Cable Trolleys for C-Rails Program
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1 Cable Trolleys for C-Rails Program
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3 Contents C-Rail and Accessories Program 02 C-Rail x... 4 Track Coupler... 4 End Stops... 4 Track Support Brackets... 4 Support Arm and Girder Clip... Brackets... Cable Trolleys Program 02 Cable Trolleys for Flat Cables... 6 Cable Trolleys for Round Cables... 7 Pairs of Rollers for Cable Trolleys... 7 C-Rail and Accessories Program 0 C-Rail 63 x Track Coupler... 8 End Stops... 8 Track Support Brackets... 8 Support Arm and Girder Clip... 9 Brackets... 9 Cable Trolleys Program 0 Cable Trolleys for Flat Cables Cable Trolleys for Round Cables Pairs of Rollers for Cable Trolleys C-Rail and Accessories Program 0260 C-Rail x Track Coupler End Stop Track Support Bracket Brackets Cable Trolleys Program 0260 Cable Trolleys for Flat Cables Cable Trolleys for Round Cables... 1 Pairs of Rollers for Cable Trolleys... 1 Cable Trolleys Light Version Cable Trolleys for Flat Cables Cable Trolleys for Round Cables Trolleys with 4 Rollers Spring Safety Hook End Stops Accessories for Festoon Systems Program 02, 0 and 0260 Towing Ropes Damping Devices Round Cable Clamps Spacers Flat Cable Organizer Helpful Hints / Spare Parts Helpful Hints Wear Parts... 3
4 C-Rail and Accessories Program 02 C-Rail x * Material: sendzimir galvanized steel Weight: 4.36 kg/m Stanrd Length: 6 m l x = 17.8 cm 4 ; W x = 6.4 cm 3 Track Coupler * 1. Weight: 1.0 kg End Stops M without Rubber Buffer 0111* with Rubber Buffer ø Weight: 1.0 kg To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Brackets ø Perm. Load: 320 kg Weight: 0.8 kg M Perm. Load: 320 kg Weight: 0.9 kg 4
5 C-Rail and Accessories Program 02 Track Support Bracket M * Hardware: galvanized steel Perm. Load: 320 kg Weight: 0.9 kg Support Arm and Girder Clip l ød 60 min. 7 Girder clip Support arm Track support bracket C-Rail Description l Weight Support arm * Material: sendzimir galvanized steel Description ø d Weight Girder clip /* M Material: galvanized steel Brackets 1 ø l l Material galvanized steel Weight
6 Cable Trolleys Program 02 Cable Trolleys for Flat Cables lw ø 40 k 106 Max. Load Capacity: kg Max. Travel Speed 100 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm ø 40 Ordering Example: Cable Trolley for Flat Cable Towing Trolley le le - 23 a Example: Order a cable trolley with stanrd-rollers for a flat cable package with a size of 110 x 4 mm (width x thickness). Selected: Cable Trolley with d a = 1 mm (According to minimum bend diameter of cable) b 2 = 130 mm s = mm : Cable Trolley : 02-2x160 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a x100* x100* x100* x160* x160* x160* x x x x160* x160* x160* x160* x160* x160* x x x x160* x160* x160* x x x x160* x160* x160* x x x l w k b 1 b 2 s l m l e a 6
7 Cable Trolleys Program 02 Cable Trolleys for Round Cables lw ø 40 k 11 Max. Load Capacity: kg Max. Travel Speed 100 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm ø 40 Ordering Example: Cable Trolley for Round Cable Towing Trolley le le - 23 a Example: Order a cable trolley with rollers with seal disks for several round cables ø mm and a support width of 200 mm. Selected: Cable Trolley with d a = 2 mm (According to minimum bend diameter of cable) b 2 = 21 mm Roller with Seal Disks 2 RS.../010 : Cable Trolley : x2/010 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b x160* x160* x160* x200* x200* x200* x160* x160* x160* x2* x2* x2* x x x x x x b 2 s l m l e a Pairs of Rollers for Cable Trolleys Program 02 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel Roller with Seal Disks 2 RS.../010 7
8 C-Rail and Accessories Program 0 C-Rail 63 x * Material: sendzimir galvanized steel Weight: 6. kg/m Stanrd Length: 6 m l x = 44.4 cm 4 ; W x = 13.0 cm 3 Track Coupler * Weight: 1.9 kg End Stops M without Rubber Buffer 0611* with Rubber Buffer ø Weight: 2. kg 43 To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Brackets Perm. Load: 0 kg Weight: 1.6 kg M Perm. Load: 0 kg Weight: 1.8 kg
9 C-Rail and Accessories Program 0 Track Support Bracket M * Perm. Load: 0 kg Weight: 1.8 kg Support Arm and Girder Clip l ød 60 min. 100 Girder clip Support arm Track support bracket C-Rail Description l Weight Support arm * Material: sendzimir galvanized steel Description ø d Weight Girder clip /* M Material: galvanized steel Brackets ø l l Material galvanized steel Weight 9
10 Cable Trolleys Program 0 Cable Trolleys for Flat Cables lw lw 1) ø 2 k 133 Max. Load Capacity: kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 2 Ordering Example: Cable Trolley for Flat Cable Example: Order a cable trolley with stanrd-rollers for a flat cable package with a size of 140 x mm (width x thickness). Towing Trolley Selected: Cable Trolley with d a = 1 mm (According to minimum bend diameter of cable) b 2 = 168 mm s = mm le le - 32 a 30 : Cable Trolley : x200 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b x160* x160* x160* ) x x x x160* x160* x160* x200* x200* x200* x x x ) x x x x160* x160* x160* x200* x200* x200* x x x x x x b 2 s l m l e a
11 Cable Trolleys Program 0 Cable Trolleys for Round Cables lw ø 2 k 13 Max. Load Capacity: kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 2 Ordering Example: Cable Trolley for Round Cable Example: Order a cable trolley with rollers with seal disks for several round cables ø mm and a support width of 200 mm. Towing Trolley Selected: Cable Trolley with d a = 2 mm (According to minimum bend diameter of cable) b 2 = 211 mm Roller with Seal Disks 2 RS.../01 le le - 32 a 30 : Cable Trolley : x2/01 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b x200* x200* x200* x2* x2* x2* x200* x200* x200* x2* x2* x2* b 2 s l m l e a Pairs of Rollers for Cable Trolleys Program 0 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel Roller with Seal Disks 2 RS.../01 11
12 C-Rail and Accessories Program 0260 C-Rail x * 18 6 l x = cm 4 ; W x = 27.4 cm 3 Weight: 10.6 kg/m Stanrd Length: 6 m Track Coupler * 82 Weight: 3.6 kg 34 End Stop M * with Rubber Buffer Weight: 2.4 kg ø 7 43 To avoid system mage we recommend the fitting of a securing bolt as illustrated. Track Support Bracket * Perm. Load: 630 kg Weight: 2.4 kg 12
13 C-Rail and Accessories Program 0260 Track Support Brackets M Perm. Load: 630 kg Weight: 2. kg M ø Perm. Load: 630 kg Weight: 2. kg Brackets l l Material galvanized steel Weight 13
14 Cable Trolleys Program 0260 Cable Trolleys for Flat Cables lw ø 62 k 109 Max. Load Capacity: 1 kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 62 Ordering Example: Cable Trolley for Flat Cable Example: To order a cable trolley with stanrd-rollers for a flat cable package with a size of 160 x 60 mm (width x thickness). Towing Trolley Selected: Cable Trolley with d a = 160 mm (According to minimum bend diameter of cable) b 2 = 168 mm s = 70 mm le le - 32 a 36 : Cable Trolley : x200 End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b x160* x160* x160* x200* x200* x200* x x x x160* x160* x160* x x x x2* x2* x2* b 2 s l m l e a
15 Cable Trolleys Program 0260 Cable Trolleys for Round Cables lw ø 62 k 148 Max. Load Capacity: 1 kg Max. Travel Speed 120 m/min Basic trolley and cable support: Steel, hot-dipped galvanized Hardware: Galvanized steel Stanrd roller: Ball bearing, galvanized steel Cable Trolley lm lm - 2 ø 62 Ordering Example: Cable Trolley for Round Cable Example: Order a cable trolley with rollers with seal disks for several round cables ø 32 mm and a support width of 108 mm. Towing Trolley Selected: Cable Trolley with d a = 320 mm (According to minimum bend diameter of cable) b 2 = 211 mm Roller with Seal Disks 2 RS.../01 le le a 36 : Cable Trolley : x2/01 79 ø End Clamp 1) 1) For assembly- 2 holes ø 12. mm to be drilled into the C-Rail at distance a. Cable Trolley Towing Trolley End Clamp d a l w k b x200* x200* x200* x2* x2* x2* x x x x x x b 2 s l m l e a Pairs of Rollers for Cable Trolleys Program 0260 Description Roller Type Sealing Type Load Capacity Special Roller Additional- Stanrd Roller 2 Z - Ball Bearing, galvanized steel 1 Roller with Seal Disks 2 RS.../01 1
16 r Cable Trolleys Light Version Cable Trolleys for Flat Cables 1 D 10 a 4 4 ø d 4 Cable Trolley Main Body: sendzimir galvanized steel Buffer: rubber Support: plastic End Clamp Insulating Plate: plastic Split Nut: plastic Hardware: galvanized steel For C-Rail Program x x 63 0 x 0260 Cable Trolley End Clamp D ø d a x0* * x0* * x0* * x0* * x0* * x0* * s Load Capacity Cable Trolleys for Round Cables 1 D 60 a I b c hmax. ø d Cable Trolley End Clamp Main Body: sendzimir galvanized steel Buffer: rubber Ball Joint: plastic Connecting Plate: plastic Hardware: galvanized steel For C-Rail Program Cable Trolley End Clamp D ø d Load Capacity x * * x * * x * * 0.27 If required, it is possible to fit one or more similar or different sized cable clips to a trolley. When fitting different sized cable clips, the largest cable clip must be fitted on top. 16 ø d r l h b c Material Cable clip Fasteners * Galvanized * Plastic 0.06 Steel * Weight
17 Cable Trolleys Light Version Trolleys with 4 Rollers l ø 40 Main body: galvanized steel Roller (ball bearing): galvanized steel Buffer: rubber 10 Spring Safety Hook 9 8 ø ø 10. For C-Rail Program x 02 Weight l Load Capacity x6 Material galvanized steel End Stops Hardware: galvanized steel Buffer: rubber For C-Rail Program Type x * x * with Buffer 0.20 x * 0.22 Weight 17
18 Accessories for Festoon Systems Program 02, 0 and 0260 Towing Ropes Type B 28 L 28 ød Type C L ød Type C suggested for use with mping devices. Different types and lengths available upon request. ø d Material Rope Galvanized Steel B Galvanized Steel with PVC Jacket Galvanized Steel with PVC Jacket C Type for Program 02, 0, 0260 Damping Devices ød L Different types and lengths available upon request. ø d Material Rope for Program Rubber core with Nylon jacket 02, 0,
19 Accessories for Festoon Systems Program 02, 0 and 0260 Round Cable Clamps Spacer ø dmax ø d1 ø d2 bi ba ~ t s h s ø d max. b i b a x100/ x1/ x200/ x2/ x100/ x1/ x200/ x2/ h s Sd 1) ) A cable separator is required between cables if the sum of the diameters of two adjacent cables is smaller than the value Σd. Material Support Rail Cable Clip Fasteners Aluminum Rubber Stainless Steel Spacers 48 b s t b Material Used with Round Cable Clamp x... Plastic x... 19
20 Accessories for Festoon Systems Program 02, 0 and 0260 Flat Cable Organizer Power cables are clamped in upper window s 1, control cables are contained in lower window s 2 with sufficient space (> 2 mm) to allow the cables to move freely. Flat cable clamps are supplied pre-assembled with upper window s 1 of minimum size and lower window s 2 of maximum size. The cable clamps can be adjusted to fit cable packages by transferring spacers from window s 2 to window s 1. Clamped Power Cable Control Cable Contained in Lower Window hmax. s2 s1 hmax. s2 s1 bi 32 bi bi and ba ba 32 b i b a s 1 + s 2 s 1min. h max. Material Cable Clamps Fasteners x Galvanized x Steel x x0/ x03/ x04/ x0/ x06/ x0/ x03/ x04/ x0/ x06/ Plastic x07/ Stainless x08/ Steel x03/ x04/ x0/ x06/ x07/ x0/ x03/ x04/ x0/ x06/ x07/ Weigth 20
21 Helpful Hints Determining the Support Distance for C-Rail Program 02 Technical Data / Calculation Assumptions The required support distance of the C-rail can be determined using the diagram below. The following calculation assumptions have been taken into consideration: 1. Simply-supported beam, uniform load symmetrical to middle of the beam 2. The load of one trolley F LW [kg/trolley] is distributed over trolley length l W as a uniform load p [kg/m] 3. Total length of the uniform load results from the cable trolley storage length l b [m] of all trolleys side by side 4. σ b zul = 100 N/mm², without consideration of the lower flange stress. σ V 160 N/mm², reference stress from bending stress and lower flange stress 6. f = I A /2 permissible deflection from the load and net weight of the rail 7. As track support bracket load the load of a field symmetrical to the mounting (bracket) is assumed Example: Given: F LW = Cable Trolley Load: 28 kg (X axis value on the left-hand graph below) l w = Cable Trolley Length: 200 mm (blue line on the left graph) Z = Overall number of Cable Trolleys: 8 l b = Cable Trolley Storage Length: 1.6 m (X axis on the right-hand graph below) (m) = Z x l w / 1000 Load Diagram for C-Rail x x 3. (0100) Cable Trolley Length l w Cable Trolley Load F LW [kg/trolley] p [kg/m] Cable Trolley Storage Length l b [m] Support Distance l A [m] Solution for C-Rail x x 3. From diagram: Required Support Distance l A = 1.9 m 21
22 Helpful Hints Load diagram for C-Rail 63 x 63 x 4 (0600) 0 Length of cable trolley I W p [kg/m] Distance between track support brackets I A [m] Cable Trolley Load F LW [kg/trolley] Cable Trolley Storage Length l b [m] Example: p [kg/m] Distance between track support brackets I A [m] Given: F LW = Cable Trolley Load: 4 kg l w = Cable Trolley Length: 2 mm Z = Overall number of Cable Trolleys: 10 l b = Cable Trolley Storage Length: 2. m (m) = Z x l w / 1000 Solution for C-Rail 63 x 63 x 4 From Diagram: Required Support Distance l A = 2. m Load diagram for C-Rail x x (140) Length of cable trolley I W Cable Trolley Load F LW [kg/trolley] Cable Trolley Storage Length l b [m] Example: Given: 22 F LW = Cable Trolley Load: kg l w = Cable Trolley Length: 400 mm Z = Overall number of Cable Trolleys: l b = Cable Trolley Storage Length: 2 m (m) = Z x l w / 1000 Solution for C-Rail x x From Diagram: Required Support Distance l A = 3.6 m
23 Helpful Hints Technical Data lb ls e lw LinstM h hges LinstE >0.1m Formulas to Determine the Number of Loops, Cable Length and Loop Depth Number of loops: n = Storage length: f (l s + e) 2 h + 1. d a - f l w l b n l w + e [m] System cable length: Loop length: L Syst = f (l s + l b ) [m] L Schl = L Syst n [m] Total cable length: Loop depth: L Best = L Syst + L inste + L instm [m] h = L Schl d a [m] d a [m] = cable support diameter e [m] = free space in storage area (recommention 0.1 m) f = recommended cable factor (see table page 24) h [m] = loop depth (measured from top edge of cable support) h ges [m] = loop depth (measured from lower edge of track profile) l b [m] = storage length incl. free space l s [m] = travel distance l w [m] = cable trolley length L Best [m] = total cable length L inste [m] = installation length, end clamp side L instm [m] = installation length, towing side L Schl [m] = cable length per loop L Syst [m] = required cable length (measured from mid of end clamp to mid of towing trolley or towing clamp) n = number of loops 23
24 Helpful Hints Definition of the cable arrangement and cable trolley selection 4x10 7x2. 4x2. 7x2. 12x1. 12x1. b 4x10 Example for flat cable trolleys Power cables dmax s 1. Formula for calculating the approximate load per trolley F LW G L [kg/m] F LW 2 h G L = weight of the cable package Selection of the cable trolley type Required cable support diameter based upon minimum bending radius of the cables Select cable support width b 2 to accommote the cable package width Determine length of trolley l w b Example for round cable trolleys For round cables: l w d a + 2 d max + 10 For flat cables: l w d a + 2 s + 10 Cable Factors Travel Speed v [m/min] Cable Factor f at h [m] < < Depending on the operating conditions the cables must be installed with an additional cable length. The additional length is calculated by taking into account the cable factor [f]. We recommend to select the cable factor according to above table. For values outside the gray area, please contact us directly. Special precautions might be required in those cases under extreme operating conditions, such as the installation of shock cords. Permissible Loads of the Rollers Travel Speed V [m/min] Average Running Time per Day [h] < > > < > Program Steel Roller Ø Permissible Load per Trolley Program PU Roller Ø Permissible Load per Trolley The lifetime of the rollers depends on the load (Hertzian stress) and the frequency of operation. The proper selection, based on travel speed, average running time per y (based on one year) and permissible load of the trolleys with various roller types, can be made by using the above table. 24
25 Wear Parts Replacement Rollers for Program 02 ø 8 13 ø 40 Description Stanrd Roller Roller with Seal Disks Replacement Rollers for Program 0 1 ø 2 Description Stanrd Roller Roller with Seal Disks Ersatzrollen für Programm 0260 ø 62 Description Stanrd Roller Roller with Seal Disks Buffer for Program 02 ø 40 M 8 Description Buffer 02-P Buffer for Program 0 und Description Buffer x/14 20 M8 Shock Cords for Program 03 and 0330 LGum ø d ød Weight [kg/m] Note In case of order please state the lengths L Gum of the respective shock cords..
26 Your Applications our Solutions Cable Trolleys from Conductix-Wampfler represent only one of the many solutions made possible by the broad spectrum of Conductix- Wampfler components for the transport of energy, ta and fluid media. The solutions we deliver for your applications are based on your specific requirements. In many cases, a combination of several different Conductix-Wampfler systems can prove advantageous. You can count on all of Conductix-Wampfler s Business Units for hands-on engineering support - coupled with the perfect solution to meet your energy management and control needs. Cable reels Motorized reels and spring reels by Conductix-Wampfler hold their own wherever energy, ta and media have to cover the most diverse distances within a short amount of time - in all directions, fast and safe. Festoon systems It s hard to imagine Conductix- Wampfler cable trolleys not being used in virtually every industrial application. They re reliable and robust and available in an enormous variety of dimensions and designs. Conductor rails Whether they re enclosed conductor rails or expanble single-pole systems, the proven conductor rails by Conductix-Wampfler reliably move people and material. Non-insulated conductor rails Extremely robust, non-insulated conductor rails with copper heads or stainless steel surfaces provide the ideal basis for rough applications, for example in steel mills or shipyards. Energy guiding chains The Jack of all trades when it comes to transferring energy, ta, air and fluid hoses. With their wide range, these energy guiding chains are the ideal solution for many industrial applications. Slip ring assemblies Whenever things are really moving in circles, the proven slip ring assemblies by Conductix-Wampfler ensure the flawless transfer of energy and ta. Here, everything revolves around flexibility and reliability! Inductive Power Transfer IPT The no-contact system for transferring energy and ta. For all tasks that depend on high speeds and absolute resistance to wear. Reels, retractors and balancers Whether for hoses or cables, as classical reels or high-precision positioning aids for tools, our range of reels and spring balancers take the load off your shoulders. Jib boom Complete with tool transporters, reels, or an entire media supply system here, safety and flexibility are key to the completion of difficult tasks. Conveyor systems Whether manual, semiautomatic or with Power & Free flexibility is achieved with full customization concerning layout and location. 26
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28 KAT d-E Conductix-Wampfler 201 subject to technical modifications without prior notice Conductix-Wampfler GmbH Rheinstrasse Weil am Rhein Germany Hotline Phone +49 (0) Phone +49 (0) Fax +49 (0)
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