Condition monitoring system with smart sensor technology for machine data acquisition

"Trust is good, checking is better" - smart plastics gives you full control over your systems. smart plastics combine igus high-performance plastics with state-of-the-art sensor technology. The condition monitoring system i.Sense for energy chains and cables consists of several components.

Various sensors are available for monitoring the condition of your system, depending on the application. This means that both mechanical factors such as push/pull forces are recorded and electrical forces such as cable quality. The connected i.Sense module in the control cabinet, evaluates all sensor data and triggers follow-up actions. This enables direct input into the PLC machine control system as well as location-independent visualisation in an online dashboard . It provides the foundations for condition-based maintenance in the smart factory.  

The advantages, benefits and added value of i.Sense, the intelligent condition monitoring system:

▲ Tech up

• Increase machine availability and maximum service life
• Better fault analysis thanks to real-time machine data acquisition
• Easy to integrate into Industry 4.0/smart factory concepts

▼ Cost down

• Eliminate unplanned downtime and machine failures
• Reduce maintenance costs with early warnings
• Implement condition-based maintenance

i.Sense sensors

i.Sense smart condition monitoring sensors are used to continuously monitor the operating condition of moving components. They can perform various functions, depending on the application. In energy chains, they are used to monitor push/pull forces (i.Sense EC.P) and to identify chain breaks at an early stage (i.Sense EC.B).

For guided chainflex cables, modern smart plastics sensor technology can be used to monitor the tensile forces on the cables (i.Sense CF.P) and measure cable quality (i.Sense CF.Q) and data transmission rate (i.Sense CF.D). All i.Sense sensors for condition monitoring can also be integrated into the energy supply system or energy chain at a later date. 

i.Sense evaluation module

Subsequently, all supplied sensor data can be evaluated during operation by the i.Sense Module II, which is mounted in the switch cabinet of the system to be monitored. In active fault management, all movement anomalies are detected and directly reported to the user or the machine control system, e.g. Siemens PLC.

With the latest generation, up to four condition monitoring sensors for energy chains and cables can be connected simultaneously with only one switch cabinet module, which means significant savings in space and cost. The new module also offers many typical Industry 4.0 use cases, such as remote resetting via WLAN/SMS and an SMS/e-mail alarm function.

i.Sense connectivity

The i.Sense module offers other network option besides direct integration into the PLC plant control system to prevent total machine failure in an emergency. One is location-independent alerting with the optional SMS module. Another is that all acquired sensor data can be output to an online dashboard.

The condition monitoring dashboard shows at a glance, online or locally, the remaining service life of components equipped with smart technology. The current condition is also displayed in colour using a traffic light code. This immediately gives the system operator a clear picture of the system's condition, enabling him to predictively plan upcoming maintenance intervals.

"Maximum reliability"

"Thanks to the digital condition monitoring and networking of the plant and products, it is possible to continuously record the condition of the components and get a predictive notification as soon as a repair or replacement is required."
Daniel Bangerter, Head of Customer Care at Güdel Deutschland GmbH

Customer applications worldwide

In international automotive production, the global crane industry, or regional wastewater plants: i.Sense condition monitoring systems are successfully used wherever maintenance costs are saved and machine downtime is prevented:

To the application overview

Push/pull force monitoring for e-chains with i.Sense EC.P

• Measures the push/pull forces acting on the e-chain
• Recommends shutdown of the equipment if a force limit is exceeded

Breakage detection for e-chains with i.Sense EC.B

• Detects chain breakage in the early stages
• Prevents overloading and subsequent system failure

Low-cost condition monitoring with i.Sense EC.W

• Real-time chain condition monitoring
• Direct, wired connection to the machine control system

i.Sense CF.P: tensile force monitoring for cables

• Measures the forces directly at the strain relief element
• Triggers a shutdown by means of the NC contact if forces are excessive

Cable quality monitoring with i.Sense CF.Q

• Measures the quality of the cable cores
• Sends a signal in the event of a core rupture or stops the system via a normally closed contact if desired

Data transmission monitoring with i.Sense CF.D

• Integrated in the cable, no extra measuring cable necessary
• Package losses are detected in good time
• Alarm via normally closed contact or network

For a solid foundation for predictive maintenance concepts, you need a smart network of individual condition monitoring systems. At igus, everything related to predictive maintenance falls under the term i.Cee. Similarly, i.Sense encompasses all condition monitoring systems. 

The central element here is the i.Cee software, which, combined with i.Sense condition monitoring sensors on the energy chain, the plain bearing bushing, or a linear carriage, transform stock products into smart ones. This upgrade creates the capability of determining maximum service life and optimal maintenance intervals in real time based on real usage data.

What is condition monitoring? Condition monitoring is the regular or continuous recording or monitoring of the condition of a machine (especially for rotating components or moving applications), system or process.

What is a condition monitoring system? Condition monitoring systems are crucial for understanding the behaviour of machines and integral to equipment reliability.

What are the advantages and added value of condition monitoring systems for equipment, machine and plant manufacturers (OEMs)? Most successful examples point to the following benefits: Maximised production, increased service life & reduced maintenance costs.

Is there a simple condition monitoring solution for industrial applications with motion? Yes, with the smart condition monitoring sensor, i.Sense EC.W, you can continuously monitor and display the condition and remaining service life of your energy supply system for just a few hundred euros. 

What is included in a condition monitoring solution and which components are used? Various sensors or access to existing data sources belonging to the system are required for condition monitoring. This allows both mechanical and electrical factors as well as external environmental parameters to be recorded. All machine data is aggregated, analysed and prepared for further distribution or dashboard display in a gateway / edge device such as the i.Sense module. 

How do condition monitoring and predictive maintenance fit and work together? All signals from the individual condition monitoring components create the necessary data basis for predictive maintenance concepts, also known as preventive maintenance. At igus, everything related to predictive maintenance is summarised under the term i.Cee ("see" = I see ahead). 

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