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Application examples with smart plastics
An overview of all industries
Selected highlights:
Agricultural engineering
Condition monitoring for high loads
Which smart plastics technology is used?
Wear coupling with integrated sensor for condition monitoring.
Why is it used?
The intelligent trailer coupling enables the customer to plan upcoming maintenance. Failures are avoided as the customer is informed in good time when a replacement is due. Expensive breakdowns or damage can thus be avoided.
Save 60% water with intelligent precision casting trolley
Which smart plastics technology is used?
Reliable energy management system with intelligent i.Sense EC.P system
Why is it used?
Amortisation within 4 years and avoidance of major damage and cost-intensive repairs to the pipework
Automotive industry
Condition monitoring at the automotive supplier
Which smart plastics technology is used?
EC.B sensor for breakage monitoring + EC.W for measuring the abrasion of the energy chains.
Why is it used?
It is important to the customer that consequential damage to the system is avoided in the event of a chain breakage. The EC.B module recognises a break in the energy chain and switches off the system or at least issues a fault message. The EC.W sensor is used to measure the wear on the e-chains, which makes maintenance plannable
Smart breakage monitoring in 22 tonne automotive driving simulator
Which smart plastics technology is used?
P4.1 Energy guiding chains including intelligent breakage monitoring i.Sense EC.B
Why is it used?
Increased plant safety and availability; complete project realisation from a single source; smart early warning system
Gantries and linear robots
Smart maintenance planning on the linear robot
Which smart plastics technology is used?
EC.M sensor for the movement data and EC.W sensor for measuring abrasion on the energy chain
Why is it used?
The two sensors transmit the measured values via the i.com module (now i.Cee module) directly to Güdel's condition monitoring system, which analyses the data and thus makes it possible to plan maintenance.
Port Cranes
Complete smart plastics package on RMG crane
Which smart plastics technology is used?
Condition monitoring: EC.P to determine the push/pull forces, EC.B to determine chain breaks, CF.P to measure the tensile force on cables, EC.M sensor for the movement data and EC.W sensor to measure the wear on the energy chain.
Predictive maintenance: i.Cee.local
Why is it used?
For maximum system protection, overview, maintenance management, product service life and safety.
Smart shipyard crane: reliable despite typhoon storms
Which smart plastics technology is used?
Roller energy chains with the i.Sense EC.P push/pull force detection system that monitors the displacement forces of the energy chains online.
Why is it used?
To prevent damage to the system and failures due to preventive maintenance or remote intervention.
12 Ship-to-shore cranes with smart heavy-duty energy chains
Which smart plastics technology is used?
E4/4 heavy-duty energy chains with smart i.Sense condition monitoring system
Why is it used?
Due to the demanding application environment to prevent damage and downtime
Robust and smart - How digitally networked energy chains strengthen STS cranes in the port of Rotterdam
Free case study for download
This case study clearly describes how EMO B.V. was able to achieve mileages of over 375,000 km on its STS cranes with igus chains for cranes®.
100% trust in i.Sense monitoring in the port of Haifa
Which smart plastics technology is used?
Complete i.Sense condition monitoring system for existing 4040HD energy chain
Why is it used?
Extension of service intervals and thus significant cost savings while reducing the risk of failure
Overview of smart plastics
Our new brochure shows you everything at a glance
Topic overview:
- Condition monitoring (i.Sense)
- Condition monitoring products
- Application examples of condition monitoring
- Predictive maintenance (i.Cee)
- Application examples for predictive maintenance
- How does the data flow with predictive maintenance?
Indoor cranes
Complete overhead crane automation thanks to i.Sense
Which smart plastics technology is used?
Complete smart plastics package with i.Sense - Condition Monitoring and i.Cee - Predictive Maintenance
Why is it used?
Real-time monitoring of the status of the energy supply system of the automated crane and a significant reduction in the risk of failure
Predictive maintenance in upholstery factory
Which smart plastics technology is used?
E4 series energy chains with i.Cee for predictive maintenance
Why is it used?
Maximum availability and maintenance recommendations before unplanned downtime occurs. The result: over 15 years of continuous operation
Intralogistics: Avoid downtime in the warehouse
Warehousing without interrupting logistics is essential for fast supply chains. Customers do not want to wait unnecessarily for their goods, while timely delivery is a decisive competitive advantage for manufacturers. The processes run largely automatically, especially with large-scale intralogistics. Not only smart plastics, but also our energy chains, cables, plain and linear bearings can help here.
Reducing costs with smart e-chains in waste cranes
Which smart plastics technology is used?
Completely pre-assembled readychain system with i.Sense tension and thrust force monitoring
Why is it used?
Additional safety is provided by an i.Sense push/pull force measurement system that monitors the entire system and switches off the crane in the event of an overload. This prevents damage to the chain and cables and therefore costly breakdowns before they can occur.
Sewage and wastewater treatment plants
24/7 emergency monitoring in the sewage treatment plant
Which smart plastics technology is used?
EC.P tensile force monitoring on the energy chain
Why is it used?
The tank scrapers in sewage treatment plants run slowly but 24/7 and damage to the system may only be recognised hours later. In order to stop the system in an emergency, the EC.P module is used in many sewage treatment plants with energy chain, which stops the system in an emergency so that the damage can be repaired and expensive total damage can be avoided.
Composting and incineration plants
Smart Move: Rolling instead of dragging on the bunker crane
Which smart plastics technology is used?
"Heavy duty" roller energy chain with included i.Sense condition monitoring system
Why is it used?
Intelligent and reliable energy and signal supply in the most adverse environmental conditions
Bulk handling
Safe bulk material conveying with sensor-equipped energy chain
Which smart plastics technology is used?
i.Sense EC.P for permanent monitoring of the prevailing push/pull forces
Why is it used?
In order to provide additional planning reliability for such dimensions, the entire cable routing is supplemented by smart plastics, i.e. intelligent sensor technology in combination with energy chains. Damage to the cable routing can thus be prevented before it occurs.
Smart push/pull force monitoring as a dirt detector
Which smart plastics technology is used?
i.Sense EC.P as a cleaning reminder for the system
Why is it used?
"If the movement of the chain is obstructed too much by dust and dirt, the push/pull force monitoring switches off the system before damage occurs and we know that it is time to clean the chain's travel path again."
Longest travel with intelligent roller chain system
Which smart plastics technology is used?
i.Sense EC.P for permanent monitoring of the system
Why is it used?
The system includes an intelligent sensor system for monitoring the push/pull forces, which can be used for an emergency shutdown in the event of increased forces.
615m travel distance with continuous condition monitoring
Which smart plastics technology is used?
Roller e-chain type 5050RHD with i.Sense Condition Monitoring System
Why is it used?
Problem-free operation without failure for more than 10 years
Packaging machines
Washing systems
Predictive operation without surprises: smart energy chains for Europe's most modern train wash system
Free case study
In this case study, we talk about how CFL, Luxembourg's national railway company, uses several energy chains from igus® together with intelligent sensor technology from smart plastics to overcome numerous challenges:
- How exactly are failures prevented?
- Which components were to blame for the failure?
- How and with which tools was the entire project approached?
- And how is it currently going?
Smart plain bearings
Do you want to put together your own smart plastics package?
Then download the digital version of our smart plastics Domino now and put together your very own configuration.
You can then look forward to a playful gift from smart plastics.
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