Cranes require electricity to power their operations, including having the ability to lift loads efficiently and precisely.
But, just like there are different types of cranes (i.e. jib cranes, gantry cranes and workstation cranes), there are also varying ways of supplying a crane with electricity.
Electrification systems for cranes can be selected based on aspects such as the environmental conditions of the application, load capacity, travel distance and speed requirements.
Metreel is a leading UK installer of crane systems. In today’s post, we’re here to give you a brief overview of the options for crane electrification systems to guide you.
Conductor Bar Systems (Busbar Systems)
Conductor bars for crane electrification can include solid or hollow bars. The bars are typically made from aluminium, copper or galvanised steel.
Solid conductor bar systems are typically cheaper and easier to install, though they are more susceptible to damage from impact or corrosion.
Hollow conductor bar systems offer enhanced durability, including better resistance to damage. However, they are more expensive to install.
Together, conduct bar systems can be used to supply power to various types of lifting equipment including overhead bridge cranes, gantry cranes, monorails and electrified rail systems in warehouses.
Pros: Conductor bar systems remain popular due to being reliable, plus their ability to carry electricity over long distances. They also offer ease of customisation, including if more bars need to be added or the whole system requires an extension.
Cons: The design of a conductor bar system (busbar system) means it is exposed and therefore, is more vulnerable to environmental factors that can cause damage to the system. Insulation is often required to protect against electric shock, arc flash and electrocution.
Festoon Systems
Festoon systems are cable management systems capable of carrying power, signals or fluids to cranes, hoists and other moving machinery.
The most common uses for festoon systems are bridge cranes, gantry cranes and jib cranes. They use trolleys which run along a track or beam which carry flat-form cables, round-form cables or flexible hoses to supply electrical currents.
When a crane requires flexible and dynamic power, including so it can operate within harsh industrial conditions, festoon systems are ideal.
Pros: One of the biggest advantages of festoon cable systems is that they offer excellent durability for challenging environments. Due to having exposed cables that are easy to access, maintenance and troubleshooting are typically more straightforward.
Cons: Festoon systems require generous clearance space which may not suit environments which have tight space restrictions. Festoon systems may limit crane speeds compared to conductor bar systems.
Cable Reels
Cable reels consist of motorised or spring-driven reels. These reels wind and unwind power cables as the crane moves.
Various cranes can be powered by cable reels, but some notable examples include mobile cranes and port cranes.
It is most common to see cable reels used for mobile or outdoor applications due to their ability to supply power in a way that is flexible, while also being able to cover long distances.
Pros: Cable reels can handle extensive runs, often exceeding the distances that other systems such as festoon or conductor bars can handle. They are best equipped to handle rugged environments, including outdoor or marine applications. Also, many cable reels are designed with spring or motor-driven mechanisms which work to maintain proper tension, reducing wear and ensuring smooth operation.
Cons: Like all machinery, the moving parts such as slip rings, motors and tension systems must be subject to regular maintenance and inspection. In particular, the constant winding and unwinding of the cable can shorten the lifespan of the cable, although specialist drum reeling cables can provide enhanced durability.
Cable Chains (Energy Chains)
Cable chains are also known as energy chains or drag chains.
They have a very different design concept to other crane electrification systems as they work to protect cables, hoses or conduits during dynamic movement.
In scenarios where the crane’s cabling requires enhanced protection from dust, debris or mechanical impact, cable cranes offer excellent suitability. Likewise, if the crane is required to perform complex motion patterns or multi-axis movement.
Where there is a requirement for cable management systems in automation-heavy and precision-driven applications, cable chains are also ideal.
Pros: The unique design of cable chains helps to shield the cables from damage including due to abrasion, tangling or environmental hazards. Cable chains can handle the demands of cranes that have multiple axes of motion, curved tracks or precise movement patterns. The controlled bending radius can also reduce stress on cables to extend their lifespan.
Cons: Cable chains are heavy and their weight must be accounted for to prevent impacting crane performance and also maintain safety. For long distance crane applications, cable chains may not perform as effectively.
Metreel – Discover Our Crane Electrification Systems UK
When it comes to choosing a crane electrification system, it’s not that one system is better than another. Instead, the aim is to choose what’s most suitable for the usage application and overall lifting requirements.
If you need any help in choosing from any of the above crane electrification systems, the Metreel team is here to help. We’re based in Derbyshire and supply our products to businesses across the UK and beyond.
Let us know about your project requirements by dropping us a message or by giving us a call on 0115 932 7010.