitable for smaller cable chain sizes. They are less susceptible to wear than sliding configurations, since there is no friction between the upper and bottom part of the chains when operating. However, the self-supporting length of a cable chain is limited.
As the travel distance increases, the net weight of the cable chain as well as the weight of the cables and hoses placed in it stress the application so that the cable chain can sag in the unsupported area. A sag is not necessarily negative, but reduces the possible speed and acceleration values of the cable chain.
If the maximum permissible sag value is exceeded, we recommend either supporting the cable chain or choosing a sliding application. If distances with a traveling distance of more than 10 m (32.81 ft) are to be overcome, the choice of cable chain usually depends on the sliding arrangement with guide channel. Special design solutions (e.g. sliding shoes) minimize the friction effects between the chain parts on top of one another. The sliding arrangement allows travel distances of up to 100 m (328.1 ft) and more.
What assembly options are available?
The application with horizontal assembly is the predominantly used cable chain. The cable chain is laid flat on a stable surface.
Side mounted application means that the chain works mounted on its side. This configuration is necessary if there is limited space upwards and normal assembly of the cable chains would require too much space. It is also necessary when the additional load of the utilities exceeds the maximum self-supporting capability of the chain, but for some reason the sliding configuration cannot be used.
The following options are available: supported applications where the cable chain is moving on a floor, inside a guide channel, for example in long travel distance applications. Or suspended applications where the cable chain is not supported from the bottom, for example in machine tools.
Vertical assembly means that the direction of motion is vertical and the arc of the chain radius does not touch the ground or the ceiling. For vertical assembly, the chain can either be suspended or brought into operation while standing.
Cables/hoses must be fastened at both ends using the corresponding accessories and should not touch the cable chain.
What material are cable chains made of?
All materials used at LAPP for the manufacture of cable chains are environmentally friendly (RoHS and WEEE). The cable chains are distinguished by the materials used for the chain links and the materials used for the cross frames.
We therefore divide the chains into:
Plastic cable chains are suitable for versatile standard applications in the vast majority of environments (including outdoors) and are also used for increased chain loads in wet and oily environments or for long travel distances. The fastest speed and acceleration values can be achieved with plastic cable chains. Both self-supported and gliding applications or applications with circular movement can be realized with plastic chains. They are made from a polyamide-based compound (Brylon 6) and are available as an open or completely closed variant.
By the way: LAPP also offers hybrid cable chains. In hybrid systems, the frame stays and protective covers are made of aluminum. The combination of plastic and aluminum helps to give the chain more rigidity/stability and resistance to harsh environments. Hybrid cable chains are available as open or fully closed variants.
Steel cable chains these are suitable for a wide range of applications and especially for environments where plastic is not resistant enough. This is the case, for example, in environments with extreme high and low temperatures. This is where steel chains offer a clear advantage over plastic chains.
Configuration options for a cable chain
The majority of cable chain systems are equipped with a single chain. However, they can also have multiple chains in the same way. If the number of chains is greater than 1, the chains run directly next to each other, in a ring shape or layered together. Often, the chain has a constant, linear motion direction – a so-called displacement. In many applications, however, rotations inside the cable chain are also required, sometimes of up to 600° and in these cases can only be achieved using a multi-chain configuration. There are also countless chain configuration options available for combined movements, i.e. for displacements and rotations.