Igus Sets World Record with Longest Plastic Energy Chain at Tušimice Power Station
Igus has achieved a world record with its plastic energy chain, measuring an impressive 615 metres of travel. Installed at the lignite-fired power station in Tušimice, Czech Republic, this energy chain is the longest of its kind in the world.
Reliable Operation Over a Decade at Tušimice Lignite Power Plant
The roller energy chain system runs continuously, 24 hours a day, and even withstands idle periods lasting a month. Remarkably, it has operated reliably for 10 years without failure.
At Tušimice, lignite (brown coal) is extracted from an open-cast mine and conveyed directly into the power station. When production stops, stockpiled coal ensures uninterrupted energy generation.
Energy Chain Powers Automated Coal Stacker
ČEZ Group, the operator of the power station, uses a large coal heap located at the site’s periphery. An automated stacker piles the coal onto this heap, and igus’ energy chain system supplies energy, data, and media to the stacker.
This led to a record-breaking 615m travel energy chain that won the 2010 Golden Vector Award, recognising the toughest and most innovative energy chain applications.
Innovative Roller Design Reduces Friction and Saves Energy
The 5050RHD energy chain installed at Tušimice features rollers, indicated by the ‘R’ in the product name. Frank Schlögel, igus sales and marketing head of engineering projects, explains the benefits:
“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. Because of the lower friction, up to 57 per cent of the required drive energy can be saved. Which, of course, is all the more worthwhile on record-breaking travels like this one.”
Schlögel and his project engineering team oversee special projects globally, guiding customers from design to assembly and maintenance.
From Cable Drums to Energy Chains: Overcoming Harsh Winters
Before igus installed its energy chain system, Tušimice used a cable drum. However, icy Czech winters caused cables to freeze, leading to unplanned shutdowns. The energy chain system eliminated these problems for the last ten years.
Together with project manager Hennlich, a Czech-based distributor, igus developed a complete energy chain package tailored to this application. Since installation, only routine visual inspections occur, and just ten crossbars required replacement during this period.
Additional Systems Using Roller Energy Chains
Besides the 615m travel chain, two more systems with roller energy chains operate at the site—one with 400m travel and another with 150m travel. These systems supply the reclaimer that moves coal from the pile to the conveyor belt leading to the power plant.
Reliable Routing with Chainflex Cables and Condition Monitoring
Inside the energy chain, igus’ specially developed chainflex cables provide power, control, and data transmission. These include motor and control cables and a fibre optic cable for data. Schlögel notes, “Bus cables are out of the question for these long travels, as the signal strength would be insufficient.”
The energy chain also carries a water hose equipped with a heating cable to prevent freezing, supporting dust control.
The system uses electronic monitoring to measure push and pull forces on the chain. It can automatically shut off if forces exceed safe limits.
Advanced i.Sense Condition Monitoring for Predictive Maintenance
Igus has enhanced condition monitoring with its i.Sense modules, designed for machine builders to enable predictive maintenance. The range includes break monitoring (i.Sense EC.B), push/pull force monitoring (i.Sense EC.P), and abrasion monitoring (i.Sense EC.W).
The system can shut down if a chain breaks, preventing further damage. The abrasion monitoring continuously measures wear, helping operators plan replacements before failures occur.
Dependable Performance Year-Round
Although the system occasionally remains idle, operators trust the energy chain to perform reliably whenever coal needs to be conveyed, regardless of the season.