The alternative to cable trolleys: energy chain systems

In cable trolleys, also known as cable trolleys, the cables hang unprotected from cranes in wind and weather. The cables themselves and the cable trolleys are exposed to fluctuating temperatures as well as sand and salt (in outdoor installations). Wind can easily cause the cables to become entangled, which can quickly lead to downtime. igus® offers a safe and modular alternative to cable trolleys on crane systems, which allows you to save cable length and avoid downtime. Energy, data, fibre optic cable, oil and air are safely routed in one system. More than 1,300 STS and over 6,500 RTG/RMG ASC cranes have been equipped with energy chain.

Free white paper:

white paper: Efficient energy supply systems for steelworks cranes

plastic-energy chain in comparison to cable trolleys

In this white paper you can find the following topics:

Advantages and disadvantages of energy chain systems and festoon systems for steel mill cranes
The most innovative solution for steel mill cranes
Technological outlook: Roller energy chain

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What is the difference between energy chain systems and festoon systems?

We have compared energy chain systems and cable trolleys on a 100 m system:

Energy chain systems

With the energy chain solution, the cables are fed into the e-chain® at the centre of the travel path. The e-chain® is pushed or pulled halfway along the route.

Cable lengths/space requirement

Approx. 50 % less cable (52 m cable length with centre-fixed and approx. 100 m travel)
Approx. 800 mm system height
Approx. 10 % less steel construction (for the cable station)

Influence on the crane support structure
No cable station required

Dynamic parameters
Rolling energy chains can be operated at over 600 m/min. speed and with over 2 m/sec2 acceleration.

Safe guidance of the cable
cables are safely guided in the energy chain and cannot get caught at any point.

Cable trolley

With a cable trolley system, the cables are attached at the end of the travel path and the cable loops are pulled along the entire path by the trolley.

Cable lengths/space requirement

Approx. 115 m cable (115 % travel length) for 100 m travel
Approx. 3,500 mm length for the " "cable loops", system height approx. 5,000 mm

Influence on the crane support structure
Cable station is required

Dynamic parameters
Cable trolley systems reach their limits at speeds of 240 m/min. and accelerations of more than 0.8 m/sec2.

Safe guidance of the cable
Cables hang uncontrolled and can get caught in the crane structure (e.g. due to wind).

For maximum service life with optimised design - P4HD.56R heavy-duty roller chain

The new heavy-duty roller chain fulfils all the requirements that apply to container cranes of the next generation and beyond.
Ever longer distances, higher dynamics, short load cycles, zero failures: That, in a nutshell, is what manufacturers of ship-to-shore container cranes demand for energy chain on crane bridges. The new P4HD.56R fulfils these requirements - with maximum cost-effectiveness.

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Energy chain systems recommended by us

E4.1 system

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

About the E4.1 system

E2/000 system

The all-rounder for unsupported applications. Favourably priced.

To the E2/000 system

System 4040R/5050R

Travelling distances up to 800 m possible. Speeds of up to 6 m/s possible.

To the 4040R/5050R system

System 4040HD/5050HD

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

To the 4040HD/5050HD system

P4.1 system

Travelling distances over 1,000 m. Speeds of more than 5 m/s. Low vibrations and travelling noise thanks to split profile roller

To the system P4.1

Predictive maintenance

Defects are recognised before they occur, downtimes or unplanned outages 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, delivered in 1 to 10 days!

To readychain

Selected application examples

Bulk handling crane with durable energy chain
On 441 metres travel with a max. acceleration of 01m/sec², a motorised cable reel 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.

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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.