Energy chain fires up massive Felixstowe rail traverser27 August 2014

An igus energy chain system has been designed into the Port of Felixstowe's new North Rail Terminal, which includes the largest capacity rail traverser in the UK.

Built by heavy rail lifting manufacturer Mechan, the traverser – which has a capacity of 170 tonnes, weighs 90 tonnes and measures 30 metres in length – moves freight locomotives between eight rail lines.

Martin Berry, Mechan's engineering director, explains that it runs on eight wheels, six of which are powered, each with a 15kW electric motor; the entire motor set being fed by a 200A, 415V three-phase supply.

The traverser is controlled by a PLC, which monitors sensor status and activates lights and signals, including wheelstops, which prevent a locomotive overrunning the rail track.

As for motor power, the PLC also transmits data via a Profibus fieldbus to a ground-based control and switching unit, which in turn drives the electric motors via the flexible energy chain.

"Felixstowe wanted an extremely reliable product [and] a reeling drum would have involved sliding contacts which are not good for communication signals," states Berry.

Hence the energy chain, which involved igus in providing a suitable system. Berry says the issue wasn't the scale of the traverse – igus has installed chains up to 615 metres long. Instead, the challenges related to the environment, and to some practical aspects of the installation.

As Felixstowe is a marine port, its rainfall has a high salt content and is corrosive, while protection from wind-born debris was also necessary – since freedom of movement might be impeded by debris.

Also, in winter, freezing temperatures and ice are encountered so igus had to design and install a robust system.

Meanwhile, the concrete bed for the traverser rails has protruding plinths at eight-metre intervals, preventing any cable trough being laid directly along the length of the main bed – yet a suitable trough would need two-metre fixing centres to allow a fast and robust installation.

Installing an I-beam to provide mounting points was also not an option as this would have interfered with the traverser travel path.

The igus project team's response comprised a customised stainless steel FLIZZ covered trough system. This contains an E4 gliding e-chain, carrying a set of chainflex power and data cables designed to survive the flex cycles, speeds and accelerations while offering EMC safety.

Associated steelwork comprised unistruts and braces, manufactured by igus to mount the system to the concrete while clearing the plinths.

"This project's success has been due to both igus' project capabilities and its products," states Berry.

"These challenges were highly project-specific, yet overcome very effectively," he continues.

"The energy chain is proving to be a more robust and compact solution than festoons or reeling drums, and the igus product has been perfectly matched to the traverser's environment."

Brian Tinham

Related Companies
Igus (UK) Ltd
Mechan Ltd

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