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Pre-assembled energy chain systems for gantry crane system in scrap handling

New e-chain® in the bulk goods crane proves itself under harsh operating conditions in daily use

Initially, scepticism prevailed. Today, however, the harbour operator is happy that his bulk goods crane for scrap handling is equipped with an energy chain solution. Despite the very harsh operating conditions, his system has been running for over two years in all weathers without any complaints. And when a new investment is due, the company is certain that it will once again choose a crane with a preassembled energy supply system including a robust stainless steel trough system.

Profile

A crane grab lifts scrap metal in a scrapyard.

Problem

At the Rhine port of Kehl, the Künz crane is used to transfer scrap of various qualities from railway wagons to the storage yard. From here, it is later transported by ship to the steelworks. The crane system, which is equipped with either a clamshell grab, a polyp grab or a magnet depending on the requirements, places high demands on the technology. Unlike container handling, the crane is constantly subjected to very strong vibrations when the scrap is torn loose. For example, T-beams or other coherent lumps of scrap protrude from the grab. In addition, it is permanently overloaded. The entire crane is constantly under load. Both the energy supply system and the guide trough have to withstand strong and extremely strong vibrations without being damaged. This can even lead to deformations that have to be constantly equalised.
The crane system is in use at all times of the year," explains master electrician Uwe Woltersdorf. "This means that it has to withstand all temperature fluctuations

Solution

Pre-assembled "Ready-Chain" energy supply systems are used in the bulk goods crane over a distance of 109 metres. Specifically, this is the"4040RHD" roller energy chain, which can be opened on both sides and is particularly suitable for heavy-duty outdoor use. The infeed point of this system is located in the centre of the travel path. In addition, robustly shielded"chainflex®" special cables guarantee functional reliability, namely single cores for the power supply as well as control, bus and fibre optic cables. Its TPE outer jacket covers temperature ranges from -35 to +100 °C and therefore fulfils all weather-related requirements 365 days a year. The
scope of delivery also includes corrosion-free stainless steel guide troughs, which are designed to support the smooth and low-friction running of the energy chain. Other special solutions round off the overall system: a customised housing protects the chain and cable from extreme weather conditions. And a floating moving end provides the necessary tolerance compensation from the chain system to the trolley. This ensures the greatest possible protection.

"We had considerable problems with the loose-hanging festoonings in particular when routinely replacing the cables, which meant that the entire system was down for long periods of time. And the crane systems with conductor rails kept breaking down from time to time."

Uwe Woltersdorf, Electrician, Kehl harbour administration

Industrial bridge over a waterway with steel beams and a cable tray.
Cable carrier system under a steel structure in an industrial facility.

Delivered, installed, operational

The collaboration between the harbour operator Kehl, the crane manufacturer Künz and the energy chain supplier igus® worked very well during the project planning and construction phase. "The specific installation situation was clarified on site in consultation with us," reports Uwe Woltersdorf. "We also received detailed drawing documentation from igus®." The pre-assembled energy supply system arrived at the construction site exactly on the agreed date and was installed under the direction of the crane builder. The electrical acceptance was then carried out with the involvement of the operator in cooperation with the energy chain supplier and the crane builder. "The installation quality was perfect," says the master electrician. "The energy chain system worked immediately."
As the company cannot and does not want to afford downtimes, the next crane will probably be equipped with another energy chain system. Uli Stichler: "Their technical and economic advantages have convinced us so far. And as we also expect a long service life based on our experience, the decision in favour of this energy supply solution has definitely paid off for us."

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