Festoon Cable System vs. Energy Chain Systems

The alternative to festoon cable systems

Traditional festoon systems leave cables hanging exposed to wind, weather, temperature changes, sand and salt, leading to tangling, wear and costly downtime. igus® e-chain® systems offer a reliable, modular alternative that protects energy, data, fibre optics, oil and air lines in one durable, low-maintenance system.

With reduced maintenance, shorter cable lengths and zero tangling, e-chains® deliver proven performance on more than 1,300 STS cranes and over 6,500 RTG/RMG and ASC cranes worldwide. e-chains® are ideal for port cranes, oil and gas applications, shore power and indoor or bulk-handling cranes.

Advantages of energy chain systems

Essentially maintenance free operation
Decreased mechanical stress on cables
No additional motors or controls required for long travels.
readychains allow for a significant reduction in required drive force
Approx. 50% less cable length required
Cables are guided with a defined bending radius at all times
Guide trough secures system from wind effects
Easily add or replace cables as needed in the energy chain
Trolley speeds of up to 32.8ft/s and travel distances of up to 2,600 ft

"There was no hesitation, no doubt in my mind, we are going to go with igus®", over a festoon system - Port of Virginia.

Alternative festoon cable system products

e-chains for cranes festoon cable system

e-chain® festoon cable carriers

Recommended products:

P4HD - e-chain® with the longest travel
P4.1 - The universal e-chain®
Guide troughs - Long travel accessories

Shop all e-chains®

chainflex® festoon cables

Recomended Products

Shop all chainflex® cables

Sensors for crane festoon system

Recomended Products

Shop all sensors for cranes

Energy chain system

In the solution with cable carriers, the cables are fed into the e-chain® in the middle of the travel. The e-chain® is pushed or pulled to halfway.

Festoon cable system

In a festoon cable system, the cables are attached at the end of the travel and the cable loops are pulled all the way by the cable trolley.

Case Study: of a cable festoon system at a 100m plant

Energy chain system

Cable lengths/space requirements

About 50% less cable
Approx. 800mm system height
About 10% less structural steel (festoon cable system)

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/sec2 .

Secure cable guidance
Cables are safely guided in the energy chain and cannot get caught anywhere.

Festoon cable system

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 cable systems reach their limits at speeds of 240m/min. and accelerations of more than 0.8m/sec.

Secure cable guidance
Cables hang uncontrollably and may get caught in the crane structure (e.g. by wind).

Successful applications

Bulk handling crane with durable energy chain

On 441 metres travel with a max. acceleration of 01m/sec², a motor cable drum 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.

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 chain 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.