Reliable cable guidance in the VELTINS Arena lawn exposure system

• What was needed: moving application including heavy duty and high abrasion/exposure to the elements
• Requirements: UV radiation, rain and temperature fluctuations required robust components. Since various strokes had to be accompanied by cable guides, a lightweight system was also desired.
• Industry: Agricultural engineering
• Success for the customer: The roller energy chains minimize push/pull forces over a travel of 120m. Together with other compact e-chains for short strokes in the system and matching chainflex cables, long service life can be achieved and maintenance costs can be minimized.

RHENAC GreenTec AG has developed a fully automatic lawn exposure system that was put into operation in the VELTINS Arena of FC Schalke 04. The R-BL-1750 can provide football turf with LED grow light for regeneration all year round without contact, as well as water and nutrients on request. The high-tech system is equipped with various sensors that record the condition of the lawn and environmental influences and make them available for evaluation in a digital log book. Parameters such as heat requirement, nutrient saturation, soil moisture and temperature, and the surrounding climate are evaluated to select individual light spectra, suitable light intensity and infrared heat.

The lawn exposure system consists of a main beam made of steel with a span of more than 80m, which travels on rails over 120m, can travel more than 12m/min and achieves acceleration of up to 1m/sec. Twelve fold-out B beams and six steplessly movable C beams along the main beam, which are equipped with LED light modules, can illuminate a total of 1,750m² of lawn. For all these adjustments, among other things, a large number of motor and bus cables as well as suitable cable guides had to be found. In addition to the sometimes long travel distances, various short strokes of 2 to 6m were to be achieved by means of energy supply systems. The external conditions, such as UV radiation, rain or temperature fluctuations, required robust and durable components. Lastly, the system should also provide significant weight savings.

Rhenac GREENTEC AG decided to use e-chains, which can be found today on all moving elements of the exposure system. Over a travel distance of 120m, the cable guides designed as roller energy chains prove themselves in that they can minimize traction/push forces and significantly reduce the required drive force compared to sliding chains. The reduced weight of the plastic chains is also noticeable over the long journey and also saves drive energy. For various smaller strokes on the B and C supports of the system, the manufacturer relies on the more compact e-chains, which are designed for medium loads and enable the LED luminaires to be reliably positioned in their positions. Space-saving rolled-up cable guides roll out to the desired length when the supports are moved and, thanks to the retaining spring, prevent the system from sagging.

The various e-chains were delivered directly from our product range with the appropriate cables designed for moving applications. In particular, a large number of readychains keep the system in operation and enable continuous data transmission of the various sensors used in the modern exposure system.

Together we were able to provide a complete solution from a single source, with the coordinated products extending the service life of the moving modules and minimizing maintenance costs.