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Overhead Crane Busbar System
vs. e-chain® Cable Carrier

Faster, smarter alternative to an overhead crane busbar system

For facility managers and engineers in the material handling and automation industries, the biggest headache is often the inefficiency and high maintenance demands of traditional crane busbar systems. These systems, while common, are notorious for their rigidity, frequent breakdowns, and limited functionality restricting energy transmission to just power, with no capacity for data or fluid transmission. Busbar systems make it challenging to keep your operations running smoothly due to unexpected maintenance, costly downtime and the safety risks that come with outdated power distribution systems. The inability to transmit data or fluids alongside power in a compact, efficient manner further compounds the challenge, leaving you stuck in a cycle of reactive maintenance, with your productivity and profitability taking the hit. This isn’t just inconvenient; it’s a threat to the sustainability  of your operations.

Don't let outdated technology hold your operations back any longer. Make the switch to the e-chain system today and experience the difference in power distribution that propels you ahead of the competition. Contact us today to schedule a free consultation and see the e-chain system in action.

Advantages of micro flizz®
the alternative to a crane busbar system

  • Easy to clean, hardly any abrasion
  • Quiet, maintenance-free and easy to install
  • Operating speeds of up to 6m/s in high-acceleration applications
  • Data rates up to 10Gbit/s. Safely guides FOC and bus cables
  • Travels up to 100m
  • Can be installed horizontally and vertically
  • Little space required
  • Optional isense CF.D technology for bus cable monitoring
  • Also available with conductive ESD e-chain®
  • Pre-configured system in modular design
Learn more about micro flizz®
Application areas: Sliding doors, storage and retrieval units, overhead cranes, industrial doors, workplace equipment, sewage treatment plants and camera systems

TechTalk:
Overhead crane electrical busbars vs e-chains®

Consider the facts before using a busbar system in your application.

Get an in-depth look into busbar systems and energy chains, read this tech talk and consider the facts before deciding which system will best suit your application.
 
Download the crane busbar system TechTalk
news 2022

What are the differences between e-chain® and an overhead crane busbar system?

System Comparison: of an overhead crane busbar system

Overhead Crane Busbar System vs e-chain

e-chain® system

In the solution with cable carriers, the cables are fed into the e-chain® in the middle of the travel. The e-chain® is pushed or pulled to halfway.
Overhead Crane Busbar System

Crane busbar system

Busbars are high maintenance systems that require a lot of care and adjusting.

e-chain® system review

Adding or Removing Cables
  • e-chain systems® make it easy to change out cables or add additional cables with minimal downtime.
  • With e-chain® all types of cables and hoses can be guided through the same system at one time.

Maintenance
  • e-chain systems® are virtually maintenance-free and can run for years without problems.

Hazardous Areas
  • e-chain systems® utilize standard electrical cables that are insulated from the surrounding environment. For hazardous locations, they are available in a special ESD (electrostatic discharge) material to further increase operational safety.

Crane busbar system review

Adding or Removing Cables
  • Adding conductor rails and carbon conductors to a busbar system is a painstaking process. If even one cable is damaged it can halt the machine for an extended period of time while it’s replaced.
  • Busbar systems are only able to run power and control cables, hoses and other cables have to be guided by a seperate system.
Maintenance
  • Busbars are high maintenance systems that require a lot of care and adjusting. With many mechanical parts, there is a lot of room for error.
  • Additionally busbars use carbon conductors that have to be changed at regular intervals.
Hazardous Areas
  • Busbars expose bare loaded conductors to the surrounding environment. This creates a safety concern, especially in hazardous or explosive environments such as paper mills, paint booths, etc.

White Paper:
e-chain® with steel-rope guide vs electrical busbar?

Consider the facts before deciding which system is best for your application.

While busbars are a common solution for energy transfer in moving applications across long distances, the autoglide 5 from igus is a worthy alternative that offers features not possible with busbars.
 
Download the steel-rope guide vs busbar white paper
news 2022

Alternative overhead crane busbar system products

e-chain® busbar cable carriers

e-chains for cranes Recommended products:
  • P4HD - e-chain® with the longest service life
  • P4.1 - The universal e-chain®
  • Guide troughs - Long travel accessories
Shop all e-chains®

chainflex® busbar cables

chainflex® cables Recomended Products
Shop all chainflex® cables

Sensors for crane busbar

Sensors for cranes Recomended Products
Shop all sensors for cranes

Replacement Types of Busbar Systems

8 Facts to consider before choosing an overhead crane busbar system.

  • 1) What is a busbar?

    Busbars are horizontal metal conductors used to supply power along the runway or bridge of a crane through steel or copper conductor bars. A collector arm slides along the conductor bar, allowing current to pass from the electrified conductor bar to the moving collector and on to the moving hoist or other traveling element.

  • 2) What are the main issues with busbar for crane electrification?

    Busbars require frequent inspection and maintenance, leading to downtime for the crane system. The collector shoes installed on the collector arms need to be regularly inspected and replaced when they wear out, requiring the system to be powered down for maintenance. Additionally, busbars are limited in the complexity and type of energy they can supply, and they expose bare loaded conductors to the surrounding environment, causing serious safety concerns, especially in hazardous or explosive environments.

  • 3) What are the functionality limitations of a crane busbar?

    Busbars are limited to power or occasionally control circuits, and adding additional components may require a full rebuild of the cable management system. They are also restricted to the transfer of electricity, which may not be sufficient in the era of Industry 4.0 where data transfer, such as for Ethernet, sensors, and camera systems, is essential.

  • 4) What are the environmental limitations of an overhead crane busbar system?

    Busbars are not suitable for areas with strict hygiene requirements, cleanroom environments, or environments with explosive and highly flammable products. They can also experience problems when used in environments with dust, debris, or corrosive elements.

  • 5) How can e-chain address the issues with a crane busbar system?

    e-chain is designed to withstand demanding environments, with a clean and durable design that reduces the need for frequent maintenance and inspection. It remains stable even under high loads and is resistant to moisture, heat, dirt, and debris. Additionally, it can guide energy, data, air, and liquids all in one system, making it suitable for the transfer of electricity as well as data transfer, which is essential in the era of Industry 4.0.

  • 6) What are the safety advantages of e-chain over a busbar for crane?

    e-chain is suitable for long travels up to 1,000m and is proven to withstand the most demanding environments. This addresses the safety concerns associated with busbars and makes it suitable for a wide range of applications.

  • 7) How can e-chain offer more functionality over a crane busbar system?

    Unlike busbars, the e-chain system can guide energy, data, air, and liquids all in one system, making it suitable for the transfer of electricity as well as data transfer, such as for Ethernet, sensors, and camera systems, which is essential in the era of Industry 4.0.

  • 8) What installation benefits does e-chain have compared to an overhead crane busbar system?

    e-chains, especially the autoglide 5 system, require significantly less installation time and effort compared to busbars, reducing overall setup costs and complexity.


festoon system vs e-chain system
System Comparison:

Energy chain systems instead of festooning

Provide guidance for cables and energy chains while keeping them protected and safe in wind and fluctuating temperatures. This minimizes downtime.


More crane technology information

chainflex® Flexible Cables in Stage Technology

10 tips for the crane industry

crane industry Brochure

Crane industry brochure

Orange Service

Engineering Services


Application Assistance

For further questions or product information, please contact:

Photo
Scott Parker

Sales and Product Manager, e-chain®

Email

Customer Service:

Monday to Friday from 8 am - 5 pm

Online:

24h


The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "kineKIT", "manus", "motion plastics", "pikchain", "plastics for longer life", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsibushi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention in this website. The products offered by igus® are those of igus® GmbH