Safe energy supply for seamless scene changes

In the Hungarian State Opera, zig-zag systems ensure a smooth podium travel

After almost five years of extensive renovation, the Hungarian State Opera in Budapest celebrated its reopening in 2022 with numerous new stage platforms and state-of-the-art stage technology covering 324 square meters. The main stage riser system, implemented by Bosch Rexroth, uses igus® zig-zag energy supply systems. These E4.42 series e-chains® pre-filled with flexible chainflex® cables ensure a reliable power and data supply to the riser systems in a space-saving and cost-efficient manner.

Profile

Opera house with ornate seating and a covered stage during renovation.

What was needed: A reliable pre-assembled energy supply system for the electrically operated platform components
Requirements: Space-saving design, stability and durability, defined bend radius, expandability for future upgrades, possibility of separating the various cables within one e-chain
Industry: Stage and Theater
Success for the customer: With the zig-zag system, the cables are guided safely within a defined bend radius. The chainflex cables that are specially developed for moving applications guarantee permanently reliable power, control, signal and data transmission. The system was designed and supplied precisely to the customer's requirements. Thanks to its compact and modular design and the option of routing several cable groups within a single e-chain, the system offers a cost-efficient solution.

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Products Used

ECS cable carrier in a zigzag layout inside a machine enclosure.

Problem

As part of the extensive renovation work on the Hungarian State Opera House, Bosch Rexroth was awarded the contract to build the main stage riser system. This included six new 12 x 3 meter stage platforms that move up a height of 6 meters at a speed of 0.5 meters per second. These make it possible to set up stage sets for upcoming scenes in advance, significantly reducing the transition time and ensuring a seamless performance.

The designers were looking for a suitable system that would ensure the safe guidance of the many cables for energy, control, signal and data transmission during the podium travel in an area that cannot be entered during the performance.

The previous stage platforms had used cables with leather jackets - a solution that was susceptible to damage and could not guarantee safe bending conditions. Maximum operational safety was required for the new system. Any risks such as a defective cable or a blocked guide mechanism, which could immediately stop the stage automation and interrupt the performance, had to be ruled out.

Solution

The zig-zag e-chain system was the perfect solution. The cables are not kinked and are guided safely within a defined bend radius. If a cable is damaged over the years or a technical change is required, the e-chain can be opened with little effort and the appropriate cable replaced or added. With the zig-zag system, the e-chain is stored in a special guide box. When the stage element is lifted, the underlying chain unfolds automatically, and when it is lowered, it zig-zags again.

Two boxes are used per stage podium, equipped with E4.42 series e-chains filled with chainflex control, servo, motor and data cables. Up to 48 cables are contained in each e-chain. It was important to Bosch Rexroth to guide the igus cables separately from other special cables. Instead of two separate e-chains, igus offers a lean and cost-saving solution with a middle side link within one e-chain.

The complete energy supply system was planned, engineered and supplied by igus as a ready-to-install readycable solution, which significantly reduced the installation time and costs. Since its installation, it has been working trouble-free and has ensured long-term operational reliability in the theater.