End-to-End Support For Your Energy Supply Systems

From the first sketch to installation and on-site commissioning

Whether it be a conversion or new installation, custom solutions do not need to be expensive. With more than 20 years of experience in project work and more than 1,000 projects each year, we have a trusted system that makes it very easy for us to design, build, install & test custom solutions.

Our focus is to always avoid over-engineering; we believe that the simplest solution is the best solution. We consistently deliver high quality solutions for a fair price.

Conversion project or new development - comprehensive technical support from start to finish

Whether you're initiating a new digital project or upgrading an existing platform, igus® offers expert guidance throughout the entire development lifecycle. Our engineering and digital specialists work closely with you to ensure optimal performance and cost-efficiency. From initial concept design to implementation, we provide full technical support at no cost to you. Whether you're starting with a blank canvas or refining a legacy system, our team is here to help you achieve a future-ready solution.

Project planning & quotation - transparent process, fixed pricing

Once you approve the initial design concept, we move into detailed project planning. Our team will collaborate with you to define all technical and operational requirements, outlining each step necessary to implement the proposed solution.

Based on this comprehensive scope, we will provide a fixed-price quotation, ensuring clarity, cost control, and no surprises. This phase is designed to align expectations and deliver a solution that meets both performance and budgetary goals.

Project execution - precision assembly & full documentation

During the execution phase, our project team develops detailed engineering drawings and comprehensive system documentation tailored to your specifications. Upon approval, production begins at our state-of-the-art 5,500m² facility.

Each system is assembled with precision, ensuring all components are pre-configured and ready for seamless integration. A complete documentation pack, including wiring diagrams, installation guides, and maintenance instructions is provided to support efficient deployment and long-term reliability.

Delivery and assembly

Following delivery of your pre-assembled energy supply system, you can now install it with the assistance of an igus® engineer, if you wish. Or our igus installation team can take over the full installation and commissioning.

Industry: Civil / transport infrastructure

igus supplies and installs new energy chain system for Fort Augustus swing bridge

What was needed?
A new energy supply system to protect and guide electrical and hydraulic services on a continuously moving structure, replacing a worn and failure‑prone cable carrier system.

Requirements:
Compact, space‑efficient design, high durability, resistance to moisture and corrosion, smooth and quiet operation, reduced mechanical stress, and minimal maintenance in continuous daily use.

Success for the customer:
The energy chain system ensures smooth, reliable movement every time the structure operates. Secure fixing and protected routing drastically reduce wear, prevent snagging and extend service life. Supplied as a robust, pre‑engineered solution, the system minimises maintenance effort, avoids unplanned downtime and delivers long‑term operational security. By extending the life of existing infrastructure rather than replacing it, the solution also supports sustainable operation through reduced material use and fewer future interventions.

Industry: Stage technology & machinery

25 years of loyal service to London's Royal Opera House

What was needed?
New energy supply system including cables for the new LED stage lighting.

Requirements:
Space-saving design, stability and durability, lightweight (<150 kg), smooth running, minimum maintenance requirements.

Success for the customer:
With the new zig-zag system, the Royal Ballet and Opera has an energy supply that is not only reliable and familiar, but has also been perfectly adapted to the high loads in daily theatre operations. igus supplied a completely pre-fitted system consisting of box, e-chains and cables, which could be installed immediately and offers maximum operational reliability. This ensures that the lighting technology remains strong and trouble-free in use over the long term. At the same time, recycling the old energy chains via the igus Chainge recycling programme improves the company's sustainability balance.

Industry: Packaging technology

Bread packaging machine: avoid cable breaks with chainflex and smart plastics

What was needed?
E4.1L series energy chain and highly bend-resistant chainflex® cable (control cable and measuring system cable), supplied as a pre-assembled readychain® system, CF.Q isense sensors, connector concept Module Connect, drylin® W linear bearing

Requirements:
Minimum bend radius of only 63 mm, high bending strength cable, high load of up to 80 double strokes per minute.

Success for the customer:
The E4.1L is characterised by high force absorption and is used together with highly bend-resistant chainflex® cables. The i.Sense sensors with CF.Q module detect wire breaks before they occur and save the user high downtime costs.

Industry: Machine tool construction

80% less working time thanks to readychain

What was needed?
energy chain of type E4.1L, energy chain of type E4/light, both designed as pre-assembled readychain®, chainflex® cable

Requirements:
As the machine takes up just seven square metres, the chains also had to fit into a small installation space. It also had to be assembled quickly.

Success for the customer:
The pre-assembled energy chains save the customer 80% of the installation time. The first machine with the readychain® has been in operation 24 hours a day, six days a week for more than 18 months without any problems.

Industry: Agriculture

Flexible and torsionally rigid energy and signal cable technology in harvesting technology

What was needed?
ready-to-install chainflex® cable sets for power and signal transmission.

Requirements:
UV- and moisture-resistant, torsion-resistant, temperature-stable, notch-resistant & low-wear.

Success for the customer:
Time and cost savings compared to internal harnessing as well as high service life and flexible handling of the cables used.

Industry: Intralogistics

Pre-assembled cable guides for continuous use in storage and retrieval units

What was needed?
E2/000 series energy chain, chainflex® cable, ready-to-connect readycable® with HARTING industrial connectors.

Requirements:
Standardised components with the aim of procuring subsystems from a single source wherever possible; use even at temperatures as low as -30 °C in deep-freeze storage, throughput of up to 30 double cycles per hour, high availability.

Success for the customer:
The ready-to-connect systems from igus® optimise the procurement process, streamline internal logistics and reduce assembly times; special connectors enable easy handling and reliably ensure power and signal transmission even at sub-zero temperatures.

Industry: Crane

Heat and dust: reay-to-install cable carrier system for indoor crane under adverse conditions

What was needed?
Pre-assembled cable carrier for use in a heavy-duty application

Requirements:
Tight installation space, resistance to high temperatures and heavy soiling, trouble-free operation.

Success for the customer:
Quick assembly on the crane bridge by delivering the filled energy chain on transport drums. The very compact chains also do not have to be dismantled or packed for onward transport to the place of use.

Industry: Robotics

Cable guidance for pick & place robots: safely guided despite a rotating axis

What was needed?
E2 micro series energy chain, designed as a reverse bend radius energy chain and travelling in a rotation module, supplied ready assembled as a readychain®.

Requirements:
Gentle cable routing to the rotating axis with a high number of cycles, in continuous operation, with 360° rotations in less than a second, speeds of up to 7 m/s and accelerations of up to 60 m/s2.

Success for the customer:
The energy chain with reverse bend radius achieves high rotation angles and, thanks to its extremely low weight, supports the robot's high flexibility and fast movements. The failure rate of the cable leading to the A5-axis has been significantly reduced.

Industry: Automotive industry

Multidimensional triflex® energy chain allows complex movements of assembly robots

What was needed?
triflex® R energy supply systems.

Requirements:
Reliable energy supply system that also flexibly supports complex movements in all axes; movements mean strong twisting, yet the energy supply must not tear or kink; in addition, simple installation and the price-performance ratio were important to the customer.

Success for the customer:
The triflex® R offers high flexibility and cable protection for complex movements in all eleven robots, which also increases the service life; it is also impact-resistant, dirt-repellent, robust, abrasion-resistant and swarf-resistant; the modular design enables cost-saving assembly and disassembly.

Industry: Building material manufacturing

Cable guidance for dust and dirt

What was needed?
E4.1 energy chain; E4/4 energy chain; pre-assembled readychain®

Requirements:
The environment in the production of concrete and sand-lime bricks is characterised by large amounts of dirt, sand and splash water. The cable ducts therefore had to be extremely stable and reliable. Quick and easy to install systems with a high level of user-friendliness were also important.

Success for the customer:
The robust e-chain system® E4.1 and E4/4 provide the machine specialist with safety despite abrasive dust and dirt. They also have a modular design and are particularly easy to install.

Industry: Automation machine tool

Automated loading of machining centres with the help of harnessed energy chains

What was needed?
Reliable solution for the automated loading of the MH HEIDI machining centre.

Requirements:
Space-saving solution and small bending radii, high load capacity, dynamics.

Success for the customer:
Time savings during assembly, reliable machine operation in automatic mode thanks to the ready-to-install cable assembly system.

Industry: Crane

Complete smart plastics package on RMG crane

Which smart plastics technology is used?
Condition monitoring: EC.P for determining push/pull forces, EC.B for detecting chain breaks, CF.P for measuring tensile force on cables, EC.M sensor for movement data, and EC.W for measuring abrasion on the energy chain. Predictive maintenance: i.Cee:local.

Why is it used?
For maximum system protection, overview, maintenance management, product service life, and safety.

Industry: Aerial work platforms

Safe and reliable energy supply in lifting work platforms with readychain®

What was needed?
Ready-to-install cable assembly system solution.

Requirements:
Harsh environmental conditions, long unsupported length.

Success for the customer:
The ready-to-install, pre-assembled energy chains can be replaced quickly during maintenance work and no assembly work is required.

Industry: Automotive

Austrian automotive parts supplier uses smart plastics

Which smart plastics technology is used?
EC.B sensor for breakage monitoring + EC.W for measurement of the abrasion along the e-chain®.

Why is it used?
For the customer, it is important that subsequent damage to the equipment be prevented in the event of chain breakage. The EC.B module detects a breakage in the energy chain and switches the equipment off or at least indicates a fault. By means of the EC.W sensor, the abrasion along the e-chains is measured, as a result of which maintenance is predictable.

Industry: Packaging

CF.Q condition monitoring can prevent failure of machines with high output

Which smart plastics technology is used?
E4.1L e-chains® and chainflex® cables pre-assembled as a readychain, CF.Q isense sensors, Module Connect connector.

Why is it used?
The i.Sense sensors with CF.Q module detect core ruptures before they occur and save the user high downtime costs.

Industry: Crane

Complete indoor crane automation thanks to i.Sense and i.Cee

Which smart plastics technology is used?
Complete smart plastics package with i.Sense - condition monitoring and i.Cee - predictive maintenance.

Why is it used?
Real-time control over the condition of the automatic crane's energy supply system and significant reduction of the risk of failure.

Industry: Bulk handling

Safe bulk material conveying with sensor-equipped energy chain

Which smart plastics technology is used?
i.Sense EC.P for continuous monitoring of prevailing push/pull forces.

Why is it used?
In order to provide additional planning security for such dimensions, the entire cable guide is supplemented with smart plastics – intelligent sensors in combination with energy chains. Damage to the cable guide can thus be countered well before it occurs.