180° shovel loader

Profile

• What was needed: Rotating energy supply with reverse bend radius, chainflex cables
• Requirements: Heavy stress on the energy supply solution due to +/- 180° movement of the shovel loader as well as the ambient conditions; an easy-to-maintain long-lasting new solution was sought
• Industry: Mining
• Success for the customer: After many years in use, not a single failure; enormous weight savings; overall high reliability, durability, freedom from maintenance and significantly increased service life.

Problem

In this shovel loader of the National Mineral Development Corp. Ltd. in India, all system components must function strongly, reliably and maintenance-free. However, the difficult environmental conditions resulting particularly from outdoor use mean that high demands are placed on all machine parts. This also quickly became apparent with the energy chains. The steel chains used showed considerable defects after only two years, which manifested themselves in damage to the rollers, spacers and chain links. In addition, the entire energy supply system began to slip.
In addition, any maintenance work meant a considerable expenditure of time. The design of the chain, for example, made it difficult to replace the damaged components quickly.
Finally, tensions in the energy chains caused the cables inside them to be damaged over time as well.
The operating company therefore had no choice but to regularly check the system for any new damage and carry out round-the-clock maintenance on all system components.

Solution

In 2010, the energy supply system was finally replaced by a rotating energy supply system with reverse bend radius from igus. The 18.5 metre long energy chain must be able to follow the 180° movement of the shovel loader completely. The system, which has now been in use for several years, has so far been operating completely without interruption, and the plant's operation has not had to be interrupted even once. The energy chain solution with reverse bend radius from igus is generally completely maintenance-free. Also decisive for the reliable functioning of the system is the significantly lower weight of 54 kilograms per metre, which is due not only to the chain itself, but also to the chainflex cables within the energy supply system. In comparison: The steel chain used before weighed about 120 kilograms per metre.
Due to the high reliability, durability, freedom from maintenance and the increased service life that the system has demonstrated in the application, the operator is planning to use it in two further plants. The operating company as well as the staff very much welcomes the switch to the energy chain from igus.

Today: Rotating energy supply system with reverse bend radius from igus

Before: The steel chain used in the beginning caused the operator a lot of maintenance work.

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