Powerful e-chains for a stage platform lift

Energy chain systems ensure safe cable guidance in Waagner-Biro moving stage platform

When special technical concepts are required in theatres, at the opera, or on cruise ships, Waagner-Biro Stage Systems GmbH is not far away. The stage technology specialist has been developing various innovative technical systems for more than 150 years – all for the big show. For safe cable guidance, the designers use our smoothly operating energy chain systems.

Profile

What was needed: E4.32 series energy supply systems, e-spool, foldable e-chains
Requirements: Stage technology involves heavy loads requiring high chain strength. It requires low-noise, inconspicuous systems that can usually use only a small amount of installation space. The system must also offer easy installation with little maintenance while maximizing service life.
Industry: Theatre and stage equipment
Success for the customer: The E4.32 is lightweight and wear resistant. Stop and rolling noise is dampened. The e-spool provides a quiet, extremely compact alternative to cable drums. And our foldable e-chains are also extremely compact, inconspicuous, and quiet.

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Fully harnessed E4.32 series energy chains ensure safe cable guidance for the eight moving platforms in the "Unter den Linden" State Opera House in Berlin.

Problem

Creating the optimal stage for the perfect performance is the challenge that stage technology specialist Waagner-Biro Stage Systems from Vienna, Austria, is tackling. Every project is different. All components must not only be effective, durable, and efficient, but also fit together perfectly. Large, well-known theatres, opera houses, arenas, and multifunctional halls worldwide are part of the Waagner-Biro Stage Systems customer base. But cruise ships are also fitted with especially space-saving technology.
Theatre and stage construction have very demanding technical requirements. They include high loads in such applications as sound and lighting systems, stage sets, and entire stage platforms, which must move safely and reliably. Vertically or horizontally, things move in the theatre. For instance, a large number of motors and cables are usually used today to set the stage machinery in motion. And solutions that do not interfere visually or acoustically with the performance are in especially high demand. The motor, data, and bus cables should therefore operate invisibly and quietly. But only a small amount of installation space is usually available. The cables themselves must be compact, move quietly in the energy supply system, and withstand high dynamic loads. Strength and robustness are therefore necessary properties. The stage technician needs systems that are easy to assemble, require little maintenance, and maximize service life.

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Solution

The designers have been using our safe, smoothly operating E 4.32 series energy supply systems for more than 13 years. They are used vertically or horizontally in stage technology, especially in platforms. Since the energy chains are made of tribo-plastics, they are both lightweight and wear-resistant. An integrated brake on the energy chain links' radius stop-dogs also dampens the stop and rolling noise.
Traditionally, cable drums are also used in stage technology for cable guidance, but often reach their technical limits in terms of accommodating cables and generating noise. Our e‑spool provides a quiet, extremely compact alternative. The cables are always protected from external influences, wear, and tensile strain. During reeling, an integrated retaining spring ensures the correct chain tension at all times. The twisterband in the e-spool allows continuous cable guidance during rotational movements without needing a slip ring.
Moving stages or heavy stage platforms means lifting heavy loads to heights of many meters. Here, too, we offer affordable, space-saving, and inconspicuous solutions. So far, the systems for such applications have been noisy, large, and visually intrusive. The zig-zag installation method with our foldable e-chains offers an effective alternative with a compact design. Reverse bend radii allow the e-chains to be stored in a zig-zag pattern so that they require very little space. When the stage or platform is raised, the e-chain unfolds quietly.

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"In addition to the wide range of products and the proven quality, we very much appreciate the very intensive, long-standing cooperation. No matter what the issue is, we always get quick, competent, support for it. We have projects worldwide, so it is a great advantage that igus can provide direct on-site support with its subsidiaries and technicians.

Erwin Papst

Head of Design at Waagner-Biro

Scissor lift stage platform podiums and airframes for personnel, the customer uses igus zig-zag solutions from our energy chain product range.

In more than 13 years of cooperation, there have been a number of large-scale projects in which the three types of chains have been the right answer to local challenges. In an opera project in which eight platforms were extended, the linear E4.32 series energy chains were the optimal solution. The energy supply system was designed in close cooperation with igus. The project uses four energy chains with matching chainflex cables per platform, delivered directly from a single source and harnessed as readychains. For stage elevator energy supply or in lighting technology, Waagner-Biro's experts use e-spool solutions. In a large opera house, 20 of the power e-spools have been successfully installed.

igus e-spools are used in such locations as the Joan Sutherland Theatre/Sydney Opera House.

Sydney Opera fly walk: e-chain connection to the tie rods

White Paper:

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Like every industry, stage technology has its own requirements regarding machine parts and materials. In this white paper, we would like to give you six tips for selecting and designing vertical energy supply systems for stage technology

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Whether you're interested in end-to-end, fully assembled solutions or looking to build your own customizable project, let us assist you with a solution based on your specific application and requirements. Contact us via the form below or call us at (800) 521-2747 to discuss your project today!

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