With the cable reel, igus offers a robust solution for the power supply in lorry trailers – without slip ring, space-saving and for universal use

A faulty power connection on a lorry ramp can bring the entire logistics process to a standstill. Cable reels with slip rings are a common weak point. With the e-spool flex, igus is launching a new type of solution that does not require slip rings (which are susceptible to faults) and allows for a reliable power supply – even under harsh conditions.

A lorry reverses onto the ramp of a logistics centre. The driver lowers the tail lift, connects the trailer to the external power connection – but the lighting in the interior stays off. The problem: the cable reel is defective, unloading is delayed and keeping to the schedule becomes a challenge. “Cable reels are standard, especially in loading bays, but they are also a weak point,” explains Michael Ditz, Product Manager Energy Chains at igus. The slip rings in particular are a weak point. The rotating contacts ensure the current flow between the stationary connection and the rotating cable during winding and unwinding. Corrosion and mechanical wear can repeatedly lead to failures. To make the power supply more reliable, igus has developed the e-spool flex, which is particularly fail-safe thanks to its crafty design.

No slip ring, compact and flexible
What sets the e-spool flex apart from conventional cable reels is that it does not require a slip ring and works with just one cable, without being split in two and without interruption. A spiral guide on the inside of the cable reel ensures that the cable does not twist during unwinding and rewinding. Users insert a few metres of the cable end into the grooves of the guide. They wind up the remaining length and insert the cable reel into a housing that can be screwed on at various positions. The cable connector always remains in position and can be attached to the trailer electronics, such as lighting, air conditioning or ventilation. When the lorry driver finally pulls on the cable, it can unwind thanks to the spiral guide without the connector rotating. The power supply at the loading ramp is therefore no longer susceptible to faults as no functionally relevant components are used that could corrode.

Confirmed in the test laboratory: e-spool flex impresses with its long service life
Furthermore, tests in the 5,500m2 igus laboratory in Cologne have shown that the system achieves a service life of around 10,000 cycles. With two loading or unloading processes per day, 365 days a year, this corresponds to a service life of around 14 years. The higher investment costs compared to a simple cable reel pay off quickly thanks to the durability and reliability of this product. igus offers the e-spool flex in different versions to meet the requirements of a wide range of applications. It is suitable for cables with diameters of 5 to 15mm and extension lengths of between 5 and 25m. Depending on the requirements, hand cranks or automatic reeling devices with retaining spring, snap mechanism and retraction brake are available for winding. In times when pressure on logistics is increasing, roads are getting fuller and loading and unloading processes are becoming more time-critical, cable reels without slip rings can help ensure that lorry trailers work more reliably and unplanned downtimes are reduced.

In addition to the e-spool flex cable reel, igus also offers other energy chains, plain bearings and linear guides that increase functional reliability at many points in and on the vehicle that are prone to failures. You can find more information here: https://www.igus.eu/industry/commercial-vehicles