Gamechanger for ports of the future

Seaports around the world are under pressure: To remain competitive, terminals must handle ever larger ships in ever shorter periods of time. To achieve this, more and more operators are relying on modern components such as robust and Industry 4.0-compatible energy chains from Igus. The motion plastics specialist has now equipped its 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 percent of cross-border trade in goods is now transported by sea. The sector is expected to grow by an average of 2.4 percent per year by 2029. This development is putting pressure on many ports to modernize their infrastructure in order to be able to handle ever more and ever larger ships quickly. The technical limits are not only reached by large elements such as harbor basins, but also by thousands of components that are often overlooked: for example, traditional festoons – cables in the form of loops that supply the trolley with power and data.

"In order to keep up with the increasing speeds and longer travel distances of STS cranes for ever-larger ships, manufacturers would have to switch to motorized festoons. However, this is complicated and error-prone. There is a constant risk that the trolley and festoons will not run synchronously, and excessive tensile loads will damage the cables and thus lead to failures – especially with long travel distances," says Jens Göbel, Industry Manager Cranes & Material Handling at igus. "Therefore, more and more port operators are switching from festoons to energy chain systems." For example, the motion plastics specialist igus has now equipped the 2,000th STS crane with e-chains.

Improve technology, reduce costs: Switching offers many advantages

This development marks a decisive step in the modernization of seaports worldwide. Igus e-chains offer numerous advantages over traditional festoons. The roller e-chains from igus, specially developed and used for this industry, are made of high-performance plastic that is weather- and radiation-resistant. This ensures a long service life and reliable operation in all weather conditions. The systems can operate at speeds of up to 10 m/s without the need for complex motorization.

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 pull-thrust force. Compared to sliding applications, drive energy is reduced by around 57 percent, a major advantage in times of rising energy prices. The internal layout of the energy chains is also easily adaptable, making it easy to install new cables, especially in times of rapid technological developments. Popular models such as the P4HD.56.R roller energy chain in the heavy-duty version achieve a service life of over 200,000 kilometers thanks to their robustness, which corresponds to an average service life of up to 15 years.

For example, a special fork-and-link principle on the P4HD.56.R ensures maximum stability under heavy additional loads, while a pin-and-bore connection made of tribologically optimized plastic minimizes wear. Furthermore, all roller e-chains can be equipped with i.Sense series sensors, which enable real-time monitoring and predictive maintenance. This reduces maintenance intervals, increases crane service life, and ensures more economical operation. Customers receive additional security through a unique 4-year warranty.

Market penetration continues to grow

Igus e-chains have established themselves, particularly in Asian ports, where new technologies are rapidly adopted. Since developing the very first roller energy chain more than 25 years ago and its first installation in 2000 at Shenghai Zhenua Industries (ZPMC), Igus has achieved a market share of around 60 percent in the new crane business. Terminals around the world, including APMT, DP World, and AGL, are following suit. In 2017, igus celebrated the 1,000th energy chain installed in an automated port facility at APM Terminals in Rotterdam.

With the 2,000th installation, igus is now setting another milestone and demonstrating the importance of innovative solutions for the future of port logistics. This includes the award-winning igus Mobile Shore Power Outlet (iMSPO), a mobile connection system for shore power supply that can be positioned depending on the ship's berth location, including at the Port of Hamburg. At the same time, igus has developed lubrication- and maintenance-free heavy-duty bearings that are being used in an increasing number of harbor cranes. Fiber composite plain bearings minimize maintenance costs and eliminate the risk of incorrect lubrication. Jens Göbel: “We are confident that, thanks to these technological developments, we will be able to work even more closely with STS crane manufacturers and terminal operators in the future to jointly shape ports for efficient and sustainable maritime transport of the future.”