Ultraquiet roller energy chain

Problem

Functionality and reliability are crucial, especially for container cranes, since they ensure the entire operation of container ports. But port terminals can also pose other special challenges: in the case of the container terminal of Contargo AG in Basel, for example, residential areas are in the immediate vicinity of business operations. This explains the strict noise regulations that are imposed on the port crane and thus also on central components, such as energy chains. Sven Zöller, Manager Terminal and M&R at Contargo AG remembers: "At the time, as a Swiss company, we saw ourselves faced with the challenge of complying with regulations concerning noise emissions in the proximity of German residents, which was not easy".

Solution

In 2003, the customer therefore opted for a plastic type-4040-CR energy chain system from igus for the container crane of the North Terminal. The travel of the roller energy chain in use amounts to 125 metres at a speed of up to 2.5m/s. The special feature: integrated rollers in the chain links ensure a smooth and low-friction running of the entire system. Since the rollers are integrated into the links of the chain and not additionally moved, or needed to run through specified openings in the guide trough, they cannot get caught on the crane or the guide trough. Using a roller energy chain also reduces the required drive power of the energy chain is also reduced by around 75%.

In addition to the type-4040-CR roller energy chain, a wide variety of chainflex cables from igus are used in the system, which have been specially designed and constructed for movements in e-chains. As very fast and secure data transmission is essential in container terminals with a high degree of automation, single-core, control, motor, bus and fibre optic cables were also used.
After TÜV Süd confirmed compliance with all regulations by means of a noise test, a similar system was installed on another crane with the same noise requirements.

Unrivalled energy chain

In the planning phase, alternative energy supply solutions were also considered in addition to the energy chain system from igus. However, it was not possible to implement festooning for various technical reasons. First, the thick cable harnesses would have protruded too far into the public space under the crane. However, it would also have been impossible to move the cable station required for festooning to the other side of the crane as the construction would have been suspended directly over the water.

The roller energy chain of the P4 system is characterised by its particularly smooth operation and long service life.

Roller energy chain P4 - the latest generation

Last but not least, igus has also further developed its roller energy chains due to the increasing requirements, such as higher speeds and accelerations for trolley travel, stricter environmental requirements and maximum system availability. The fifth generation, the [Link pagenr="5666" title="roller energy chain "P4""], runs much more smoothly and is therefore quieter and more durable than the energy chain used at the North Terminal. Since the two profile rollers on the upper run do not run exactly on the lower run, but offset, the roller pair of the upper run rolls past that of the lower run, which means that the rollers run smoothly on a continuous surface over the entire travel. Shocks and vibrations are eliminated, which protects the chain from damage. This means that the high expectations in terms of system service life and noise level can also be met in the future without any problems.