High demands on the second-largest sea lock in the world

The operators of the Wilhelmshaven sea lock rely on e-chain systems from igus®

Absolute reliability under difficult conditions is crucial for the operation of key structures such as locks and bridges. For many years, cable carrier systems from igus® have proven their reliability day after day. This is also the case at the sea lock in Wilhelmshaven. Energy supply systems from igus® have been used in the second largest sea lock in the world for over 10 years. Special challenges such as the exposed sea location, requirements for dyke protection and reliable 24-hour continuous operation have to be mastered.

Profile

What was needed: Cable routing at the four lock gates
Requirements: continuous operation 24 hours a day, seawater resistance, long travel time
Industry: Locks and docks
Success for the customer: minimised operation and maintenance, trouble-free operation even after more than 10 years of use

Problem

The Wilhelmshaven sea lock - the second largest sea lock in the world - is a double lock with a chamber length of 390 metres and a width of 60 metres. It is the only access to Wilhelmshaven's inner harbour, which is exclusively drained via this lock.
The navy is also dependent on the lock being available day and night. The high logistical importance and the associated 24-hour operation place the highest demands on system availability.
In particular, it was necessary to ensure a constant supply of energy to the four lock gates. In addition to the high system availability, there are also new requirements due to the particularly exposed location to the sea climate. Located directly by the sea, an energy supply system must be extremely resistant to seawater. As the structure is also located in the sea dyke, the requirements for dyke protection must be met. Together, these two requirements place extremely high demands on the operational safety of the lock.

Solution

The operators decided in favour of an e-chain® from igus® for the energy supply. The entire system consists of a stainless steel trough in which the type 4040RHD energy chain is located. This is a very robust chain that is seawater-resistant, oil-resistant and UV-resistant. The travel of the energy chain is approx. 65 metres and the entire chain is fitted with rollers to reduce friction and keep the tensile/push forces low. A floating moving end of the cable carrier system also serves to compensate for lateral guide inaccuracies. It can compensate for the clearance by approx. +- 50 mm to the right and left and is guided by the trough so that the chain is always aligned with it. The cable covering of the energy chain consists of chainflex® cable from igus®, which is also seawater-resistant and UV-resistant and specially designed for the constant flexing cycle in the chain.

"After ten years of operation, we can say that we have had very good experiences with the product. Particularly in terms of durability. Operation and maintenance are kept to a minimum. We make do with a visual inspection and this has worked very well so far."