Bucket wheel excavator: Increased efficiency in bulk goods handling

Profile

What was needed: Ready-to-connect energy chain system incl. assembly
Requirements: Compact design, optimised cable management, high reliability, reduction of downtimes
Products: e-chain® series E4.80, chainflex® CF300, CF34, CF9, CFLG.G
Industry: bulk handling
Success for the customer: Joint development for the most efficient design, optimisation of cable management for swivel operation and space requirements for future automation

Application:
One of our bulk handling customers was upgrading their bucket wheel excavator with a new chute system and the harbour engineers were faced with some design challenges. The existing dynamic cable management system for the slewing operation needed to be reconfigured to create more space for the chute system and to accommodate more data cables for future automation. They turned to igus® to find a heavy-duty and reliable solution.

The challenge

We were faced with the challenge of supplying a mobile cable management system in a marine environment in the coal industry. The system needed to be modular to allow removal for other maintenance components of the stacker reclaimer, such as the main slewing ring bearing. The system needed to operate with higher reliability than the existing system and have minimal downtime for maintenance.

The igus® project engineering team from the USA and Germany made several site visits to gain a comprehensive understanding of the electrical and mechanical operations of the Stacker Reclaimer.

Solution

igus® developed a turnkey energy chain solution comprising the energy chain, chainflex®-cable and a customised stainless steel cable tray system with the exact dimensions of the bucket wheel excavator. The existing cable management system was relocated from inside the bucket wheel excavator to the outside of the main housing to create more space for the new cable tray system and better access for routine maintenance. The open stainless steel pipe guide channel system allows stones, pellets and dust to fall through the guide system. The cable carrier system operates without a machine stop 24/365. igus® chainflex® cables were selected to work for many years in a harsh environment.

With the customer's technical approval, igus® manufactured the entire energy chain system and was on site with factory-trained personnel for installation and commissioning. Close co-operation with the local mechanical and electrical contractors was crucial to ensure that the system was installed correctly.

We have subsequently carried out several further retrofits to the other stacker reclaimer at this coal terminal.
The first system was installed in 2011 and has been in continuous operation ever since.

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