Encoder Feedback Cables

DriveCliq – the machine tool standard

Several years ago, the shift from analogue encoder systems to the then-new DriveCliq technology presented challenges, particularly with long cable lengths and new connector designs. Working closely with key customers such as WALDRICH (Coburg), we developed a more robust M23 round signal connector, improving both machinability and data transmission beyond the original solution.

If you require a solution not listed in our catalogue, contact us, we will work with you to assess and optimise your application.

Cable in the forklift - a special challenge

An unusual application involves winding and unwinding cables on forklift masts via plastic rollers. The constant pulling and deflection place extreme strain on the cable stranding. After earlier issues, igus® collaborated with the customer to test a solution using specially bundle‑wound cores. This rope construction neutralises internal forces, eliminating corkscrew effects and core breakage. If you’re facing similar cable performance challenges, we can help find the right solution.

Crane cable carrier in demanding environments

A company supplying steel rails to the international railway industry replaced festoon systems on its indoor and outdoor cranes to reduce both maintenance requirements and costs. The new energy chain systems are comprised of igus®' E4/4 heavy duty series cable carriers, aluminium guide troughs and chainflex® cables.

Cable management for high-bay warehouse operation

In the meat-processing industry, igus® readychain® cable carrier systems streamline storage and handling in high-bay warehouses, cutting installation time from three days to just four hours, minimising assembly errors, and reducing the risk of plant downtime, delivering reliable, efficient operation for complex storage-and-retrieval units.

Crash simulation robots using cable carriers

Decommissioning a nuclear power plant demands precise, reliable solutions. For dismantling 46-foot steel tanks, a milling cutter powered by igus® series 28 E4/00 energy chain carriers ensured smooth operation in zigzag applications. Guiding chainflex® CF9 continuous-flexible cables and hoses, this system delivered dependable power and fluid supply, proving the durability and reliability of igus® components in the most demanding environments.

Cable carriers and cables for touch-free car wash systems

A leading car wash manufacturer delivers self-service, automatic, tunnel, and freestanding car wash systems, with its touch-free car wash being a customer favourite. This state-of-the-art system handles vehicles of all sizes, including large trucks and Hummers, using advanced software and reliable components.

Large screen LED installation

The igus® E4 energy chain safeguards fibre-optic, power, and control cables on 26-foot automated LED displays at Victory Plaza, ensuring reliable operation 18 hours a day, 360 days a year. Designed for extreme weather, UV, and low-temperature resistance down to –30 °F, it outperforms competitor systems by preventing corkscrewing and premature failure, delivering a durable, low-maintenance solution for high-duty outdoor LED applications.

Automated mic reel with no signal loss

The e-spool microphone reeler extends cables up to 30 m automatically from the ceiling, no manual work, no risk of cable damage. It eliminates slip rings (a common source of interference) using a twisterband system for smooth, uninterrupted signal transmission. Built-in safety features, special XLR cable with strain relief and auto-stop on exceptional load, protect both gear and operators.

FOC with Tight Bend Radii Solutions

When copper bus cables fail under tight bend radii and millions of double-strokes, chainflex® fibre optic cables outperform with up to 40% smaller minimum bend radius and far longer service life. Fibre optics deliver high-speed data immune to EMC interference, with signal integrity preserved even when cable curvature changes, something copper cores can’t reliably maintain.

Belt-driven units for automatic gates

In this application, chainflex® CF9 TPE control cables have a much longer service life than the cables previously used. These are safely guided by igus® energy chains cable carriers from the E2 micro family. Furthermore, the belt-drive units of the gates are equipped with tribologically optimised iglide® plastic plain bearings, which have reduced wear rate considerably.

Nuclear Power Plant Decommissioning

Decommissioning a nuclear power plant demands precise, reliable solutions. For dismantling 46-foot steel tanks, a milling cutter powered by igus® Series 28 E4/00 energy chain carriers ensured smooth operation in zigzag applications. Guiding chainflex® CF9 cables and hoses, this system delivered dependable power and fluid supply, proving the durability and reliability of igus® components in the most demanding environments.

Control Cables in Composting Plant

igus® roller energy chains and chainflex® cables keep composting plants running reliably in extreme heat, humidity, and abrasive environments. The roller design minimises friction and wear, extending service life from annual replacements to over five years. Built for continuous flex and harsh conditions, these systems reduce downtime, cut maintenance, and ensure efficient, long-term operation.

Pre-assembled energy supply for amusement park ride

With readychain®, igus® is assigned all the procurement logistics, from the purchase of all essential special parts to the safe, efficient delivery of the ready-to-install system on a fixed date. There is a number of reasons to opt for a pre-assembled cable carrier system in mechanical and plant automation. Manufacturing costs, sources of error and project planning costs are reduced, whilst reliability is increased.

Reliable cables solution in machining centres

igus® energy chain systems for large machining centres deliver reliable, high-speed energy and media supply over long travel distances. Pre-assembled readychain® solutions simplify installation, reduce downtime, and handle heavy loads with precision. These systems keep gantry machines running smoothly while protecting cables from wear, vibration, and contamination.

chainflex® cables in concrete manufacturing

A manufacturer with a five-axis CNC router available in four main styles. replaced cables with chainflex in their application. The cables had to be able to withstand heavy duty applications, and at the same time possess a high degree of flexibility. The replacement cables have been in place over 10 years.

High-speed roller door

The igus® Micro flizz® cable carrier system delivers reliable power and data supply in compact spaces, even at extreme speeds up to 6 m/s and in temperatures as low as −40°F. Pre-assembled with energy chain, guide channel, and cables, it ensures smooth, quiet, and lubrication-free operation while withstanding millions of cycles. Ideal for roller doors, long-travel, and high-acceleration applications, Micro flizz® helps engineers achieve long service life with minimal maintenance and reduced downtime.

Leather-Cutting Machine Success with igus® chainflex®

A furniture manufacturing plant faced recurring cable failures in its leather-cutting station. Despite continuous operation for 14-hour days, cables would fail every two months, causing up to a full day of downtime per incident. The company retrofitted the machine with chainflex® CF9 control cables, designed for extreme bending and compact installations.

Minimal Bend Radius In Stacking Unit

The igus® chainflex® CF98 control cable solved repeated breakdowns in automated phosphorous-screen stacking units, operating in just 0.7-inch (18 mm) bending radii and enduring 300,000 cycles per month in tight spaces, eliminating downtimes that previously cost over $9,300 annually. Pre-harnessed inside an igus® energy chain, the CF98 cable now delivers uninterrupted, long-term performance, enhancing both operational reliability and cost efficiency.

Robotic cable dress packs

chainflex® robotic cables are built for multi-axis motion, handling ±180° torsion every 3 feet with millions of cycles. Dress pack solutions with triflex® energy chains keep cables secure, guided, and protected in demanding robot applications.
Reduce downtime and extend robot life with cables designed specifically for dynamic robotic environments.