igus has launched the iComm box, which aims to optimise operating processes and minimise downtimes. With the communication module, the i.Sense sensors for condition monitoring of igus motion plastics can be integrated into the superwise service. Intelligent algorithms provide a status analysis of the monitored machines and systems. The superwise dashboard provides information in real time and allows for optimum monitoring and control. In addition, the costs for data transmission have been included in the product price.
igus’ iSense series of intelligent sensors 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 costly consequential damage.
“The new communication module now opens up the cost-effective and simple option of expanding the functionality of these sensors,” explained 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,” added Habering.
Fast return on investment with maximum security
The new solution enables a fast return on investment as it can optimise maintenance management and prevent expensive downtime.
The i.Sense EC.P sensor, which measures tensile and shear forces in the energy chain, demonstrates 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, such as when 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, which will be encrypted and separated from the customer’s TCP-IP network, providing 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 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,” said Habering. If companies are unable to monitor the systems themselves, igus will assume responsibility for the applications as part of the superwise service. As the i.Cee portal is connected to the igus CRM system, sales employees are informed of all reports and will receive a corresponding task.
For example, in the event of a plant shutdown, they can organise fast deliveries and reach out when something needs to be done. Customers are not required 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,” explained 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.”
