With the zig-zag energy supply for strong stage lighting

Built in 1964, the theatre building is a listed building. Much of the technical equipment has evolved historically, including the lighting, which is attached to several movable rods. They are suspended from the ceiling at a height of 15 metres above the stage. To ensure that the scene is properly illuminated during the performance, a permanent power supply must be guaranteed that can withstand the movement of the poles.

Previously, the necessary cables were guided through fabric cables in which the relevant power cables were firmly woven in. Although these have performed their service on site largely smoothly for many years, problems have become more frequent in the recent past. Due to the fixed installation of the cables, it is very difficult to replace individual broken strands. At the same time, dust often accumulates on the fabric, which significantly increases the fire load of the system. Finally, fabric cables do not utilise a defined bend radius, so that after a few years, cable breaks occurred, causing unreliability in the lighting.

The technicians therefore looked for a safer alternative that would last at least 15 years. The particular challenge here was to find a system that could both be integrated into the existing overall construction and easily adapted at a later date. This is because the municipal theatre is about to undergo a general refurbishment, at the end of which the stage may look completely different.

As is usual for all German theatres, renovations and technical repairs are carried out during the 6-week summer break. The remodelling had to be completed within this time frame.

The theatre has therefore turned to igus and installed an energy chain in the zig-zag system during the 2022 season break.

The advantage here is that the cables are not kinked here, but are guided safely in a defined bend radius. If a cable is damaged over the years or a technical innovation is required, the energy chain can be opened with little effort and the corresponding cable replaced or added. With the zig-zag system, the e-chain is stored in a special guide box, which is installed directly on the lighting bar and therefore at the lower end of the chain. When the bar is lowered, the chain unfolds automatically and then zig-zags again in the opposite direction. This process has enabled the municipal theatre to install a reliable and durable alternative to the fabric cable that fits into the existing system.

The guide boxes are standardised modular lightweight boxes, which allow the application to be expanded in the future. And in the event that further cables are to be added to the chain during the conversion, igus has also already made provisions: the chain is large enough to accommodate several additional cables without any problems. The municipal theatre is satisfied with the purchase of the new system. Since its installation, the chain has proved its worth and there have been no problems.

According to Julian Zell, the lighting manager at the Ingolstadt municipal theatre, the success of the application is also due to the fact that igus takes time to address the challenges and needs of its customers. "We felt very well looked after throughout the entire installation process," says Zell. Thanks to the excellent cooperation between igus and the municipal theatre, it was possible to keep to the tight schedule during the intermission. In addition to consulting, designing and delivering the complete systems, igus also carried out the installation service on site - hand in hand with the other trades. After three and a half weeks, all systems were fully installed.

igus itself also benefited from the application, not least because the concept of the modular guide box has now established itself as the new standard.