Energy supply on the forklift? Of course, says igus ...

A wide range of cables are used in industrial trucks, including in seats or in the mast. The motion plastics specialist igus offers special cables for precisely these moving applications. With a 36-month guarantee and the smallest bending radii, they are suitable for applications with permanent stress. The "chainflex" range comprises a total of 1,354 different cables for a wide variety of dynamic applications. These include, for example, special cables for use on cameras and monitors, which enable flawless data transmission even under extreme tensile forces of 2,800 N. One example in which chainflex cables are used is the EK-X order picker from Still. The industrial truck can pick goods from shelves at a height of up to 12 meters. To connect the order picker's cabin to the power and signal cables, these are routed via deflection pulleys in the mast. The system was equipped with chainflex cables in order to prevent corkscrews at the lifting height of the EK-X and thus prevent failures due to wire breakage. The result: even with a lifting height of 12 meters and 14 meter long cables, chainflex works when used with deflection pulleys. Thanks to their special design, in which the cores are first twisted into bundles and then arranged around the cable core with a small lay length, they are more resistant than conventional cables.

Route cables safely even in the tightest of spaces

Bending radii place high demands on the material of the cables.

Regardless of where cables are used on the forklift, it makes sense to also use energy chains for reasons of cable protection. Energy chains have been developed precisely for this task because they not only have a high torsional resistance and a cable-friendly interior, but also allow the smallest bending radii and internal heights. Their design makes them modular, quick to assemble and very light. Adjustments are easy to make and cables can be installed or replaced in a flash. The rounded shapes on the inside of the e-chains protect the cables. In addition, large pins in the energy chains ensure greater stability and a long service life for the cable carriers. In industrial trucks, energy chains are used for seat adjustment or in the mast, for example. A stable cable carrier is particularly important when drivers change regularly and the seat needs to be adjusted, for example, in order to protect the cabling under the seat and in the cockpit. Plastic energy chains not only guide cables reliably but are also particularly durable in dynamic applications. They are also used in the mast of narrow-aisle forklift trucks, where they protect cables from external influences and increase their service life thanks to the predetermined routing.

Determine service life with test laboratory examinations

Schematic: Applications for cables and energy chains on forklift trucks.

Both energy chains and chainflex cables are tested for wear and load capacity under real conditions in the 2,750 m² igus test laboratory. Every year, 4,100 energy chain system tests and two billion test cycles are carried out for the highly flexible chainflex cables. Various online tools have been developed on the basis of the test results, which can be used to precisely determine the product service life. On request, igus also carries out customer tests to examine the use of the products under very individual conditions. These include tests on tensile and shear forces, friction values, drive forces, wear and abrasion. In addition, tests are carried out on dirt, impact, shock, weather and temperature resistance.

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