Marathon drag chain system: Solutions for long travel distances

1.1 Drag chains used in heavy-duty applications

In heavy-duty industries such as mining, machine building, steel production, drag chains used must withstand heavy loads and operate efficiently under high pressure. These drag chains are designed to support the weight of cables and cable accessories without causing any damage. In addition, drag chains used in these industries often need to travel over long distances or navigate curves, requiring smooth and stable movement. As the distance increases, so does the risk of cable damage and system inefficiencies, which can lead to costly maintenance and downtime. This is where drag chains with rollers become essential.

>>See more: Why are drag chains used in various industries?

1.2 What are drag chains with rollers?

Drag chains with rollers offer a safe and reliable solution when sliding systems are impractical due to long travel distances or excessive friction. In these systems, the upper section of the drag chain runs on rollers rather than sliding over the lower section. These rollers are mounted on ball bearings along both sides of the chain, enabling it to travel over extended distances while significantly reducing the power needed for operation.

In sliding systems, direct contact between the upper and lower sections of the drag chain increases friction over time, leading to wear and tear, system inefficiency, or even failure—particularly in applications with heavy loads or long travel distances.

By incorporating rollers, friction is greatly minimized. This allows the drag chain to move more smoothly, extending the system’s lifespan, reducing maintenance costs, and ensuring stable operation. This is especially crucial in industries where long travel distances are common, such as cranes, steel mills, and port machinery.

>>See more: Drag chains from EKD Systems

2.1 About EKD Systems

EKD Gelenkrohr GmbH (EKD Systems) is a German-based company belonging to the HELUKABEL Group. Founded in 1970 by Ernst Klein, EKD Systems is a developer and manufacturer of steel, stainless steel, and plastic drag chains. At EKD Systems, we focus on providing customized system solutions tailored to customers’ needs, mainly for small and medium-sized orders. Currently, the company owns multiple machining centers, its own die, and mold-making department, and a fully automated plastic injection molding department.

2.2 Marathon Systems from EKD Systems

The Marathon systems are patented solutions from EKD Systems for applications with unlimited travel distances, high speeds and high accelerations. The upper part of the drag chains runs over support rollers along the entire travel on continuous flat rails, and the rollers rotate at a radius to guide the drag chain on the lower rail. When moving in reverse, the rollers rotate out and guide the drag chains without wear during the entire travel. The Marathon systems are compatible with both steel and plastic drag chains, making it a versatile solution for various applications.

3.1 The reduction of sliding friction

One outstanding advantage of the Marathon systems is that, due to the roller guidance of the drag chain, it achieves a reduction of friction-related travel forces of up to 90%, resulting in energy savings and efficiency. This improves operating efficiency in applications requiring long-distance travel.

3.2 Reduced starting moments

Sliding friction between the upper and lower parts of the drag chains can generate significant resistance, leading to high starting moments and increased energy consumption. However, by eliminating sliding friction and incorporating rollers in the Marathon systems, starting moments are significantly reduced. This not only allows the system to run smoothly but also reduces mechanical stress, prolongs the lifespan of the drag chain, and conserves energy. In applications requiring long-distance travel, such as seaports, steel mills, or large production lines, lowering starting moments improves efficiency and minimizes maintenance costs.

4.2 Applications of Marathon drag chain systems

This highly efficient solution is well-suited for numerous applications, including the replacement of sliding chains, cable reel systems, festoon systems, and busbar systems. It is extensively used in ship-to-shore operations, particularly in container handling for RTG and STS cranes, as well as in bulk and coal material handling. Furthermore, the Marathon System offers versatility for use across a wide range of industries.

The Marathon drag chain system completes HELUKABEL’s solutions for heavy-duty industries, offering customers a comprehensive solution:

5.1 Marathon drag chain systems for harsh environmental conditions

Modern industrial systems, such as cranes, hoists, and festoons, increasingly demand faster operating cycles and higher speeds. The Marathon systems are fully capable of meeting these requirements, offering high-speed operation, rapid acceleration, and exceptional durability.

5.2 HELUKABEL’s drag chain compatible cables

HELUKABEL’s product portfolio encompasses various cables that are specifically designed for drag chains , ensuring high performance even in the harshest conditions. With their resistance to abrasion, heat, and continuous bending, our cables and wires meet the stringent demands of heavy-duty industries, enhancing system reliability. At our Windsbach manufacturing facility, these products undergo rigorous testing to ensure that our customers receive the highest quality.

>>See more: Put to the Ultimate Test – Part 3: Drag Chain Tests at Windsbach

5.3 Customized solutions tailored to customer’s needs

Understanding that each business has unique technical requirements, HELUKABEL offers flexible, customized solutions tailored to the specific needs of each customer. From cable design and construction materials to complex drag chain systems, we are committed to delivering the most optimal solutions. Our flexibility in meeting customized demands makes HELUKABEL a reliable partner for both large and small projects, contributing to improved operational efficiency and ensuring absolute safety.