180° shovel loader
A reverse bend radius energy chain from igus replaces a steel chain in the shovel loader and has been running for years without maintenance or failure.
With this shovel loader, the structure can be rotated by +/-180°. The energy supply also needs to follow this movement. The use of plastic e-chains resulted in a significant increase in service life and dependability. After the changeover to an 18.5 metre long igus e-chain with reverse bend radius rotating energy supply system and chainflex cables, the system now runs strongly, reliably and maintenance-free without failure. In addition, more than half of the weight was saved – a further advantage, as the cables in the e-chain alone weigh 54 kilograms per metre. The jury therefore decided to honour this solution with the silver vector.
Profile
- What was needed: Rotating energy supply with reverse bend radius, chainflex cables
- Requirements: Heavy stress on the energy supply solution due to +/- 180° movement of the shovel loader as well as the ambient conditions; an easy-to-maintain long-lasting new solution was sought
- Industry: Mining
- Success for the customer: After many years in use, not a single failure; enormous weight savings; overall high reliability, durability, freedom from maintenance and significantly increased service life.
Problem
In this shovel loader of the National Mineral Development Corp. Ltd. in India, all system components must function strongly, reliably and maintenance-free. However, the difficult environmental conditions resulting particularly from outdoor use mean that high demands are placed on all machine parts. This also quickly became apparent with the energy chains. The steel chains used showed considerable defects after only two years, which manifested themselves in damage to the rollers, spacers and chain links. In addition, the entire energy supply system began to slip.In addition, any maintenance work meant a considerable expenditure of time. The design of the chain, for example, made it difficult to replace the damaged components quickly.
Finally, tensions in the energy chains caused the cables inside them to be damaged over time as well.
The operating company therefore had no choice but to regularly check the system for any new damage and carry out round-the-clock maintenance on all system components.
Solution
In 2010, the energy supply system was finally replaced by a rotating energy supply system with reverse bend radius from igus. The 18.5 metre long energy chain must be able to follow the 180° movement of the shovel loader completely. The system, which has now been in use for several years, has so far been operating completely without interruption, and the plant's operation has not had to be interrupted even once. The energy chain solution with reverse bend radius from igus is generally completely maintenance-free. Also decisive for the reliable functioning of the system is the significantly lower weight of 54 kilograms per metre, which is due not only to the chain itself, but also to the chainflex cables within the energy supply system. In comparison: The steel chain used before weighed about 120 kilograms per metre.Due to the high reliability, durability, freedom from maintenance and the increased service life that the system has demonstrated in the application, the operator is planning to use it in two further plants. The operating company as well as the staff very much welcomes the switch to the energy chain from igus.
