Reliable cable guidance in the VELTINS Arena lawn exposure system

What was needed: E4/4 series rol e-chains, E2 series energy chains, e-spool energy chains, chainflex cables

Requirements: UV radiation, rain and temperature fluctuations required robust components. As various strokes had to be accompanied by cable guides, a particularly reliable system was also required.

Industry: Technology for agricultural applications

Success for the customer: The rol e-chains minimise the pull/push forces over a travel of 120m. Together with other compact energy chains for the short strokes in the system and matching chainflex cables, a long service life can be achieved and maintenance costs minimised.

RHENAC GreenTec AG has developed a turf lighting system that has been put into operation in the VELTINS Arena, home of FC Schalke 04. The R-BL 3500 lighting system can provide the football turf with contactless LED grow light for regeneration all year round. The high-tech system is equipped with various sensors that record the condition of the turf and make it available for evaluation.

The turf lighting system consists of a main steel beam with a span of more than 80 metres, which travels on rails over a distance of 120 metres. Several fold-out B-beams and continuously travelling C-beams along the main beam, which are equipped with LED light modules, can illuminate the entire turf area. To enable buses to pass underneath the structure, it can also be raised continuously from its operating position at a height of 1.50 metres to 4.65 metres. For all these adjustments, 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, various short strokes of 2 to 6 metres had to be realised using energy supply. The external conditions such as UV radiation, rain or temperature fluctuations required robust and durable components.

Rhenac GREENTEC AG decided to use energy chains, which can now be found on all moving elements of the lighting system. The two large plastic energy chains of the E4/4 series, which travel along the football pitch with the entire main beam of the system, are the most striking.

Over a travel of 120m, the cable guides, which are designed as rol e-chains, prove their worth by minimising the pull/push forces and significantly reducing the drive force required compared to sliding chains. For various smaller strokes on the B and C beams of the system, the manufacturer relies on the more compact E2 series energy chains, which are designed for medium loads and enable the LED lights to be reliably placed in their positions. The e-spool energy chains are also responsible for the infeed movements, i.e. space-saving rolled-up cable guides that unroll to the desired length when the beams are moved and prevent the system from sagging thanks to the retaining spring.

The various energy chains were supplied directly with the appropriate cables designed for moving applications from our product range. In particular, a large number of chainflex bus cables and chainflex motor cables keeps the system in operation and enable the continuous data transmission of the various sensors of the modern lighting system.
Together with our in-house installation service, we were able to provide a complete solution from a single source, whereby the coordinated products extend the service life of the moving modules and minimise maintenance costs.