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The alternative to cable trolley systems: energy chain systems


 

With cable trolley systems, also known as festoon systems, the cables "hang" from the cranes, unprotected against wind and weather. The cables themselves and the cable trolleys are exposed to varying temperatures as well as sand and salt (at outdoor facilities). The wind often lets the cables get tangled, which quickly results in downtime. igus offers a reliable and modular alternative to cable trolley systems on cranes, which helps you save cable length and avoid downtime.

White paper: efficient energy supply systems for cranes in steel plants

Plastic energy chains compared to cable trolleys

In this white paper, you can find the following topics:

  • Advantages and disadvantages of energy chain systems and cable trolleys for steelworks cranes
  • The most innovative solution for cranes for steel plants
  • Future technologies: roller energy chains

Download white paper now

Advantages of energy chain systems on cranes

Tech up, Cost down. It's our job.

Tech up

Tech up

  • Save over 50% of the cable length with energy chain systems
  • Reduce the load of the cable with a predefined bend radius
  • Save steel construction for loop stations
  • Save cable weight
  • Energy, data, FOCs, oil, and air guided in a single system

Cost down

Cost down

  • Approx. 50% less cable compared to cable trolleys
  • No additional mechanical stress of the cable
  • Savings on steel structure
  • Virtually maintenance-free

Proof

Proof

  • More than 80% of all RTG/RMG and ADC cranes are equipped with e-chains
  • More than 50% of all cranes have been adapted from festoons to e-chains
  • More than 1,300 STS and over 6,500 RTG/RMG ASC cranes are equipped with energy chain systems

Sustainability

Sustainability


What are the differences between energy chain systems and cable trolley systems?

We have compared energy chain systems and cable trolleys at a 100m plant:

Energy chain systems

Energy chain systems

In the solution with energy chains, the cables are fed into the e-chain in the middle of the travel. The e-chain is pushed or pulled to halfway.
 


Cable lengths/space requirements
  • About 50% less cable (52m cable length with centre-fed installations and approx. 100m travel)
  • Approx. 800mm system height
  • About 10% less structural steel (for the cable festoon)

Influence on the crane girder construction
No cable festoon required
Dynamic parameters
Rolling energy chains can be operated at a speed of over 600m/min. and with over 2m/sec. acceleration.
Secure cable guidance
Cables are safely routed in the energy chain and cannot get caught anywhere.

Cable trolley systems

Cable trolley systems

In a cable trolley system, the cables are attached at the end of the travel and the cable loops are pulled all the way by the trolley.


Cable lengths/space requirements
  • Approx. 115m cable (115% travel length) for 100m travel
  • About 3,500mm length for the "cable loops", system height approx. 5,000mm
     
     

Influence on the crane girder construction
Cable festoon is required
Dynamic parameters
Cable trolley systems reach their limits at speeds of 240m/min. and accelerations of more than 0.8m/sec.2 
Secure cable guidance
Cables hang uncontrollably and may get caught in the crane structure (e.g. by wind).

 


White paper: efficient energy supply systems for cranes in steel plants

Plastic energy chains compared to cable trolleys

In this white paper, you can find the following topics:

  • Advantages and disadvantages of energy chain systems and cable trolleys for steelworks cranes
  • The most innovative solution for cranes for steel plants
  • Future technologies: roller energy chains

Download white paper now

Energy chain systems recommended by us

E4.1 series

E4.1 series

High loads, long unsupported lengths and also for sliding applications.

E2/000 series

E2/000 series

The all-rounder for unsupported applications. Cost-effective.

4040R/5050R series

4040R/5050R series

Travels up to 800m possible. Speeds up to 6m/s possible. 

4040HD/5050HD series

4040HD/5050HD series

Very high stability. High tensile stability (20% higher tensile strength than in 4040 series). Standard for long travels.

P4.1 series

P4.1 series

Travels of more than 1,000m.  Speeds of more than 5m/s.  Low vibration and noise thanks to split profile roller

Predictive maintenance

Predictive maintenance

Defects are detected before they occur, unscheduled downtime and failures are avoided.

chainflex cables

chainflex cables

Designed for use in energy chains. Numerous types of cable with different approvals and certificates of conformity.

readychain harnessing

readychain harnessing

Ready-to-install e-chain systems and pre-assembled cables for your machines. No minimum order quantity, delivery in 1 to 10 days!


Selected application examples


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The terms "igus", "Apiro", "CFRIP", "chainflex", "conprotect", "CTD", "drygear", "drylin", "dryspin", "dry-tech", "easy chain", "e-chain", "e-chain systems", "e-loop", "e-ketten", "e-kettensysteme", "e-spool", "e-skin", "flizz", "ibow", "igear", "iglidur", "igubal", "kineKIT", "manus", "motion plastics", "pikchain", "plastics for longer life", "print2mold", "readycable", "readychain", "ReBeL", "robolink", "speedigus", "tribofilament", "triflex", "xirodur" and "xiros" are legally protected trademarks of the igus® GmbH/Cologne in the Federal Republic of Germany, and, where applicable, in some foreign countries.
igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsubishi, NUM, Parker, Bosh Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mentioned on this website. The products offered by igus® are those of igus® GmbH.