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Project information sheet: Caja Mágica

This new tennis stadium was built on behalf of Madrid to host the Olympic Games 2020 and is based on a draft of the French star architect Dominique Perrault.

The requirements placed on Rexroth:

Lifting and horizontal movement of three roofs: There will not be rain breaks any more, nevertheless the best players of the world can compete against each other in the open air.

The technical principle and concept by Rexroth:

Over the Central Court with place for 12.000 spectators two Rexroth hydraulic cylinders specially designed for this project shift the 103 x 73 meter big roof. It weights 1.800 tons - this corresponds to the weight of an about eight kilometre long queue of cars. Hydraulic cylinders lift the roofs, and hydraulic motors drive the roof including the cylinders horizontally on rails.

The control concept by Rexroth:

Two independent working laser measuring systems, for each movement (two for lifting, two for the horizontal movement in each side of the roof); supervise the movements with an accuracy of +/-2 mm from the whole distance. A cus-tomized synchronisation close loop system designed by Rexroth evaluates the measuring signals and works despite the long distance with extreme ac-curacy: Horizontal position synchronisation on 65 meters of travelling dis-tance, with a maximum deviation between both sides, lower than 20 mm. This prevents tensions within the structural steel construction of the roof. The same technology is used in the cylinder systems for lifting: Two independent laser measuring systems per cylinder guarantee position synchronization with an accuracy of 20 mm between the cylinders for lifting without tensions in the steel construction.

In roof 2 and 3 the lifting is controlled via two independent transducers (one laser system and one multi round encoder). The horizontal movement is con-trolled as per roof 1.

The services rendered by Rexroth:

Rexroth took also over responsibility for the whole processing, from the Engineering and production of components up to the assembly and com-missioning of the drive system. Using state-of-the-art simulation programmes to ensure performance of the customized large cylinder.

  • 6 hydraulic cylinders for roof tilting (two 16 meter long cylinders for roof 1, two identical cylinders for each roof 2 and 3)
  • 16 hydraulic A2FM motors for the horizontal movement
  • 4 cylinders for tilting the locking supports on roof 2 and 3
  • 6 hydraulic Power Unit inside a container
  • 6 containers with the power unit and electrical cabinets installed (local control from the container also possible)
  • 6 Electromechanical cylinders for locking the horizontal movement
  • Special frame constructions for placing the power units on top of the cylinders
  • Electric cabinets
  • Two PLC working in parallel for security reasons
  • Central and local Visualisation through a SCADA system (SCADA: Concept for monitoring and control of complex technical processes; includes different components like PC, PLC, visualization and control software etc.; often used for industrial and infrastructure processes, e.g. power generation, wind farms, water treatment etc.)
  • 22 boogies (wheel diameter 800 mm), thereoff 7 per roof side of roof 1 (=14 bogies) and 2 per roof side of roof 2 and 3 (= 8 bogies) Assembly of the whole scope of supply, hydraulic piping, electric cabling, electric and hydraulic commissioning