New igus communication module connects i.Sense sensors and superwise service for cost-effective, fast and reliable condition monitoring in real time

New igus communication module connects i.Sense sensors and superwise service for cost-effective, fast and reliable condition monitoring in real time

Optimise operating processes and minimise downtimes: this is what the new iComm Box from igus helps you with. Thanks to the communication module, the i.Sense sensors for condition monitoring of igus motion plastics can be seamlessly integrated into the superwise service. Intelligent algorithms provide a detailed status analysis of the monitored machines and systems. The superwise dashboard provides information in real time and allows for optimum monitoring and control. A decisive advantage: the costs for data transmission are already included in the product price.

Stop a system right away before a mechanical defect leads to expensive consequential damage: this works best when technology supports the human eye in monitoring. For this reason, igus has been offering intelligent sensors from the i.Sense series for several years, which monitor the condition of moving machine components such as energy chains, cables, linear guides, plain and spherical bearings and slewing ring bearings. In the event of an anomaly, they immediately trigger a message or an automatic system stop to prevent expensive consequential damage. “The new communication module now opens up the cost-effective and simple option of expanding the functionality of these sensors,” explains Richard Habering, Head of the smart plastics Business Unit at igus. It connects the sensors with the superwise service from igus and thus enables fast and reliable data transmission. All reports are saved with measured values in the igus i.Cee portal and can be evaluated at a later time for diagnostic purposes. In addition, intelligent algorithms use the sensor data to calculate the movement profile of energy chains, for example. Based on the detailed analysis, precise predictions can be made about their condition. The superwise dashboard clearly displays real-time information on service life, maintenance recommendations and information on anomalies. “This approach ensures that no potential service life remains unused and at the same time minimises the risk of failure,” says Habering.

Fast return on investment with maximum security

Potential users of the communication module include companies from the process industry such as sewage treatment plants and concrete works, container cranes in ports and the manufacturing industry, including car manufacturers. The new solution enables a fast return on investment as it can optimise maintenance management and prevent expensive downtime. “One minute of system downtime costs up to €10,000 in the automotive industry. If we can save just a few seconds with the iComm Box, which is quickly achieved, the investment has already paid off,” emphasises Habering. The i.Sense EC.P sensor, which measures tensile and shear forces in the energy chain, shows how the iComm Box works: the measured values are transmitted via a cable to an evaluation module in the control cabinet, which can be connected to the PLC to trigger an automatic system stop in an emergency – for example, if a guide trough becomes loose. A new feature is the possibility to connect this evaluation module to the iComm Box via an additional cable. The communication module then sends the data to the superwise dashboard via the mobile network – encrypted, separated from the customer’s TCP-IP network and therefore with maximum security. There are no costs for this transfer. By purchasing the module, the user acquires a data flat rate for ten years.

igus assumes responsibility for monitoring

In the personalised dashboard, the customer can always see the remaining service life of the networked components as a percentage value and the ideal time for the next maintenance. “The dashboard is intuitive and easy to use, making monitoring child’s play,” says Habering. If companies still do not have time to monitor the systems themselves, igus takes on responsibility for the applications as part of the superwise service. The i.Cee portal is directly connected to the igus CRM system. This means that the sales employees are always informed of all reports and automatically receive a corresponding task. For example, in the event of a plant shutdown, they can organise fast deliveries. They reach out proactively when something needs to be done. This means that the customer doesn’t even have to look at the dashboard. “With this service, we relieve our customers’ human resources and thus their productivity in times of a shortage of skilled labour,” explains Habering. “With the iComm Box, we offer an all-in-one system so that you are ideally positioned to master the challenges of Industry 4.0.”