Sometimes it just pays to do things yourself. When Rula Bulk Handling could not source a cable tensioner large enough for a new cableway, the engineers knew they had to come up with an inventive solution.
Erecting a cableway poses some unique challenges, and one crucial aspect is effectively managing cable tension. In a system like this, the cable is fed into a cable tensioner before being pulled over the pylons. The problem they faced was that due to the size of the cable, they would need to find a tensioner large enough to run the new cableway safely. After discovering that no such tensioner was immediately available, Rula approached Axiom Hydraulics and ifm to assist with building their own.
If there was ever a project for Axiom’s experts to sink their teeth into it was this one, and they welcomed the opportunity to work together with Rula to develop the new tensioner. ”We knew it would not be an easy task, but we were excited to assist Rula in realising this one-of-a-kind machine,” says Axiom application engineer, Greg Behrens. “From the initial concept phase right through to final commissioning, Axiom was on hand to provide Rula with both technical insight and support.”
The tensioner in this system utilises a hydrostatic brake system to control cable tension that is wound between drums, and it is able to induce a staggering 20 tons of braking force. The system variably controls the cable tension as necessary, while incorporating multiple passive and active emergency systems and redundancies. Every aspect of the tensioner is monitored and controlled to manage the cable tension safely and effectively.
The natural choice when it came to the display and controller for the machine was ifm. The company is a trusted manufacturer of sensors and systems for the automation industry and is well known for its robust and reliable products. With its industry and application expertise, ifm successfully provides system solutions that are both innovative and economical. An ifm HMI and PLC monitored and controlled various
aspects of the system to control the tensioner safely. Together with ifm, Axiom provided a complete electrohydraulic solution for the machine. This included custom-designed manifold blocks with Sun Hydraulics cartridge valves, low speed, high-torque Black Bruin motors, a variable displacement bent axis Brevini piston pump, a sizeable hydraulically driven ASA Hydraulik cooler, and additional hydraulic hardware to meet the system requirements. With Axiom’s impressive portfolio of brands, there was no doubt that this machine was equipped with world-class components and parts.
With the electrohydraulic system completed, the structural fabrication, fitting of electrics, corrosion protection, component fitment and final testing were all performed in-house by Rula. To ensure that the machine could handle the induced loads, Rula performed multiple finite element analyses (FEAs) to check stress and deflection distributions during worst-case</nobr> loading conditions.
“This stimulating project proved that tough engineering challenges are what we live for, and it reminds us why we love engineering. Axiom Hydraulics is proud to have played a role in this unique project, and we look forward to the next challenge,” concludes Behrens.
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