igus® e-chainsystem® E4.1L - the economical standard

Low weight, easy assembly and cable-friendly design.

The E4.1L system is the ideal energy chain for mechanical engineering and applications of all kinds where there must be an optimum relationship between technical requirements and economic efficiency.

Overview E4.1L

Save up to 80% of installation time with E4.1L

See how assembly time can be reduced with E4.1L and what features this e-chain® offers E4.1L makes filling quick and easy. E4.1L even makes retrofitting cables much easier: individual cables can simply be taken out and new ones inserted without cables located above them having to be removed from the e-chain®.

Now save installation time

1... Optimised ratio of inner to outer dimensions

... low weight
... optimised installation space

Functional principle

The functioning principle of the optimised inner and outer dimensions

More effective space

Due to narrower outer links and the geometry of the crossbars, an optimum ratio of inner to outer dimensions can be achieved. This is how useful space is obtained in the e-chain®.

igus® tested

Effective space tested

Given the same installation space, several cables and hoses can be guided in the E4.1L.

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2... Pivoting & removable crossbars

Open, fill and close in seconds

...crossbars can be removed completely
...openable on one side for fast filling and closing

Functional principle

Simple and fast

Thanks to their design, the crossbars can not only be removed from the E4.1L completely but can also be detached on one side. The crossbars thus remain attached to one side of the e-chain®, cables can be inserted or removed, and the e-chain® can be closed in the blink of an eye.

igus® tested

Breaking test in the igus® laboratory

The crossbars can withstand high forces up to 450 N. Tested in test EW13-004

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3... Cable-friendly and flexible interior separation

For a longer service life due to a rounded base

... reduce cable wear almost by half
... fewer parts, more possibilities
... flexibly adjustable

Functional principle

Cable-friendly plastic crossbars

Smooth, cable-friendly and rounded contours ensure a long service life of the cable and hoses. With a few standardised parts, better and more cable-friendly interior separation is possible.

igus® tested

Wear tests

With the new rounded separators, the cable wear was reduced almost by half.

Test 3.748:Separator 301 versus new version 45.1. In this case as well, the combination of plastic and jacket material is shown to be the best choice.

Application example

Plastic crossbars help to increase the cable service life

Plastic crossbars in use

In this application, rounded crossbars help to increase service life in plastics machining equipment.

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4... Sound brake

Dampens stop-dog and rolling noises

... noise level from 33 dB(A) possible, 44 dB(A) with igus® E4 series measured
... many series certified by the TÜV (Technical Inspectorate) Rheinland

Functional principle

Brake

The principle is simple but extremely effective. A wedge-shaped contour in the e-chain® stop-dog dampens the impact noises.

igus® tested

Test for noise emissions in the igus® laboratory

Noise test

We test igus® e-chains® for noise emissions in our own laboratory. Many series are also checked by the TÜV. The noise levels of igus® e-chains® are between 33 db(A) and 46 dB(A), for example.

Test 4.381:E4.32 with operating noises under
44 db(A) stop-dog noise, at 1 m/s

Application example

e-chain® with dampening pads for noise reduction

Even lower noise with dampening pads

If the unrolling noise has to be reduced even further, the optional dampening pads can help. They enable a reduction of up to 5 dB(A).

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5... Vertical, rectangular stop-dogs

For maximum force absorption and therefore a high degree of stability in the case of unsupported lengths

... max. fill weight unsupported up to 600 kg/m possible
... max. unsupported lengths (FLB) 7.0 m (+25% with the optional XXL material)

Functional principle

Double, rectangular stop-dog

More than two stop-dogs are very difficult or impossible to synchronise Due to a rectangular geometry, the distribution of force is considerably better than in the case of a round stop-dog (formula for surface pressure, p=F/A). The complete E4.1L product range has the double, rectangular stop-dog.

igus® tested

Breaking test in the igus® laboratory

We test every energy supply product for pressure and breaking force with the help of a Zwick testing machine in the igus® laboratory in order to be able to provide reliable information on the maximum fill weight and unsupported length.
Test EW13-004

Application example

Automatic welding machine with upright E4.1L

The double rectangular stop-dogs and the undercut design principle of the e-chain® ensure high lateral stability and optimum cable protection even in the case of an upright e-chain®.

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6... Vertical stop-dogs and large pins

Better force distribution and thus absorbs higher push/pull forces and loads

... pull/push forces up to 7,000 N possible
... fill weights up to 600 kg/m and more possible

Functional principle

Vertical stop-dog and large pin

Due to the offset stop-dogs, the force is directed through three points, namely the two stop-dogs and the large pin, instead of the force being absorbed centrally. This reduces the load on the individual elements, the pin and dog-stops to around 1/3.

igus® tested

Endurance test lasting 96 hours - maximum unsupported lengths

The maximum load over a period of 96 hrs is tested. The photo shows an E4.1 with the optional material "XXL", which enables the maximum unsupported length to be increased even more by +25% to approx. 8 m.

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7... Large pin/bore connection

High push/pull forces and reduced wear due to tight tolerances.

... travel of more than 600 m possible
... acceleration of 10 m/s² and more

Functional principle

Large pin/hole connection

Close tolerances and large pin/hole connections ensure high push/pull force absorption. Due to the tight tolerances and the resulting almost complete absence of clearance, extremely high accelerations can be achieved and wear is also reduced.

igus® tested

Tensile test with Zwick material testing machine

We test every energy supply system for tensile strength in the igus® laboratory with the help of a Zwick testing machine in order to obtain reliable information on the maximum possible travel and the possible acceleration values.

Test 3.992:A tensile force of more than 30.000 N is possible

Application example

E4.1L in palletising machine

In this example, an E4.1L is being used in a palletising machine for drinks crates. Due to the rapid movements of the machine, it is especially important that the chain is designed for high speeds and stability.

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8... Inner/outer link principle

For a straight run, a high degree of parallelism and exceptional strength

... alternating inner and outer links provide straight run
... precise parallelism of the e-chain® bands ensures durability

Functional principle

Inner/outer link principle

In an alternating sequence, inner and outer links interlock with each other, as a result of which the run of the e-chain® is especially straight. This enables the e-chain® to move very easily and, at the same time, enhances the durability of the product.

igus® tested

Inner/outer link principle of an E4.1L e-chain®

Function test

The inner and outer link principle is tested in all E4.1L e-chains

Application example

On site assembly over long distances

This e-chain® is guided in a guide trough that only has minimal clearances. This is enabled by the very straight run of the E4.1L and prevents wear on the side of the e-chain®.

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9... Undercut design

For a high degree of stability during lateral acceleration and for high torsional rigidity thanks to an "interlocking feature"

... fill weights of 7.7 kg/m on 2 m unsupported
... ideal for laterally rolling applications or high torsional forces

Functional principle

Undercut design

Interlocking chain links ensure a very high degree of torsional rigidity of the e-chain® and long unsupported lengths even in the case of laterally rolling applications.

igus® tested

Breakage test with Zwick material testing machine

Here we also test each system for maximum load bearing capacity so that reliable information on the service life can be provided in our online service life calculator.

Test 4.099:2 m E4 e-chain® with a 7.7 kg/m fill weight

Application example

Sideways position in an automatic welding machine

An E4.1L e-tube in a sideways position in an automatic welding machine can be seen. It protects cables against flying sparks and, thanks to the undercut design, is also extremely stable for uses where it is in a sideways position.

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10... Few parts, one material

Quickly assembled, no varying material expansion

... acceleration of up to 784 m/s²
... same materials

Functional principle

Few parts

A few parts that are made of one material and guarantee the smallest possible clearance are especially important for high rates of acceleration. A uniform material is the ideal solution in the case of expansion or shrinkage caused by temperature differences.

igus® tested

Speed test

Speeds up to 10 m/s and more are continuously tested in the igus® laboratory in order to meet the highest requirements.

Application example

E4 in a crash test installation

Extremely high accelerations of up to 784 m/s² require an exactly tailored and clearance-free energy supply system. A few parts ensure this.

Crash test facility

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11... Wear pads

Long service life in spite of being used in a sideways position and having a long travel

... wear pads on the sides ensure a long service life
... an important criterion especially in the case of applications where it is turned 90°
... an operating distance of 10,000 km and more is guaranteed

Functional principle

Wear pads

The wear pads on the sides of the E4.1 ensure that this e-chain® also withstands heavy levels of stress and also has a long service life.

igus® tested

Service life test in the igus® laboratory

Length of travel tested

In endurance tests, the service life of the e-chains® in an abrasion test and when the travels are long is tested. Every e-chain® can complete a total travel distance of at least 10.000 km and often much more

Application example

e-chains® for cable guiding in a crane head

Circular "RBR" application with e-chains® rotated 90°

Due to the wear pads, large circle diameters with high fill weights are possible. In this crane head, the laterally rolling e-chain® performs a 400° turn.

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12... Cable-friendly plastic crossbars

For an even longer service life of the cables due to the rounded design

... cables with plastic crossbars last longest
... no structural deformation when force is applied from outside

Functional principle

Cable-friendly plastic crossbars

Smooth, cable-friendly inner contour and rounded crossbars ensure a long service life of cables and hoses. In tests, the combination of the Tribo-optimised plastic of the crossbars on the one hand, and the jacket material of the cables on the other, is found to result in the longest cable service life.

igus® tested

Table comparing the wear of igus® cables to that of competitors' products.

Test of plastic crossbars

Cable wear on plastic crossbars: Jacket made of a wide variety of materials show the best wear results with plastic crossbars. Moreover, compared to aluminium crossbars, they cannot be structurally deformed when force is applied from outside.

Application example

Coal excavator

Of course, wear plays a large role in such rough applications as well, such as here in a coal excavator. In this context, hydraulic cables, among other things, are routed in the e-chain® and a failure can be extremely expensive.

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13... Locking crossbars with scale markings

Easy pre-configuration with interior separation ensures secure retention even in the case of "laterally rolling applications".

... makes it easy to insert interior separation elements that can be locked in at 5 mm intervals
... absolutely even, no wear of the cables due to scaling

Functional principle

Scale of the crossbars

Scalable crossbars are standard for all E4 models. This makes pre-configuration with interior separation elements easier and shortens the assembly time. The separators with catch-tabs can be placed in the crossbar in 5 mm increments and will reliably hold in place (approximately. 25 kg holding strength of the separator in locking position). Spacers are not necessary for laterally rolling applications.

igus® tested

Cable wear

We conduct long-term tests on all chainflex® cables for wear, and service life in continuously moving use. We also test customer-specific cables in order to predict the system service life.

Application example

E4.1L e-chain® hanging sideways

Cables guided safely and reliably in an E4.1L e-chain® that has been turned 90°. The interaction of energy chain material and jacket material is a decisive factor when it comes to service life.

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14... Large selection

Available as e-chain® and e-tube in 4 sizes with many widths

... extender crossbar for hoses with a Ø of up to 300 mm

Functional principle

Animated film of the E4.1L with possible options and extras

Accessories and extras

A variety of extras make the E4.1L system very flexible and are available from stock. For example, there are extender crossbars for holding hoses with a Ø of up to 300 mm or different noise-dampening options.

igus® tested

Extension link test

Due to the additional extension link, widths of up to 2000 mm are possible.

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15... Good protection against dirt and swarf up to 850 °C

For the protection of your cable

... hot chips up to 850°C cannot burn into it
... extremely impermeable design and yet easy to open

Functional principle

igus® energy-tubes protect against dirt and chips up to 850°C

For the protection of your cable

igus® energy-tubes have been used successfully for protection against chips for almost 20 years. Dust, dirt, oil, aggressive environments, moisture, low temperatures and high temperatures have no effect on the robust plastic energy supply systems. Chips thatare up to 850 °C hot simply bounce off the optional HT material - they cannot burn into the material.

igus® tested

Statistics regarding the burning in of chips in relation to the chip temperature

The amount of chips that have burned into the material in relation to the temperature

In the test, 20 g of hot chips (200 to 850 °C) was brought into contact with different materials. The graphic shows the amount of chips that have burned into the material. The test winner is igumid HT with hot chips up to 850 °C

Application example

e-tube in a gantry milling machine used to make tram points

E4 tubes in a gantry milling machine

Safe protection against hot chips is provided by the energy-tube in the case of this gantry milling machine used to make tram points. In spite of the enormous amount of chips produced as well as the high temperatures, the milling machine could operate without any problems thanks to the igus® e-tube.

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16... Guide more

Guide corrugated tubes parallel to the e-chain®

...enables extra cable guidance at a later time
...easy to extend with the help of TUBs

Functional principle

TUB extension

TUBs can be fastened to the side of the E4.1L so that corrugated tubes can be guided parallel to the energy chain. They have a feature that makes it easy to fit PMA clips.

igus® tested

Guide corrugated tubes safely

The clip feature on the side of the E4.1L makes it easy to clip in corrugated tubes so that they can be guided safely alongside the e-chain®.

Application example

Corrugated tubes additionally guided alongside the e-chain®

TUBs in use

The TUB extension is used wherever additional cables have to be guided retroactively. The parallel guidance of corrugated tubes is especially popular in mechanical engineering.

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17... No Camber (NC)

Simply rotate the outer link

...an e-chain® for solutions with or without pretension
...no corrective thermal processing necessary, available from stock

Functional principle

No camber

An e-chain® with camber can quickly be made into an NC version by simply turning the outer links. NC versions are only needed in the case of very special applications such as in hanging installations or where space is restricted.

igus® tested

e-chain® in a storage and retrieval unit

Testing of special applications

Products for special applications such as this storage and retrieval equipment are also tested. For example, the guidelok slimline F system, which prevents the e-chains® from swinging out in storage and retrieval equipment.

Application example

e-chain® hanging in a palletising machine

Hanging installation in a palletising machine

Especially in hanging installations or where space is restricted, an e-chain® without camber is the first choice. Thanks to its outstanding stability, the E4.1L is the ideal solution for such applications.

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18... Openable extender crossbars

Ideal for routing large hoses

... suitable for hoses with an outer diameter of up to 137 mm ...

Functional principle

Openable extender crossbars

The E4.1L can be supplemented with extender crossbars, which increase the size of the interior of the e-chain®. The crossbars can be mounted in different ways: from one or both sides, alternating with normal crossbars and combinations of all these options.

Application example

Example of an application for openable extender crossbars

Extender crossbars in woodworking

In the case of this woodworking and sandwich processing machine, the e-chain® was fitted with extender crossbars to hold the suction hose for wood chip removal. The extender crossbars hold the hose securely in the energy supply system and are openable.

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19... Sealed lid (e-tube)

All-round protection yet still quick to fill with cables

... easily accessible from above or below
... with a better seal than many competing products and nevertheless easy to open

Functional principle

Hinged lids

The lids of the close E4.1L e-tubes can be opened easily and removed completely. This makes it easy to insert cables and the e-tubes can also be closed with a very tight seal.

Test> Most impermeable igus® e-tubes IP tested:

System RX

igus® tested

Test of the impermeability of igus® e-tubes

Impermeability tested

In the igus® laboratory, the impermeability of e-tubes is tested under extreme conditions. In this way, a method of maximum cable protection can be developed and the stop-dogs remains completely free of chips.

Application example

e-tube for protection against chips and dirt

The example shows an e-tube in use in a machine, where it is intended to protect cables from chips and dirt as soon as the machine starts operating. The e-tube is nevertheless easy to open when new cables have to be inserted or old ones replaced.

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20... Sealed mounting bracket

... protection against chips up to the front edge of the e-tube
... can be retrofitted with integrated C profile for the installation of a tension relief system
... universal connection

Functional principle

KMA protects cables against chips all around

Sealed all round

Can be retrofitted and are highly impermeable. Mounted on the front, the impermeable plastic-and-metal mounting bracket (KMA) keeps dirt and chips away, thus providing ideal protection for the cables.

igus® tested

KMA in a machine tool protects cables against chips

KMA test in a machine tool

With the impermeable KMA, the last "gap" in applications in the working environment of machine tools has been closed. The chip-proof plastic-and-metal mounting brackets have integrated C-rails and protect the cables right up to the front end of the e-chain® and, at the same time, enable strain relief (with the help of CFX strain relief clamps).

Application example

KMA in use on an e-chain® turned 90°

At the front, the e-chain® in this example is flanged on and protected all round with a KMA element.

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21... Strain relief for electrical cables

Space-saving and safe chainfix product range

... three times greater tensile strength in igus® chainfix clamps
... also resistant to oil, coolant and water

Functional principle

Strain relief

Strain relief systems from igus® have been specially developed for use in e-chains® and dynamic applications. The combination of chainflex® cable materials and touching plastic components of the chainfix strain relief systems is designed for durability of the cables and maximum holding strength.

igus® tested

igus® chainfix clamp in the tensile strength test

Clamp in tensile strength test

The tensile strength of the igus® chainfix clamp is more than three times greater than that of commercially available strain relief systems.

Application example

Strain relief in a machine tool

Reliable and safe strain relief for media, data and control cables provided with this ready-to-install readychain® system for machine tools.

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22... ESD versions available from stock

ESD material against static loads

...material and undercut design ensure permanent electric conductivity.

Functional principle

Prevention of static loads due to igumid ESD

The igumid ESD material guarantees long-lasting and maintenance-free conductivity over many years due to the additives it contains. In order to ensure this, each component of the e-chain® must be completely conductive throughout.

igus® tested

Conductivity test

The igumid ESD material has been tested with over 10 million cycles in the igus® technical center and thus fulfils extremely high requirements. The continuous end-to.end conductivity is measured in all e-chains® with ESD material. Only products that pass the test are given a test seal and shipped to customers.

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1,244 chainflex® cables and more than 4,000 harnessed drive cables from stock

... From 1 metre, no cutting charges, no minimum quantities
... chainflex® works or money back
... 36 month guarantee

Functional principle

Wide variety of cables

Flexible cables in energy chains or robots need special characteristics to last through many cycles, high speeds and accelerations, as well as demanding environmental conditions. Electromagnetic compatibility and compliance with standards and guidelines such as NFPA 79, UL, CSA, VDE, Inter- and Profibus are also taken for granted today. The igus® chainflex® product range contains the appropriate cables for very different applications.

Overview of chainflex® product range

igus® tested

Test of chainflex® cables in the igus® climate chamber

Extensive tests of all chainflex® cables

All chainflex® cables are always tested under realistic conditions. Fitted in an e-chain® as well as in motion, like here in the igus® climate chamber at -40°C.

chainflex® works

Application example

chainflex® in use in an automatic CNC multiple-spindle lathe

Reliable on all axes

In this automatic CNC multiple-spindle lathe, every single working position has to be reliably supplied with media, energy and signals. Outstanding freedom of movement on all axes requires considerable cable durability and reliability.

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igus® e-chainsystem® E4.1L - the economical standard

Low weight, easy assembly and cable-friendly design.

Save up to 80% of installation time with E4.1L

1... Optimised ratio of inner to outer dimensions

Functional principle

More effective space

igus® tested

Effective space tested

2... Pivoting & removable crossbars

Open, fill and close in seconds

Functional principle

Simple and fast

igus® tested

Breaking test in the igus® laboratory

3... Cable-friendly and flexible interior separation

For a longer service life due to a rounded base

Functional principle

Cable-friendly plastic crossbars

igus® tested

Wear tests

Application example

Plastic crossbars in use

4... Sound brake

Dampens stop-dog and rolling noises

Functional principle

Brake

igus® tested

Noise test

Application example

Even lower noise with dampening pads

5... Vertical, rectangular stop-dogs

For maximum force absorption and therefore a high degree of stability in the case of unsupported lengths

Functional principle

Double, rectangular stop-dog

igus® tested

Breaking test in the igus® laboratory

Application example

Automatic welding machine with upright E4.1L

6... Vertical stop-dogs and large pins

Better force distribution and thus absorbs higher push/pull forces and loads

Functional principle

Vertical stop-dog and large pin

igus® tested

Endurance test lasting 96 hours - maximum unsupported lengths

7... Large pin/bore connection

High push/pull forces and reduced wear due to tight tolerances.

Functional principle

Large pin/hole connection

igus® tested

Tensile test with Zwick material testing machine

Application example

E4.1L in palletising machine

8... Inner/outer link principle

For a straight run, a high degree of parallelism and exceptional strength

Functional principle

Inner/outer link principle

igus® tested

Function test

Application example

On site assembly over long distances

9... Undercut design

For a high degree of stability during lateral acceleration and for high torsional rigidity thanks to an "interlocking feature"

Functional principle

Undercut design

igus® tested

Breakage test with Zwick material testing machine

Application example

Sideways position in an automatic welding machine

10... Few parts, one material

Quickly assembled, no varying material expansion

Functional principle

Few parts

igus® tested

Speed test

Application example

E4 in a crash test installation

11... Wear pads

Long service life in spite of being used in a sideways position and having a long travel

Functional principle