Energy chains for high temperatures

• What was needed: High-temperature energy pipe of the E4 system, consisting of the material 'igumid® HT'
• Requirements: hot, sharp-edged chips of more than 600 °C in all sizes hit the system components
• Industry: Switch manufacturing, infrastructure
• Success for the customer: a completely new material was presented to the customer at that time, which can withstand temperatures of up to 850°C and permanently bear the high load, easily accessible e-tube reduces maintenance and machine downtimes to a minimum, cost-effective installation, as existing guide trough could continue to be used

The French company Vossloh Cogifer has specialised in the field of fixed installations for rail networks of all kinds for over 100 years. As one of the market leaders, the plant manufacturer plans, designs and produces customised switches and crossings for all loads, profiles and track gauges worldwide. The Trier site primarily manufactures tram turnouts, with a total of between 300 and 400 turnouts being produced each year.
All turnouts are manufactured in two-shift operation using modern machinery. This includes sawing and drilling machines, milling benches and a CNC-controlled portal milling machine, which has been in use since 2002. In order to protect the cables from the many hot chips in the long term, the company relies on a closed system, an energy pipe. However, due to the extreme requirements on site, the old energy supply system was usually worn out after a maximum of nine months, so the manufacturer was involved and together they looked for an alternative solution. Various approaches, such as a metal energy supply system, were considered and then rejected.
Milling the points not only produces an extremely high number of chips of all sizes, but they are also very sharp-edged. "Some of them come flying in red-hot like needles. 600 °C and more are not uncommon," says Matthias Krames, summarising the conditions on site. The chips used to leave traces of burning and melting in the plastic, and the lid of the energy supply system opened in places due to the enormous load. Chips gradually penetrated, making it critical for the inserted cables. As a result, the system repeatedly came to a standstill. In addition, the plant manufacturer was looking for a cost-effective solution that would also last in the long term.

The existing energy tube was replaced by a high-temperature energy tube from igus®. The use of these high-temperature energy tubes significantly increases machine service life, especially during machining. This is where the closed systems really come into their own, as they reliably protect the cable from dirt, moisture and heat. At this time, igus had presented® igumid ® HT′ as a material in which hot chips bounce off the energy supply system without leaving a trace, even at temperatures of up to 850 °C. And during an inspection after the first few weeks, no chips stuck to or penetrated the housing, and no pattern was visible on the plastic. "We are very satisfied with this solution," confirms Matthias Krames, Maintenance Manager at Vossloh Laeis. "The machine has been running without any problems since the replacement. The replacement was worthwhile for us."
With a chain length of 61 links, a travel of up to 9 m and a maximum table speed of 10 m/min, the E4 system with normal pendulum connection elements is used due to the long unsupported length. It is complemented by the integrated strain relief. All of these components have a positive effect on the stability and durability of the entire energy supply system. The fact that energy conduits can always be opened on both sides was extremely practical, especially during installation. The existing intact cables could be inserted quickly, and the existing guide trough was still used, so that the replacement was really cost-effective. As the cables remain accessible at all times after insertion into the pipe, maintenance and machine downtimes are reduced to a minimum.
"We are confident that this energy pipe will meet our requirements in the long term. The experiences of the first few weeks and months have been very positive," concludes Matthias Krames.