Safe energy supply for seamless scene changes

As part of the extensive renovation work on the listed opera house, Bosch Rexroth was awarded the contract to build the main stage riser system. This includes six new 12 x 3 metre stage platforms that move up to 6 metres high at a speed of 0.5 metres per second. They 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 safe guidance of the many cables for energy, control, signalling and data transmission during the podium travel - in an area that must not 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 now 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.

The zig-zag energy supply system is the perfect solution here. The advantage: the cables are not kinked, but are guided safely within a defined bend radius. If a cable is damaged over the years or a technical change is required, the energy 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 energy chains of the E4.42 series as well as chainflex control, servo, motor and data cables. Up to 48 cables are contained in one chain. It was important to Bosch Rexroth to guide the igus cables separately from other special cables. Instead of two separate energy chains, igus offers a lean and cost-saving solution with a middle side link within one and the same chain.

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