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Safe energy supply for seamless scene changes

In the Hungarian State Opera, zig-zag systems ensure a smooth podium travel

After almost five years of extensive renovation, the Hungarian State Opera in Budapest celebrated its reopening in 2022 - with numerous new stage platforms and state-of-the-art stage technology on 324 square metres. The main stage riser system, implemented by Bosch Rexroth, uses igus zig-zag energy supply systems. Pre-fitted e-chains from the E4.42 series, fitted with flexible chainflex cables, ensure a reliable power and data supply to the riser systems - in a space-saving and cost-efficient manner.

Hungarian State Opera in Budapest, auditorium

Profile

  • What was needed: A reliable energy supply system for the electrically operated platform components
  • Requirements: Space-saving design, stability and durability, defined bend radius, expandability for future upgrades, possibility of separating the various cables within one and the same chain
  • Industry: Stage technology, stage machinery
  • Success for the customer: With the zig-zag system, the cables are guided safely within a defined bend radius. The chainflex cables, specially developed for moving applications, guarantee permanently reliable power, control, signal and data transmission. The system was designed and supplied precisely to the customer's requirements. Thanks to its compact and modular design and the option of routing several cable groups within a single chain, the system offers a cost-efficient solution.

Products used

Zig-zag energy chain system
Zig-zag energy chain system
e-chain E4.42 series
e-chain E4.42 series
chainflex control, servo, motor and data cable
chainflex control, servo, motor and data cable

Problem

As part of the extensive renovation work on the listed opera house, Bosch Rexroth was awarded the contract to build the main stage riser system. This includes six new 12 x 3 metre stage platforms that move up to 6 metres high at a speed of 0.5 metres per second. They make it possible to set up stage sets for upcoming scenes in advance, significantly reducing the transition time and ensuring a seamless performance.

The designers were looking for a suitable system that would ensure safe guidance of the many cables for energy, control, signalling and data transmission during the podium travel - in an area that must not be entered during the performance.

The previous stage platforms had used cables with leather jackets - a solution that was susceptible to damage and could not guarantee safe bending conditions. Maximum operational safety was now required for the new system. Any risks such as a defective cable or a blocked guide mechanism, which could immediately stop the stage automation and interrupt the performance, had to be ruled out.

Solution

The zig-zag energy supply system is the perfect solution here. The advantage: the cables are not kinked, but are guided safely within a defined bend radius. If a cable is damaged over the years or a technical change is required, the energy chain can be opened with little effort and the appropriate cable replaced or added. With the zig-zag system, the e-chain is stored in a special guide box. When the stage element is lifted, the underlying chain unfolds automatically, and when it is lowered, it zig-zags again.

Two boxes are used per stage podium, equipped with energy chains of the E4.42 series as well as chainflex control, servo, motor and data cables. Up to 48 cables are contained in one chain. It was important to Bosch Rexroth to guide the igus cables separately from other special cables. Instead of two separate energy chains, igus offers a lean and cost-saving solution with a middle side link within one and the same chain.

The complete energy supply system was planned, dimensioned and supplied by igus as a ready-to-install solution, which significantly reduced the installation time and costs. Since its installation, it has been working trouble-free and ensures long-term operational reliability in the theatre.

Zig-zag system at the Hungarian State Opera

With the zig-zag system, Bosch Rexroth has implemented a reliable cable guide system for the moving stage platforms in the Hungarian State Opera. The chain unfolds when the stage is raised and then zig-zags back into a guide box as it moves in the opposite direction.

Zig-zag system at the Hungarian State Opera

Each of the six stage platforms is equipped with two zig-zag boxes. The platforms can be raised up to 6 metres at a speed of 0.5m/s.

Zig-zag system at the Hungarian State Opera

An e-chain moves up to 48 cables. A middle side link allows the chainflex cables to be guided separately from the customer cables in a chain. This eliminates the need for a separate energy supply system and significantly reduces the cost of the system.

Zig-zag system at the Hungarian State Opera

Everything from a single source: The complete system with guide box, energy chain and cable package was designed by igus and delivered ready for installation.

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