engineering guideline festoon systems for i- · pdf file · 2015-05-21engineering...

Engineering GuidelineFestoon Systems for I-beams

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Wampfler expertisein Heavy Duty Cable Trolleys

Solutions for a moving world:Whenever objects or peopleare in motion, Wampfler canprovide customized solutionsfor flexible energy, data andmedia transmission.

Wampfler stands out for theirmany years of experience andwide know-how in the deve-lopment and manufacturing offestoon systems.

These trolleys carry flat andround cables for the trans-mission of electrical energyand data as well as hoses forthe transmission of liquids, airor gases.

Wampfler festoon systems areused in various applications allover the world, among othersin steel works, ports, galva-nizing and composting plants.

Structure and Content

Components

• Step 1Selection and arrangement of cables

• Step 2Selection of the cable trolley program

• Step 3Calculation of the system

Layout

System illustration

This engineering guideline willassist you with the layout ofnon-motorized systems. Itprovides the basic data for thelayout and calculation offestoon systems.

Sizes and units

A

B

6

8

14

16

Figure:program 0360

A

Typical Componentsof a Cable Trolley for I-beams

Cable support

Function: support of cables according to minimum bending radii

Design: one-piece (max. stability and bending strength)

Material: steel, hot dipped galvanized

Specificfeature: riveted nut for easy assembly

Clamping bar

Function: fixation of the cableson the cable support

Material: rubbersteel, hot dipped galvanized

Specificfeature: group clamping segmented

for the clamping of different cable diameters

Center plate

Function: attachment of cable supports,buffers and chassis


Specificfeature: for maximum stability

Side shield

Function: arrangement of the rollers in aminimum space


Specificfeature: three-point fixation for

optimum distribution of forces

Main roller (HTR)

Function: allow movement of cable trolley, carry the cable trolley weight as well as cable weight

Design: cylindrical or flanged roller

Material: steel or plastic bandage

Specificfeature: precision ball bearing lubri-

cated for lifetime with addi-tional sealing disk (2RS1)

Anti-lift roller (GDR)

Function: protection against lifting, increased protection against tilting

Design: cylindrical roller

Material: steel bandage



Horizontal guide roller (HFR)

Function: precise guidanceof the cable trolley

Design: cylindrical roller

Material: steel or plastic bandage



Large-volume buffer

Function: minimize the impact load of the cable trolley

Material: rubber / polyurethane

Specificfeature: optimized characteristic

B

System with towing trolley

System with towing clamp

6

2

7

3

4

1

1. towing trolley/towing clamp2. cable trolley3. cable organizer4. cables5. damping device6. towing rope7. end clamp

Systemillustration 5

b1 cable trolley widthb2 max. permissible clamping widthCE beam clearance end clamp sideCM beam clearance towing sideda support diameter

e free space within storage distance

h cable loop depth

hacable trolley height from lower edge of beamto upper edge of cable support

hgescable loop depth from lower edge of beamto loop bottom

k drill hole distance for towing rope fixationlb storage distance including free space (e)lE end clamp lengthlges track beam lengthLinstE installation length end clamp sideLinstM installation length towing sidelK towing clamp lengthlM towing trolley length

lMFdistance from middle of towing trolleyto middle of towing window

ls active travel (e.g. main trolley or crane travel)lw cable trolley length

The thicker energy cables (e.g.4x50) shall be placed on topof the cable package. This willassure good heat dissipationand proper clamping of thesmaller cables.

Occurring tractive forcesduring the movements canpartly be absorbed by thesecables.

Arrangement of flatcables on the cable support

The flat cable package mustbe piled in such a way that allcables are clamped compacton the cable supports andcannot slip.

The cable package height inrelation to the width shall notbe too high, since otherwisethe cable package will beunstable and individual, espe-cially smaller cables, will notbe clamped sufficient anymore.

6

Layout Step 1Cable selection and arrangement

The first step to layout afestoon system is

• Preparation of a list ofrequired cables and theircross sections.

• Selection of the appropriatetype of cable (flat or roundcable) and of the requiredquality for the respectiveapplication (PVC or Neoprenecable) from our cableprogram

Prior to making a selection ofthe required cable trolleys it isimportant to follow the detailslisted on the right for thelayout of the cable package:

very good - 100 % clamping

good - 50 % clamping

bad

Whenever possible widercables should be usedinstead of multiple smallercables , e.g.:1 piece 12 x 1.5 instead of3 pieces 4 x 1.5 !

Applies for all cables:Observe balance of torque.

7

Arrangement of flatcables within the cableorganizer

Cable organizers are used tohold together the cablepackage in the cable loop. Thethicker energy cables (e.g.4x50) are clamped in the upperwindow, all the other cables areguided in the lower windowand can move freely. Thearrangement of the cablepackage must be suitable to fitinto the respective clampingwindow.

very good

bad

Arrangement of roundcables on the cable support

The diameters of the roundcables shall not vary too muchin order to allow properclamping on the cablesupports.

very good

bad

If deviations in diameters ofadjacent cables are more than15 mm use additional clampingpieces for a proper clamping.

Arrangement of roundcables within the cableorganizer

Cable organizers are used tohold together the cablepackage in the cable loop. Theouter cables are clamped, allthe other cables are guided inthe inner window and canmove freely.

Unscreened energy cables withlarger copper cross sectionsshould be favored for the outercables (e.g. 1x120 or 4x25).

Additional spacers can beinstalled in the cable organizerto avoid overlapping of cablesin case of larger differences indiameter.

!Clamping of screenedcables shall be avoided. !

Layout Step 1

Additional clamping piece

Spacer

*Reduction factorsfor main rollers with Vulkollan® orAdiprene® bandages

In case of higher ambient temperatures,depending on the trolley load, you mayhave to choose a higher roller diameterfor Vulkollan® and Adiprene® rollers,since the permissible cable trolley loadFLW is, depending on the ambienttemperature, reduced by the followingfactors:

Main rollers withsteel bandages

Ø in mm

Travel speed v in m/minup to 63 80 100 125 160 200 250 300

Permissible cable trolley load FLWin kg

40 40 36 3250 75 68 60 5163 125 110 95 85 7580 220 190 162 142 125 110

100 355 305 265 230 200 185 160125 590 550 500 450 410 380 350 310160 1150 1090 1050 1015 990 970 950 925

8

Layout Step 2Selection of the cable trolley program

1 Determination of thecable trolley load (FLW)The second step for thecalculation starts with theapproximate determination ofthe cable trolley load (FLW).

FLW = 2 x h x GL

2 Selection of the main roller size

With the determined cable trolley load FLW the required main roller sizecan be defined from the following table. First of all the material of themain roller has to be selected:

Operating time : ~16h / dayAmbient temperature : -30°C ... +80 °C

Main rollerswith Vulkollan®

bandagesØ in mm

Travel speed v in m/minup to 63 80 100 125 160 200 250 300

Permissible cable trolley load FLWin kg

40 32 29 2650 60 53 47 4263 110 98 90 80 7080 195 170 155 135 115 100

100 325 280 250 215 185 165 150112 430 395 360 330 305 275 250 210125 540 515 460 410 380 350 320 290160 1020 975 940 915 890 870 850 825

Specification Materialstandard rollers made of hardened steel

for low noise emission and low beam wearrollers with plastic bandagesmade of a Polyurethane-ElastomerVulkollan®

for tropical or subtropical climate rollers with hydrolysis resistant plasticbandages, e.g. Adiprene®

FLW = cable trolley load in kgh = cable loop depth in mGL = cable package weight

in kg/m

Main rollerswith Adiprene®

bandagesFLW = FLW Vulkollan® x 0,8

!Ambienttemperature

Reductionfactor

40°C ... 50°C 0.90

50°C ... 60°C 0.80

60°C ... 70°C 0.65

Operating time : ~16h / dayAmbient temperature : -30°C ... +40 °C

( )

9

3 Determination of the cable trolley program

With the size of the main roller- the suitable cable trolley program and- the possible chassis types for this programcan be defined from the following table:

Main rollersØ in mm

vmaxin m/min type of cable program

Possible chassis typestrack beam

parallel flange tapered flange40 50 flat/round 0314 S S40 75 flat 0315 - H40 100 flat/round 0320 S, SG H, HG, S, SG50 120 flat/round 0325 S, SG H, HG, S, SG63 150 flat/round 0330 S, SG H, HG, S, SG

50/63/80/100 160 flat 0350 HF, HFG, S, SG H, HG, HF, HFG, S, SG50/63/80/100/112/125 160 round 0360 HF, HFG, S, SG H, HG, HF, HFG, S, SG

100/112/125 180 round 0364 HFG HFG112/125 300 round 0365 HMG, HMP HMG, HMP

125 210 flat 0370 HMG, HMP HMG, HMP125/160 300 round 0375 HMG, HMP HMG, HMP125/160 300 round 0380 HMG, HMP -

160 300 round 0385 HMG, HMP -

Minimum beam dimension

The following beam dimensions are necessary due to the installationspace required by the chassis in the beam:

Chassis type overview see next page >>>

4roller-Ø + r + s + 10Minimum beam width bmin in mm = 2 x

Air gap A (between main roller and beam flange) = min. 10 mm

!

motorized systems are usedfor the fields highlighted in gray– Please contact us –

Layout Step 2

rolle

r-Ø

10

4 Selection of the chassis type

Standard application dataI-beam tapered flangebeam width max. 100 mmtravel speed < 120 m/min main roller material steel, plastic

TypeH

Chassis with cylindrical main rollersguidance of the chassis at the radius of the beam web

• For simple applications with lowlateral forces

• Not suitable for towing trolley

guidance of the chassis simple optimalprotection against tilting low highprotection against lifting low highwear of beam/rollers high low

Standard application dataI-beam tapered flangebeam width max. 100 mmtravel speed < 120 m/min main roller material steel, plastic

TypeHG

Chassis with cylindrical main rollersand anti-lift rollersguidance of the chassis at the radius of the beam web

• For simple applications with lowto medium lateral forces andtilting torques

• Suitable for towing trolleys


Standard application dataI-beam parallel/tapered flangebeam width max. 140 mmtravel speed < 150 m/min main roller material steel, plastic

TypeHF

Chassis with cylindrical main rollersand horizontal guide rollersguidance of the chassis at the beam flange

• For applications with low tomedium lateral forces

• Not suitable for towing trolley


Chassis with cylindrical main rollerswith horizontal guide rollers and anti-lift rollersguidance of the chassis at the beam flange

11

Standard application dataI-beam parallel/tapered flangebeam width max. 140 mmtravel speed < 180 m/min main roller material steel, plastic

TypeHFG

• For applications with medium tohigh lateral forces and tiltingtorques



Standard application dataI-beam parallel/tapered flangebeam width max. 140 mmtravel speed < 80 m/min main roller material steel

TypeS

Chassis with flanged main rollersguidance of the chassis at the beam flange

• For applications with low tomedium lateral forces

• Not suitable for towing trolleys


Standard application dataI-beam parallel/tapered flangebeam width max. 140 mmtravel speed < 80 m/min main roller material steel

TypeSG

Chassis with flanged main rollersand anti-lift rollersguidance of the chassis at the beam flange

• For applications with low tomedium lateral forces and tiltingtorques



Layout Step 2

12

4 Selection of the chassis type

Standard application dataI-beam parallel/tapered flangebeam width max. 200 mmtravel speed < 300 m/min main roller material plastic

TypeHMG

Chassis with cylindrical main rollers withhorizontal guide rollers at the beam center weband anti-lift rollersguidance of the chassis at the beam center web

• For applications under verydifficult conditions (e.g. STScontainer cranes)



Standard application dataI-beam parallel/tapered flangebeam width max. 200 mmtravel speed < 300 m/min main roller material plastic

TypeHMP

Chassis with cylindrical main rollers withhorizontal guide rollers at the beam center weband anti-lift plateguidance of the chassis at the beam center web

• For applications with motorizedcable trolleys and heavy cablepackages



13

5 Determination of the cable support diameter

For the determination of the cable trolley size the required cable support diameter da is to choose.This must correspond with the cables being installed.

The smallest permissible cable support diameter da is determined on the basis of the largest cables:

Example of calculationflat cable:

Example of calculationround cable:

The thickness of the largest flat cable is 13 mm

Accordingly the minimum support diameter is:da = 10 x 13 mm = 130 mm

The outer diameter of the largest round cable is 20 mm

Accordingly the minimum support diameter is:da = 10 x 20 mm = 200 mm

thickness of flat cableSFL ≤≤ 12,5 mm

thickness of flat cableSFL ≥≥ 12,5 mm

outer diameter of round cabledRL = outer diameter

min support-Øda in mm

8 x SFL 10 x SFL 10 x dRL

Layout Step 2

14

2 x h + 1,25 x da - f x lW

f x (ls + e)n =

Layout Step 3Calculation of the system

1 Determination of thenumber of loopsFor the determination of thenumber of loops it is required todefine the cable loop depth hand choose the additional cablelength factor f from the tablebelow.

n = number of loopsls = active travel in mf = additional cable length

factor (see table below)h = cable loop depth in mda = support diameter in mlW = cable trolley length in me = free space in storage

distance(recommendation ≥ 0.5 m)

For the fields highlighted inyellow we recommend the use ofdamping devices or motorizedsystems to stabilize the cableloops.– Please contact us –

For the fields highlighted ingray motorized systems will beused.– Please contact us –

2 Determination of therequired storage distancefrom middle of end clampto middle of towing trolleyFor further calculations roundup the number of loops.

lb = (n-1) x lW + lE +lM + e

lb = storage distance from middle of end clamp to middle of towing trolley in m

n = number of loopslW = length of cable trolley in mlE = length of end clamp in mlM = length of towing

trolley/towing clamp in me = free space in storage

distance(recommendation ≥ 0.5 m)

3 Determination of thecable system length frommiddle of end clamp tomiddle of towing trolleyand of the order length ofthe cable

LBest = LSyst + LinstE + LinstM

LSyst = required cable system length from middle of endclamp to middle of towingtrolley/towing clamp in m

f = additional cable length factor

ls = active travel in mlb = storage distance in mLinstE = installation length

end clamp side in mLinstM= installation length

towing side in mLBest = cable order length

inclusive installation length in m

LSyst = f x (ls + lb)

additional length factor f cable loop depth h in mtravel speed

vmax in m/min < 0,8 0,8 - 1,2 1,3 - 2,0 2,1 - 3,2 3,3 - 5,0 5,1 - 8,0

32 1,10 1,10 1,10 1,10 1,10 1,1033 - 40 1,15 1,10 1,10 1,10 1,10 1,1041 - 50 1,20 1,15 1,10 1,10 1,10 1,1051 - 63 1,25 1,20 1,15 1,10 1,10 1,1064 - 80 1,25 1,20 1,15 1,10 1,1081 - 100 1,25 1,20 1,15 1,10

101 - 125 1,25 1,20 1,15126 - 160 1,25 1,25 1,20161 - 200 1,25 1,25 1,25201 - 250 1,25 1,25 1,25251 - 300 1,25 1,25 1,25

Determination of the additional cable length factor f

n determines the number ofrequired cable trolleys:Number ofcable trolleys = n-1

!

15

4 Determination of theactual cable loop

h = cable loop depthLSyst= required cable system

length measured from middle of end clamp to middle of towing trolley or towing clamp in m

da = support diameter in mn = number of loops

2xnLSysth = - (0,63 x dA)

5 Dimensioning of thetowing rope lengths

For travel speeds higher than50 m/min we recommend theuse of towing ropes.

Please take the dimension k forthe towing rope fixation from therespective cable trolley program.

nLSyst - (k+0,084)LZug = 0,95x

6 Selection of thedamping device

LGum = shock cord length in mLZug = towing rope length in m

1,5LZugLGum =

The selection of the correctdamping device (quantity anddiameter of the shock cords)depends on various factorsof the respective application.

– Please contact us –

!

Layout Step 3

16

b1 mm cable trolley width

b2 mm max. permissible clamping width

cE m, mm beam clearance end clamp side

cM m, mm beam clearance towing side

da mm support diameter

dRL mm outer diameter round cable

e m, mm free space within the storage distance

f additional cable factor length

FLW kg cable trolley load

GL kg/m cable package weight

h m, mm cable loop depth

ha m, mm cable trolley height from lower edge of beam to upper edge of cable support

hges m cable loop depth from lower edge of beam to loop bottom

k m, mm drill hole distance for towing rope fixation

lb m cable trolley storage including free space (e)

LBest m cable order length

lE m, mm end clamp length

lges m track beam length

LGum m shock cord length

LinstE m installation length end clamp side

LinstM m installation length towing side

lK m, mm towing clamp length

lM m, mm towing trolley length

lMF m, mm distance from middle of towing trolley to middle of towing window

ls m active travel (e.g. main trolley or crane travel)

LSyst m cable system length

lW m, mm cable trolley length

LZug m towing rope length

n number of loops

s mm clamping height at the cable trolley

sFL mm thickness of flat cable

v m/s, m/min travel speed

Symbols and units

Wampfler – the complete program

Your Applications- our Solutions

Festoon systems by Wampflerare but one component of thewide range of the Wampflerenergy, data and media supplysystems. The right solution foryour application always ensuesfrom the wholly specific appli-cation at hand.And many times, it is preciselythe combination of severalWampfler systems that willrender very convincingbenefits. You can findconsulting and engineeringcompetence in our companiesand subsidiaries worldwide -just like our solutions!

Festoon systemsIt's hard to imagine Wampfler cabletrolleys not being used in virtuallyevery industrial application: They'rereliable and robust in an enormousvariety of dimensions and designs.

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Conductor railsWhether they're enclosed conductorrails or expandable single-polesystems, the proven conductor railsby Wampfler reliably move peopleand material.

Energy guiding chainsThe "Jack of all trades" when itcomes to transferring energy, dataand media. With their wide range,these energy guiding chains holdtheir own in industrial applications.

Inductive Power Transfer IPT®

The no-contact system for trans-ferring energy and data. For all tasksthat depend on high speeds andabsolute resistance to wear.

Cable reelsMotorized reels and spring cablereels by Wampfler hold their ownwherever energy, data and mediahave to cover the most diversedistances within a short amount oftime - in all directions, fast and safe.

Wampfler AGRheinstrasse 27 + 3379576 Weil am RheinGermany

Customer SupportPhone +49 (0) 7621/66 22 22

Phone +49 (0) 7621/6 62-0Fax +49 (0) 7621/6 [email protected]

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engineering guideline festoon systems for i- · pdf file · 2015-05-21engineering...

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