Ultraquiet roller energy chain

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".

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 rol e-chain in use amounts to 125m at a speed of up to 2.5m/s. The special feature: integrated rollers in the chain links ensure smooth and low-friction running of the entire system. The rollers are integrated into the links of the chain and not additionally moved, nor do they need to run through specified openings in the guide trough. Therefore, they cannot get caught on the crane or the guide trough. Using a rol e-chain also reduces the required drive power of the energy chain by around 75%.

In addition to the type-4040-CR rol e-chain, a 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.

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.

Last but not least, igus has also further developed its rol e-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 rol e-chain "P4", runs much more smoothly and is therefore quieter 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 future without any problems.