Bearing technology and energy supply systems for hydropower plants

Machine components used in hydropower generation must function reliably and continuously, as failures due to material wear and frequent maintenance can have a negative impact on energy yield. igus offers customised solutions from prototype to high-volume production that improve the technology of your wave power plants, turbines or rake cleaners. Our plain and spherical bearings, lead screws and energy supply systems have many advantages: They are suitable for use under water, dirt and UV-resistant, quiet and low vibration and fit into tight installation spaces thanks to their compact design. Our dry-tech bearing technology made from tribo-optimised plastics is characterised by extremely low friction coefficients and a long, predictable service life and is 100% lubrication-free and maintenance-free.

basic flizz energy supply system

• Cost-effective complete system consisting of energy chain, chainflex cables and stainless steel housing
• Protection against weather and dirt exposure
• Low-maintenance, for travels up to 100m

Plain and spherical bearings

• Lubrication-free flanged bushings made of the all-round material iglidur G or iglidur H especially for underwater applications
• Rod ends igubal KBRM: corrosion-free, suitable for liquid media, with robust, long fibre-reinforced polymer spherical ball

Bearing technology and e-chain

• Bar stock plates made of iglidur JB: highly wear-resistant with a low coefficient of friction
• Heavy-duty lead screw nut dryspin JGRM  + high helix lead screw dryspin stainless steel AISI 304 with right-hand thread
• Pillow block drylin RJUM + round shaft EEWM in stainless steel AISI 420C
• Energy chain Series E4.1: light, robust, modular

Plain bearings

• For guiding the piston:
  Sleeve bearings iglidur H370 for high loads, with very good wear resistance under water
• For fixing the water column and the main pivoting movement:
  High-strength wound slide bearings igutex TX1 or igutex TX2, very wear-resistant under extreme loads

Plain bearings

• For guidance of the piston:
  Sleeve bearings iglidur Q for high loads, wear-resistant on many shafts
• For supporting the main axis:
  High-strength wound slide bearings igutex TX1 or igutex TX2, very wear-resistant under extreme loads

Plain bearings

Cylindrical bushings iglidur UW: extremely wear-resistant underwater endurance runner, the first choice for pump applications

Plain bearings

Flanged bearing iglidur H370 for high loads, with very good wear resistance under water

Safe energy supply even in high swells

The point absorbers from CorPower Ocean are lightweight, compact and cope well with storms thanks to the new "Wavespring Phase Control Technology". A cascade gearbox that drives a power generator converts the buoy's up-and-down movement into rotational movement. Two E4.1 series e-chains together with chainflex servo, power and control cables ensure safe energy supply within the buoy.

Plain bearings for long-life wave energy converters

For Rotary Wave's WEC, the designers were looking for bearings that were extremely resilient and suitable for the harsh seawater environment. The surface pressures achieved are around 50MPa, the maximum speed amounts to 10rpm. The decision was made in favour of iglidur Z plain bearings. They help achieve significantly better results than, for example, sintered plain bearings with a bronze surface.

First plastic WEC reliably moved with iglidur

PolyGen's wave energy converter is the world's first WEC to be made predominantly of plastic. For the bearing points on the axes of the flaps, bearings were needed that could withstand the high mechanical loads and corrosive salt water for as long as possible. The perfect solution was found at igus: iglidur flanged bushings made of the material H370, specially developed for the wet area.

Uninterruptible power transmission at the tidal turbine

The company Tocardo was looking for a way to guide the cables safely from the turbine to the converter in the control cabinet and thus achieve the longest possible service life for the system. igus provided the perfect solution with E4/4 e-chains: they are corrosion-resistant, completely resistant to persistently damp environments, easy to install, and quick to open if a cable needs to be replaced.

Tidal turbine moving safely on rough seas

The OpenHydro tidal turbine generates green electricity in the North Sea. The generator can be moved down 20 metres if necessary, which means that the cables are mostly below the water surface. A metal chain was not suitable for the harsh conditions at sea. The operator therefore relies on ourE4/4 plastic energy chain, which ensures maintenance-free operation of the turbine.

Saves space and maintenance costs: basic flizz system on the rake cleaner

The H-cleaner from Muhr, a global specialist for these systems, uses a proven standard for the energy supply to the carriage: the basic flizz system. Completely installed in just 1.5 hours at the Rochlitz hydroelectric power station, the compact system safely moves the cables up to 15 metres. Although well hidden, the energy chain is easily accessible for maintenance or when new cables need to be added.