Ultraquiet roller energy chain

Contargo AG relies on energy chain from igus® in the container crane

In the container harbour in Basel, a plastic roller energy chain from igus® ensures quiet and at the same time very low-maintenance operation of the harbour crane. Noise emissions in particular were a challenge that had to be overcome when the crane was built more than ten years ago due to its proximity to a German residential area. Even after many years in operation, the solution continues to impress the terminal operators - and is easy on the nerves of local residents.

Problem

The functionality and reliability of container cranes in particular are crucial, as they ensure the entire operation of container ports. But port terminals can also pose other special challenges: In the case of Contargo AG's container terminal in Basel, for example, residential areas are in close proximity to the business operations. This is the reason for the high noise regulations imposed on the harbour crane and therefore also on central components such as the energy chain. Sven Zöller, Terminal and M&R Manager at Contargo AG, recalls: "As a Swiss company, we were faced with the challenge of complying with the noise emissions for the German residents, which was not easy".

Solution

In 2003, the customer therefore decided in favour of a type 4040 CR energy chain system made of plastic from igus® for the container crane at the North Terminal. The travel of the roller energy chain used is 125 metres at a speed of up to 2.5 m/s. The special feature: Integrated rollers in the chain links ensure that the entire system runs smoothly and with low friction. As the rollers are integrated into the chain link of the chain and do not have to be additionally moved and swivelled or run through openings provided in the guide trough, they cannot get caught on the crane or the guide trough. The required drive power of the energy chain is also reduced by around 75 per cent through the use of a roller energy chain.

In addition to the roller energy chain type 4040 CR, various chainflex® cables from igus® are also used in the system, which have been specially designed and constructed for the movements in e-chain®. Single core, control, motor and bus cables as well as fibre optic cables were also used. This is because very fast and secure data transmission is essential in container terminals with a high degree of automation.
After TÜV Süd had confirmed compliance with all regulations by means of a noise test, a similar system was finally used on another crane with the same noise requirements.

"The system is very easy to maintain, we only carry out a visual inspection at regular intervals. There are no parts on the energy chain that need to be replaced at regular intervals"

Sven Zölle, Manager Terminal and M&R, at Contargo AG in Basel

Unrivalled energy chain

In addition to the energy chain system from igus®, alternative energy supply solutions were also considered during the planning phase. However, festooning could not be realised for several technical reasons. Firstly, the thick cable strands would have protruded too far into the public space under the crane. It would also not have been possible to relocate the cable station required for a festoon to the other side of the crane, as the installation would have been suspended directly above the water.

Looking to the future

Everything has been running smoothly at the North Terminal in Basel for several years now. "We only had one breakdown in 2015. And it wasn't due to the chain," confirms Sven Zölle. "The system is very easy to maintain, we just carry out a visual inspection at regular intervals. There are no parts on the energy chain that need to be replaced at regular intervals."

Roller energy chain P4 - the latest generation

igus® has also further developed its roller energy chains, not least due to the ever-increasing requirements such as higher speeds and accelerations during cross-travelling, increased environmental requirements and maximum system availability. The fifth generation, the roller energy chain " P4 ", is even smoother running and therefore quieter and has a significantly longer service life than the energy chain used at the North Terminal. As two profile rollers on the upper run do not run exactly on the lower run, but are offset, the pair of rollers on the upper run roll past those on the lower run, which means that the rollers run smoothly on a continuous surface over the entire journey. Shocks and vibrations are eliminated, protecting the chain. This means that the system's high expectations in terms of service life and noise level can also be easily met in the future.

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