Game-changer for ports of the future.

More and more operators are relying on energy chains instead of festooning to modernise their systems and meet increasing requirements

Seaports are under pressure worldwide: to remain competitive, terminals have to handle larger ships in shorter periods of time. Therefore, more and more operators use modern components such as igus's robust energy chains that are compatible with Industry 4.0. The motion plastics specialist has now equipped the 2,000th STS crane with e-chains and is making more and more terminals fit for the future.

According to a recent report by the United Nations Conference on Trade and Development (UNCTAD), over 80% of cross-border trade in goods is now transported by sea. The sector is expected to grow by an average of 2.4% per year until 2029. This development is putting pressure on many ports to modernise their infrastructure and handle more and larger ships quickly. There are technical restrictions, however - not only due to large elements such as harbour basins, but also owing to thousands of components that are often overlooked: traditional festoons, for instance, i.e. looped cables that supply the trolley with energy and data. "To keep up with the increasing speeds and longer travels of STS cranes for ever larger ships, manufacturers would have to start motorising the festoons. However, this is complicated and error-prone. There is a constant risk of the trolley and festoons not running synchronously and excessive tensile loads damaging the cables and leading to breakdowns - especially over long travels," says Jens Göbel, Industry Manager Cranes & Material Handling at igus. "This is why more and more port operators are switching from festoons to energy chain systems." Hence, the motion plastics specialist igus has now equipped the 2,000th STS crane with e-chains.

Switching systems offers many advantages

This development marks a decisive step in the modernisation of seaports across the globe. The e-chains from igus offer numerous advantages over traditional festoons. The igus rol e-chains consist of high-performance plastic that is resistant to weathering effects and radiation. They have been developed specifically for this industry, and ensure a long service life and reliable operation in all weather conditions. The systems can operate at speeds of up to 10m/s without the need for complicated motorisation. Thanks to the integrated rollers and the associated low coefficient of friction, it is possible to increase the payload and acceleration while maintaining the same push/pull force. Compared to gliding applications, the drive energy is reduced by around 57%, a major advantage in times of rising energy prices. The interior separation of the energy chain is also easy to change, so that new cables can be inserted without much ado - an important feature in times of rapid technological developments. Popular models such as the roller energy chain P4HD.56.R in the heavy-duty version are so robust that they achieve a running performance of over 200,000km, which corresponds to an average service life of up to 15 years. A special clevis-and-tongue principle in the P4HD.56.R ensures maximum stability with higher additional loads, while a pin/bore connection made from tribologically optimised plastic minimises wear. In addition, all rol e-chains can be equipped with sensors from the i.Sense series, which allow for real-time monitoring and predictive maintenance. This reduces maintenance intervals, increases crane service life and makes operation more economical. Customers receive additional security through a unique 4-year guarantee.

Market presence continues to increase

The e-chains from igus have become particularly popular in Asian ports, where new technologies are quickly adopted. Since the development of the very first roller energy chains more than 25 years ago and the first installation at Shenghai Zhenua Industries (ZPMC) in 2000, igus has achieved a market share of around 60% in the new crane business. Terminals around the world, including APMT, DP World and AGL, are following suit. In 2017, igus celebrated the installation of its 1,000th energy chain in an automated port facility at APM Terminals in Rotterdam. With the 2,000th installation, igus has now marked another milestone, demonstrating how important innovative solutions are for the future of port logistics. Another award-winning system, igus Mobile Shore Power Outlet (iMSPO), is a mobile connection system for shore power supply that can be positioned according to the location of the ships at the berth, including at the Port of Hamburg. At the same time, igus has developed lubrication-free and maintenance-free high-load bearings that are becoming increasingly popular in port cranes. Fibre-reinforced plain bearings minimise maintenance costs and avoid the risk of incorrect lubrication. Jens Göbel: "We are confident that these technological developments will enable us to work even more closely with STS crane manufacturers and terminal operators to design ports for the efficient and sustainable maritime transport of the future."