Energy chains for a 70m travel in Cloos welding systems

• What was needed: E4.1 series energy chain as an open (E4.56) and closed (R4.56) variant
• Requirements: upright, horizontal, suspended or linear sliding movement of the energy supply with a high number of cables and hoses for power, data, pneumatics and hydraulics; high cable weight of up to 10 kg per metre; long travel distances of up to 70 m; protection against sparks, dirt and dust
• Industry: Machine tools, welding systems
• Success for the customer: the vertical stop-dog in the energy supply enables maximum force absorption and ensures high stability even with long lengths; the closed E4.56 offers optimum protection against chips; the customer has also been able to significantly reduce the noise level in the system by switching from steel chains to plastic energy guides

The fully automatic systems from Carl Cloos Schweißtechnik GmbH fulfil the highest safety requirements, which also apply to the energy supply systems used. In the application, these must move the cables and hoses for power, data, pneumatics and hydraulics in an upright, horizontal, suspended or linear sliding position without interruption. The special tandem arc process in particular required an energy chain that could easily cope with the additional loads from the cable and hose. The welding process was developed by Cloos in 1996. The technology involves two arcs burning in a common fusion strip. The result: the welding process is faster, the seams are longer and the deposition rate is higher. Overall, the additional cables and hoses achieve a weight of up to 10 kilograms per metre.
The machine manufacturer also required an energy chain solution for another system for the production of control cabinet frames whose length, width and height can vary greatly. The fully automated production system for welding the frames consists of 15 interlinked robots, a number of manipulators and extensive control technology that coordinates the production processes. Thanks to the use of a Cloos system and an extensive conversion, cycle times have been significantly improved and downtimes permanently reduced.

The energy chain E4.56 from the E4.1 series proved to be the optimum solution, even for the new welding process. This is because the vertical stop-dog in the energy supply enables maximum force absorption and ensures high stability, even with long unsupported lengths.
The e-chain® has a rear grip and therefore high torsional strength, and is also variable in width. As a closed conduit variant R4.56, the guidance is used where sparks, dirt or dust play a role. It offers the moving cable and hose optimum protection. Even slow starts, abrupt stops and speeds of 1.7 metres per second are special requirements that the E4.56 easily meets. In the construction machinery sector, the travel of a welding robot can be up to 70 metres. Other application scenarios can be found in the automotive industry, in the manufacture of commercial vehicles, in railway technology and in agricultural machinery. 
Several R4.56 and E4.56 energy chains from the E4.1 sliding, suspended and vertical series are used in the system for manufacturing control cabinet frames. Previously, the machine manufacturer used energy chains made of steel, but these were very loud when travelling. The R4.56 and E4.56 energy chains, on the other hand, are made from maintenance-free tribo-polymers. As a result, they are not only particularly light and wear-resistant, but also very quiet. An integrated brake on the wheel stops additionally dampens stop-dog and rolling noise. A quality criterion that pays off for Cloos customers.