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

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

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

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

Have your energy chains processed as part of the igus chainge recycling programme no matter which manufacturer they came from
igus supports the circular economy for plastics and is investing in chemical recycling

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

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.² acceleration.

Secure cable guidance
Cables are safely routed in the energy chain and cannot get caught anywhere.

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

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

To E4.1 series

E2/000 series

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

To E2/000 series

4040R/5050R series

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

To 4040R/5050R series

4040HD/5050HD series

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

To 4040HD/5050HD 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

To P4.1 series

Predictive maintenance

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

To the systems for predictive maintenance

chainflex cables

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

To the chainflex cables

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!

To readychain

Selected application examples

Approx. 15 years ago, RTG, STS, RMG and ASC cranes were equipped almost to 100% with festoons for the supply of the crane's trolley.
Today, more than 80% of all RTG/RMG and ADC cranes are equipped with e-chains. More than 50% of the STS cranes have been adapted from festoons to e-chains. In the last 15 years, igus alone has equipped more than 1,300 STS and over 6,500 RTG/RMG ASC cranes with energy chain systems.

Bulk handling crane with durable energy chain

On 441 metres travel with a max. acceleration of 01m/sec², a motor cable drum and thus slip rings were used for the main power and data supply. Due to the high maintenance requirements, the operator opted for a new roller energy chain and fail-safe chainflex cables. This arrangement is not only simpler, safer and more secure than the motorised cable drum previously used, it also facilitates the supply of data via fibre optic cables.

Go to complete user report

Customised solution for STS cranes

This STS application is exposed to strong wind and consequently requires an energy supply that reliably withstands such conditions. For the customer, it was important that the cables were safely and securely guided in a controlled manner at all times, despite the double boom pivot point. igus designed and tested a customised solution that was subsequently installed together with the crane manufacturer: now, a P4 energy supply and a range of chainflex cables from igus are in use; these guide cables at a speed of up to 240m/min. over a travel of 117 metres.

More than 10 years of trouble-free use

With this RTG crane, the e-chain system from igus has been working trouble-free for more than 10 years, without even one component of the energy chain having to be replaced. With a travel of 19.2m and a speed of 70m/min and an acceleration of 0.7m/sec², the system keeps its promises: reliable cable guidance. The energy chain guides a range of chainflex cables which were developed specifically for moving applications.