GUEST COLUMN | IGUS
ELEVATING INDOOR CRANE & HOIST OPERATIONS WITH ADVANCED CABLE MANAGEMENT SYSTEMS
Exploring how modular cable carriers made from engineered plastics support automation efforts while withstanding harsh operating conditions in crane applications. By Rob Mammone and Dan Thompson, product managers, igus, based in Rhode Island.
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exception. Remote operation, advanced safety features and integration with Industrial Internet of Things (IIoT) technologies are just some of the benefits you can expect when you integrate these traditionally manual machines with new, cutting-edge automated systems. Keep in mind, however, that the addition of sensors, controllers and communication networks increases the already lengthy list of demands placed on crane cable management systems. Not only must these devices be able to efficiently organize a wider variety of cable components, but they must also prioritize safe and reliable operation despite the harsh operating conditions associated with crane and hoist applications. Let’s explore how modular cable carriers
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made from highly engineered plastics can successfully support automation while addressing the typical challenges associated with crane operation — specifically, indoor and electric overhead traveling (EOT) cranes in production plants. We’ll also discuss the ways these technologies offer a compelling alternative to festoon cable systems, overhead crane busbar systems and cable reels.
utomation is transforming machines from all corners of the manufacturing world — and cranes and hoists are no
THE DRAWBACKS OF TRADITIONAL FESTOON AND BUSBAR SYSTEMS Although they have their place, festoon and busbar systems have limitations when it comes to efficient, reliable cable management in many crane applications. In traditional festoon systems, cables and hoses hang unprotected on the crane. Able to swing freely, they’re prone to tangling or getting caught on the structure, leading to downtime and costly repairs. In outdoor facilities, cables also face wind, weather, varying temperatures, sand, salt and other adverse conditions. In addition, festoon systems require regular maintenance to lubricate the cable trolleys and ensure the motors, shock cords, tow ropes and other parts are operating wear-free. Because the cables are clamped in bunches at each trolley, adding or replacing cables is also a time-consuming hassle. In addition to their high maintenance
requirements, festoon systems consume a lot of space on the crane rail, requiring roughly 115 percent of the travel length in cable and limiting the amount of crane travel. Electrical busbar systems, which supply
power to the crane via metal conductor bars, are even more labor-intensive than festoon systems, requiring regular inspection and maintenance.
For example, personnel must regularly inspect and replace the collector shoes installed on the collector arms once they wear out, requiring the entire system to be powered down. Despite their complexity, busbar systems
are also limited in their functionality. Each conductor requires its own conductor bar and collector, meaning it’s usually not feasible to install more than eight conductor bars on a single system. For this reason, busbar systems are limited to power and control cables only, with additional cables and hoses requiring guidance by a separate system.
MODULAR, COMPACT AND INNOVATIVE CABLE CARRIERS Modular cable carriers, or energy chains, made from highly engineered plastics overcome the various challenges faced by traditional festoon and busbar systems in indoor and EOT crane applications. An example is the igus e-chain system, in which the cables are fed into the e-chain in the middle of travel. The e-chain is then pushed or pulled halfway. These modular systems can accommodate energy, data, air and liquids all in the same energy chain, enabling them to accommodate Ethernet, sensors, camera systems and other IIoT technologies and supporting plant owners in their automation efforts. Here’s a rundown of some of the additional benefits of e-chain cable management systems: Space savings. Modular cable carriers require roughly 50% less cable and
x | October 2024 | Dockside Lift & Move Supplement
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