Long Travel e-chains® for Cloos Welding Systems

• What was needed: E4.1 series e-chain as open (E4.56) and closed (R4.56) variants
• Requirements: upright, horizontal, suspended and 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 meter; 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-dogs in the energy supply enable maximum force absorption and ensures high stability even with long lengths. The lids of the R4.56 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 e-chains.

The fully automatic systems from Carl Cloos Schweißtechnik GmbH meet the highest safety standards, including those required for the energy supply systems used. In these applications, energy chains must reliably guide cables and hoses for power, data, pneumatics, and hydraulics in upright, horizontal, suspended, and linear sliding configurations without interruption.

One of the key challenges arose from Cloos's tandem arc welding process, which places particularly high demands on cable management. Developed by Cloos in 1996, the process uses two arcs burning simultaneously in a common fusion strip. As a result, welding speeds increase, seams can be produced more efficiently, and deposition rates are significantly higher. However, the additional cables and hoses required for the process create loads of up to 10 kilograms per meter, making a robust cable carrier solution essential.

In addition to its welding machine applications, Cloos required an energy chain solution for a separate system used in the production of control cabinet frames with highly variable dimensions. This fully automated production line consists of 15 interconnected robots, multiple manipulators, and extensive control technology that coordinates the entire manufacturing process.

By integrating the Cloos system and implementing extensive modifications, the company was able to significantly improve cycle times while permanently reducing downtime.

An E4.56 series e-chain® proved to be the ideal solution for the new welding process. A vertical stop-dog design in this e-chain from the E4.1 product line enables maximum force absorption and delivers exceptional stability, even over long unsupported lengths. The e-chain also features a rear grip that provides high torsional strength and allows for variable widths to accommodate different cable and hose packages.

For areas of these systems exposed to sparks, dirt, and dust, a fully enclosed R4.56 e-tube from the same E4.1 product line provides additional protection. The enclosed design shields moving cables and hoses from harsh operating conditions, helping to ensure long service life and reliable performance.

Series E4.1 e-chains also handle demanding motion profiles with ease, including slow starts, abrupt stops, and travel speeds of up to 1.7 meters per second. In construction machinery applications such as these, welding robots may travel distances of up to 70 meters. Similar requirements can also be found in the automotive industry, commercial vehicle manufacturing, railway technology, and agricultural machinery.

The same product family is also used in Cloos systems for manufacturing control cabinet frames. Several R4.56 and E4.56 e-chains are installed throughout the production system in gliding, suspended and vertical configurations. Previously, the machine manufacturer relied on steel cable carriers, which generated significant noise during operation. Conversely, the R4.56 and E4.56 models are manufactured from maintenance-free high-performance tribo-polymers, making them lightweight, wear-resistant, and exceptionally quiet.

The Noise levels of the e-chains are further reduced by an integrated wheel brake that dampens both stop-dog impact and rolling noise. The result is a quieter, more efficient system and a quality advantage that ultimately benefits Cloos customers.