Cable Conveyance Methods for a Submerged Arc Welder on Track

[KLove]

Hello,

I am tossing around some ideas to manage the power cable for a mobile submerged arc welding system. The manipulator runs along a 75' straight track, and I need to find a way to keep the power cable safe while the carriage is in transit back and forth. So far the ideas are:

Cable Carrier (E-Chain)
Some type of pulley system coming off the carriage that picks the cable up and keeps it away from the moving carriage (this only mitigates a small part of the issue, as the cable would still lie on the floor)
Festoon System
Reel

So my question has two parts; how would you do it, and more specifically for this forum's experts, is a reel system even feasible? It seems as a concept the most efficient but with the voltage and size of cable involved it may not even be possible.

For reference the cable is a Carol 4/5 type SOOW 90C P-7K-123033 rated for 600 volts, with a 1.1" OD.

Any insight would be greatly appreciated, thank you!

 

[MacGyverS2000]

What's wrong with the "slack wire with hangers every 10 feet" scenario used in other track-based systems?

Dan - Owner

http://www.Hi-TecDesigns.com

 

[KLove]

I looked into designing and building a system that would work just like other festoon systems (similar to what are used on overhead hoists), but with the current constraints it doesn't really seem feasible. I find myself circling back to a simple cable carrier system running alongside the track. Seems like it would be safe, relatively efficient, and after delving into other ideas the cheapest (which is what management was concerned about in the first place, of course). Does anyone know of any major downfalls of using a cable carrier? I think that is probably the way we will go.

 

[MacGyverS2000]

How do you get "unused" cable back into the carrier once it has been pulled out during "use"?

Dan - Owner

http://www.Hi-TecDesigns.com

 

[KLove]

Sorry, I meant this type of apparatus, so the cable isn't actually pulled out of anything, the chain just runs along the floor beside the track from a central point.

 

[FacEngrPE]

I had success with both festoon and cable carrier systems in crane applications. The cable carrier solution is necessary when dictated by available space - it's more compact. The two systems have different items impacting maintenance costs:
Festoon - the carrier wheels are the ware items, make sure you have spares.
Cable Carrier - if using the reinforced nylon like this one

https://www.igus.com/info/energychains,

life limiting factor is mechanical damage, never have seen failure from wear. However housekeeping and installation details are important,

https://toolbox.igus.com/flexible-cables/5-hidden-cable-carrier-killers.

Cables can walk longways as the carrier travels, so even spare cables must be clamped per the carrier OEM instructions.

Disclaimer - while I have used IGUS products I do not have enough experience with other products to know that IGUS is better or worse. I did find the sales support engineering staff competent.

I did jobs with sliding shoe power pickups - they are electrically noisy, which might cause trouble with
Fred

 

[waross]

I had a gantry crane with about 700 feet of travel.
Something like this worked well.

Bill
--------------------
"Why not the best?"
Jimmy Carter