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The alternative to cable festoon systems: energy chain systems

With festoon systems, the cables hang unprotected on cranes in wind and weather. The cables themselves and the festoon systems 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 festoon systems on cranes, which helps you save cable length and avoid downtime. Energy, data, fibre optics, oil and air are safely managed in one system. More than 1,300 STS and over 6,500 RTG/RMG ASC cranes have been fitted with energy chains.
 
Would you like more information about our energy chains? Our experts will be happy to get in touch with you.
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Energy chain system in cranes

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

We have compared energy chain systems and festoon systems at a 100m plant:

Energy chain systems

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 halfway.


Cable lengths/space requirements
  • About 50% less cable (52m cable length with centre-fixed installations and approx. 100m travel)
  • Approx. 800mm system height
  • About 10% less structural steel (for the cable festoon)

Influencing the crane girder construction
No cable station required
Dynamic parameters
Rolling energy chains can be operated at a speed of over 600m/min and with an acceleration of over 2m/sec .
Secure cable guidance
Cables are safely guided in the energy chain and cannot get caught anywhere.

Cable festoon systems

cable festoon systems

In a festoon 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
Festoon 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).

 


Energy chain systems recommended by us

E4.1 system

E4.1 system festoon system High loads, long unsupported lengths and also for sliding applications.
Find out more

E2/000 system

E2/000 system festoon system The all-rounder for unsupported applications. Cost-effective.
Find out more

System 4040R/5050R

System 4040R/5050R festoon system Travels up to 800m possible. Speeds up to 6m/s possible. 
Find out more

System 4040HD/5050HD

System 4040HD/5050HD festoon system Very high stability. High tensile stability (20% higher tensile strength than in 4040 series). Standard for long travels.
Find out more

P4.1 system

P4.1 system festoon system Travels of more than 1,000m.  Speeds of more than 5m/s.  Low vibration and noise thanks to split profile roller
Find out more

Predictive maintenance

Predictive maintenance festoon system Defects are detected before they occur, unscheduled downtime and failures are avoided.
 
Find out more

White paper: efficient energy supply systems for cranes in steel plants

Plastic energy chains compared to festoon systems

In this white paper, you can find the following topics:

  • Advantages and disadvantages of energy chain systems and festoon systems for steelworks cranes
  • The most innovative solution for cranes for steel plants
  • Future technologies: roller energy chains
Download now

Related products

readychain®

readychain Ready-to-install harnessed energy supply systems
Find out more

energy chains

energy chains Guide and protect your cables and hoses
Find out more

chainflex®

chainflex Flexible cables for moving applications
Find out more

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

The new heavy-duty rol e-chain meets all the relevant requirements for container cranes of the next and future generations.Longer and longer travels, greater dynamics, short stress cycles, zero failures: in brief, this is what is demanded by the manufacturers of ship-to-shore container cranes for energy chains on the crane bridges. The new P4HD.56R fulfils these requirements - with maximum economy.
Ask for a free sample now

Selected application examples


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Consulting

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The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "igutex", "kineKIT", "manus", "motion plastics", "pikchain", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsubishi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention on this website. The products offered by igus® are those of igus® GmbH