Engineering Guideline Festoon Systems for I-beams

1 Engineering GuidelineFestoon Systems for I-beamsKAT0300-0101-E3 Wampfler expertisein Heavy Duty Cable TrolleysSolutions for a moving world:Whenever objects or peopleare in motion, Wampfler canprovide customized solutionsfor flexible energy, data andmedia stands out for theirmany years of experience andwide know-how in the deve-lopment and manufacturing offestoon trolleys carry flat andround cables for the trans-mission of electrical energyand data as well as hoses forthe transmission of liquids, airor Festoon Systems areused in various applications allover the world, among othersin steel works, ports, galva-nizing and composting plants. Structure and ContentComponents Step 1 Selection and arrangement of cables Step 2 Selection of the cable trolley program Step 3 Calculation of the systemLayoutSystem illustrationThis Engineering Guideline willassist you with the layout ofnon-motorized Systems .

2 Itprovides the basic data for thelayout and calculation offestoon and unitsA B681416 Figure:program 0360 ATypical Componentsof a Cable Trolley for I-beams Cable supportFunction: support of cables according to minimum bending radiiDesign: one-piece (max. stability and bending strength)Material: steel, hot dipped galvanized Specificfeature: riveted nut for easy assembly Clamping barFunction: fixation of the cableson the cable supportMaterial: rubbersteel, hot dipped galvanizedSpecificfeature: group clamping segmented for the clamping of different cable diameters Center plateFunction: attachment of cable supports,buffers and chassisMaterial: steel, hot dipped galvanizedSpecificfeature: for maximum stability Side shieldFunction: arrangement of the rollers in aminimum spaceMaterial: steel, hot dipped galvanizedSpecificfeature: 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 weightDesign: cylindrical or flanged roller Material.

3 Steel or plastic bandageSpecificfeature: precision ball bearing lubri-cated for lifetime with addi-tional sealing disk (2RS1) Anti-lift roller (GDR)Function: protection against lifting, increased protection against tiltingDesign: cylindrical rollerMaterial: steel bandageSpecificfeature: precision ball bearing lubri-cated for lifetime with addi-tional sealing disk (2RS1) Horizontal guide roller (HFR)Function: precise guidanceof the cable trolleyDesign: cylindrical rollerMaterial: steel or plastic bandageSpecificfeature: precision ball bearing lubri-cated for lifetime with addi-tional sealing disk (2RS1) Large-volume bufferFunction: minimize the impact load of the cable trolleyMaterial: rubber / polyurethaneSpecificfeature: optimized characteristicBSystem with towing trolleySystem with towing clamp trolley/towing clampSystemillustration5b1cable trolley widthb2max.

4 Permissible clamping widthCEbeam clearance end clamp sideCMbeam clearance towing sidedasupport diameterefree space within storage distancehcable loop depthhacable trolley height from lower edge of beamto upper edge of cable supporthgescable loop depth from lower edge of beamto loop bottomkdrill hole distance for towing rope fixationlbstorage distance including free space (e)lEend clamp lengthlgestrack beam lengthLinstEinstallation length end clamp sideLinstMinstallation length towing sidelKtowing clamp lengthlMtowing trolley lengthlMFdistance from middle of towing trolleyto middle of towing windowlsactive travel ( main trolley or crane travel)lwcable trolley lengthThe thicker energy cables ( ) shall be placed on topof the cable package. This willassure good heat dissipationand proper clamping of thesmaller tractive forcesduring the movements canpartly be absorbed by thesecables.

5 Arrangement of flatcables on the cable supportThe flat cable package mustbe piled in such a way that allcables are clamped compacton the cable supports andcannot 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 Step 1 Cable selection and arrangementThe 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 cableprogramPrior 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 % clampinggood - 50 % clampingbadWhenever possible widercables should be usedinstead of multiple smallercables , :1 piece 12 x instead of3 pieces 4 x !

6 Applies for all cables:Observe balance of Arrangement of flatcables within the cableorganizerCable organizers are used tohold together the cablepackage in the cable loop. Thethicker energy cables ( ) 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 goodbad Arrangement of roundcables on the cable supportThe diameters of the roundcables shall not vary too muchin order to allow properclamping on the goodbadIf deviations in diameters ofadjacent cables are more than15 mm use additional clampingpieces for a proper clamping. Arrangement of roundcables within the cableorganizerCable 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 energy cables withlarger copper cross sectionsshould be favored for the outercables ( 1x120 or 4x25).

7 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 pieceSpacer*Reduction factorsfor main rollers with Vulkollan orAdiprene bandagesIn 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 loadFLWis, depending on the ambienttemperature, reduced by the followingfactors:Main rollers withsteel bandages in mmTravel speed v in m/minup to6380100125160200250300 Permissible cable trolley load FLWin kg40403632507568605163125110958575802201 9016214212511010035530526523020018516012 5590550500450410380350310160115010901050 10159909709509258 Layout Step 2 Selection of the cable trolley program1 Determination of thecable trolley load (FLW)The second step for thecalculation starts with theapproximate determination ofthe cable trolley load (FLW).

8 FLW= 2 x h x GL2 Selection of the main roller sizeWith the determined cable trolley load FLWthe 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 CMain rollerswithVulkollan bandages in mmTravel speed v in m/minup to6380100125160200250300 Permissible cable trolley load FLWin kg40322926506053474263110989080708019517 0155135115100100325280250215185165150112 4303953603303052752502101255405154604103 803503202901601020975940915890870850825 SpecificationMaterialstandardrollers made of hardened steelfor low noise emission and low beam wearrollers with plastic bandagesmade of a Polyurethane-ElastomerVulkollan for tropical or subtropical climate rollers with hydrolysis resistant plasticbandages, Adiprene FLW= cable trolley load in kgh= cable loop depth in mGL= cable package weight in kg/mMain rollerswith Adiprene bandagesFLW = FLW Vulkollan x 0,8!

9 Ambienttemperature Reductionfactor40 C .. 50 C .. 60 C .. 70 time:~16h / dayAmbient temperature : -30 C .. +40 C( )93 Determination of the cable trolley programWith 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 rollers in mmvmaxin m/mintype of cableprogramPossible chassis typestrack beamparallel flangetapered flange4050flat/round0314SS4075flat0315-H 40100flat/round0320S, SGH, HG, S, SG50120flat/round0325S, SGH, HG, S, SG63150flat/round0330S, SGH, HG, S, SG50/63/80/100160flat0350HF, HFG, S, SGH, HG, HF, HFG, S, SG50/63/80/100/112/125160round0360HF, HFG, S, SGH, HG, HF, HFG, S, SG100/112/125180round0364 HFGHFG112/125300round0365 HMG, HMPHMG, HMP125210flat0370 HMG, HMPHMG, HMP125/160300round0375 HMG, HMPHMG, HMP125/160300round0380 HMG, HMP-160300round0385 HMG, HMP- Minimum beam dimensionThe following beam dimensions are necessary due to the installationspace required by the chassis in the beam.

10 Chassis type overview see next page >>> 4roller- + r + s + 10 Minimum beam width bminin mm = 2 xAir 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 2roller- 104 Selection of the chassis typeStandard application dataI-beamtapered flangebeam width mmtravel speed< 120 m/min main roller material steel, plasticTypeHChassis with cylindrical main rollersguidance of the chassis at the radius of the beam web For simple applications with lowlateral forces Not suitable for towing trolleyguidance of the chassissimpleoptimalprotection against tiltinglowhighprotection against liftinglowhighwear of beam/rollershighlowStandard application dataI-beamtapered flangebeam width mmtravel speed< 120 m/min main roller material steel, plasticTypeHGChassis 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 trolleysguidance of the chassissimpleoptimalprotection against tiltinglowhighprotection against liftinglowhighwear of beam/rollershighlowStandard application dataI-beamparallel/tapered flangebeam width mmtravel speed< 150 m/min main roller material steel.