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Record-breaking application running for 10 years with 100% reliability

Still a world record: The world's longest plastic energy chain with 615m travel comes from igus®

Running continuously for 24/7 or standing idle for month on end – these are the extreme conditions that the world's longest plastic energy chain has to cope with at the lignite-fired power station in Tušimice, Czech Republic. The roller energy chain system from igus® has been achieving this for ten years now without missing a beat on the record travel length of 615 metres.
The application in Tušimice was awarded the golden vector award back in 2010. Every two years, igus® initiates this competition to select the toughest and most exciting energy chain applications. Ten years later, this system is still tough and exciting, while also ideal for long-term use. At Tušimice the coal is stored in a long heaps on the periphery of the power plant site, which theoretically could be used to fuel the power station for a full week. To pile the coal automatically on the heap, a 'stacker' is used. To supply the stacker with energy, data and media, the ČEZ Group opted for an energy chain system from igus®. Result: 615m travel – a world record.

Problem

The customer was looking for a fail-safe energy supply system for the coal-fired power plant in Tušimice. The stacker piles the coal into a heap. It is supplied with energy, data and media via cables and hoses.

Solution

At the Tušimice power station the 5050RHD energy chain is used. The 'R' in the name stands for 'rollers'. By using a roller, the coefficient of friction on long travels drops dramatically, when the upper run of the chain runs on the lower run. Thereby, the coefficients of friction is reduced and up to 57 percent of the required drive energy can be saved while moving the energy chain system.

Product page series 5050RHD

In ten years of operation here, only a few plastic crossbars have been replaced.

In addition to the motor, control and data cables, a water hose is routed in the energy chain of the 5050RHD series (here right in the chain), which can be heated.