Application examples with smart plastics
Smart customer references with energy supply systems
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Smart customer references from bearing technology
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An overview of all industries:
Port cranes | Indoor cranes |
Sewage and wastewater treatment plants | Composting and incineration plants |
Bulk handling | Packaging machines | Washing systems
Selected highlights:
Intelligent sensors for long operating times
GHD Georg Hartmann Maschinenbau is one of the world's leading manufacturers of systems for slicing and packaging foodstuffs. Those in charge were looking for a reliable energy supply with pneumatic and electrical cables in order to refine a packaging machine with high processing cycles. Today, a monitored smart solution that indicates faults even before the machine fails is being used.
To the customer reference
Total networking in the indoor crane
A large German crane manufacturer uses the i.Sense condition monitoring system to ensure an optimum production process. It uses the EC.B break detection, EC.P push/pull force monitoring, and CF.P chainflex tensile force monitoring products. All dynamic data are saved by the i.Cee module and processed. Here, machine learning and AI algorithms calculate the service life and display it on a web dashboard on the i.Cee dashboard on any internet-enabled device as "days until the next recommended maintenance work"
Predictive maintenance in a train washing station
The train washing plant belonging to the Société Nationale des Chemins de Fer Luxembourgeois (CFL) cleans local and long-distance trains daily in its 200 metre-long wash hall. To allow the wash trolleys to travel on both sides of a train, several energy chains are used with intelligent sensor technology that monitors the plant condition and plans maintenance predictively.
To the customer reference
Automotive industry
Condition monitoring for automotive parts suppliers
Which smart plastics technology is used?EC.B sensor for breakage monitoring + EC.W for measurement of the abrasion along the energy chain.
Why is it used?
For the customer, it is important that subsequent damage to the equipment be prevented in the event of chain breakage. The EC.B module detects a breakage in the energy chain and switches the equipment off or at least indicates a fault. By means of the EC.W sensor, the abrasion along the e-chains is measured, as a result of which maintenance is predictable
More about this application
Intelligent breakage monitoring in a 22-ton automotive driving simulator
Which smart plastics technology is used?P4.1 energy chains with i.Sense EC.B intelligent breakage detection
Why is it used?
Increased plant safety and availability; complete project implementation from a single source; smart early-warning system
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Gantries and inear robots
Smart maintenance planning for linear robots
Which smart plastics technology is used?EC.M sensor for motion 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 the Güdel condition monitoring system, which evaluates the data, making maintenance plannable.
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Port Cranes
Complete smart plastics package on RMG crane
Which smart plastics technology is used?Condition monitoring: EC.P for determining push/pull forces, EC.B for detecting chain breaks, CF.P for measuring tensile force on cables, EC.M sensor for movement data, and EC.W sensor for measuring abrasion 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.
More about this application
Smart shipyard crane: Functionally reliable despite typhoons
Which smart plastics technology is used?Roller energy chains with EC.P push/pull force detection that monitors the displacement forces of the energy chains online.
Why is it used?
To prevent failures and damage to the system by means of predictive maintenance or remote intervention.
More about this application
Twelve ship-to-shore cranes with smart heavy-duty energy chains
Which smart plastics technology is used?E4/4 Heavy Duty energy chains with the smart i.Sense condition monitoring system
Why is it used?
To prevent damage and downtime in the demanding application environment
More about this application
Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam
Download a free case study
This case study illustrates how EMO B.V. is able to achieve over 375,000km on its STS cranes with igus chains for cranes®.
Go to the PDF download
100% trust in i.Sense monitoring in the port of Haifa
Which smart plastics technology is used?Complete i.Sense condition monitoring system for an existing 4040HD energy chain
Why is it used?
Extension of service intervals and thus significant reduction of both costs and the risk of failure
More about this application
General smart plastics overview
Our new brochure shows you everything at a glance
Topic overview:
- Condition monitoring (i.Sense)
- Condition monitoring products
- Condition monitoring application examples
- Predictive maintenance (i.Cee)
- Application examples for predictive maintenance
- Predictive maintenance data flows
Download brochure
Indoor cranes
Complete indoor 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 control over the condition of the automatic crane's energy supply system and significant reduction of the risk of failure
More about this application
Predictive maintenance in a cushion factory
Which smart plastics technology is used?E4-series energy chains with i.Cee for predictive maintenance
Why is it used?
Provides the highest availability with maintenance recommendations to prevent unplanned failures. The result: fifteen years of continuous operation already
More about this application
Intralogistics: Avoid downtime in the warehouse
Storage without interruption of logistics is essential for fast supply chains. Customers do not want to wait unnecessarily for their goods, and for manufacturers, on-time delivery is a decisive competitive advantage. The processes run largely automatically, especially in larger-scale material handling. Not only smart plastics, but also our energy chains, cables, plain and linear bearings can help here.To the detailed page
Reducing costs with smart e-chains in a waste crane
Which smart plastics technology is used?Completely harnessed readychain system with i.Sense Push/Pull Detection System
Why is it used?
i.Sense push/pull force measurement also provides additional safety, monitoring the entire system and shutting down the crane if it becomes overloaded. This prevents damage to the chain and cables and thus costly failures, reacting to them before they can occur.
More about this application
Sewage and wastewater treatment plants
24/7 emergency monitoring in the sewage treatment plant
Which smart plastics technology is used?EC.P pull force monitoring system for the energy chain
Why is it used?
The sedimentation tank surface scrapers in wastewater treatment plants operate very slowly, but do so 24/7 and it is possible that damage to the system will not be detected until hours later. In order to shut down the plant in an emergency, the EC.P module is used in many wastewater treatment plants with an energy chain, shutting down the plant in an emergency so that the damage can be rectified and total damage is avoided.
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Composting and incineration plants
Reduce water consumption by 60% with an intelligent precision watering trolley
Which smart plastics technology is used?Reliable energy supply system with intelligent i.Sense EC.P system
Why is it used?
Amortisation within four years and avoidance of major damage and expensive cable guide repairs
More about this application
Smart move: Rolling instead of hauling on a bunker crane
Which smart plastics technology is used?Heavy Duty roller energy chains with the smart i.Sense condition monitoring system
Why is it used?
Intelligent, reliable supply of power and signals under extremely adverse environmental conditions
More about this application
Bulk handling
Safe bulk material transport with sensor-equipped energy chain
Which smart plastics technology is used?i.Sense EC.P for continuous monitoring of prevailing push/pull forces
Why is it used?
In order to provide additional planning security for such dimensions, the entire cable guide is supplemented with smart plastics – intelligent sensors in combination with energy chains. Damage to the cable guide can thus be countered well before it occurs.
More about this application
Smart push/pull force detection system as a dirt detector
Which smart plastics technology is used?i.Sense EC.P as a system cleaning reminder
Why is it used? "If the chain's travel is too impaired by dust and dirt, the pull/push force detection shuts the system down before damage occurs, and we know it's time to clean the chain's travel again."
More about this application
Longest travel with intelligent roller chain system
Which smart plastics technology is used?i.Sense EC.P for permanent monitoring of the plant
Why is it used?
The system includes an intelligent sensor system for monitoring the pull/push forces, which can be used for an emergency shutdown in the event of increased forces.
More about this application
615m travel with continuous condition monitoring
Which smart plastics technology is used?5050RHD rol e-chain with i.Sense condition monitoring system
Why is it used?
Trouble-free operation without failure for more than ten years
More about this application
Packaging machines
Cable monitoring for bread packaging machinery
Which smart plastics technology is used?
CF.Q = Cable monitoring
Why is it used?
At 80 cycles per minute, several million cycles are reached within just a few months. Of course, the machine should operate for many years without failing. CF.Q does not lengthen the service life of the cables but can calculate their exact service life and thus makes maintenance 100% predictable.
CF.Q = Cable monitoring
Why is it used?
At 80 cycles per minute, several million cycles are reached within just a few months. Of course, the machine should operate for many years without failing. CF.Q does not lengthen the service life of the cables but can calculate their exact service life and thus makes maintenance 100% predictable.
Bread packaging machine
Washing systems
Predictive maintenance in train washing station
Which smart plastics technology is used?
EC.M motion sensor, EC.W abrasion sensor, EC.B breakage sensor, i.Cee:plus for the evaluation of sensor data, i.Cee:net for the transfer of data to the i.Cee dashboard
Why is it used?
The purpose of condition monitoring of the built-in components is to ensure that, if damage occurs, the machine is shut down, whereby the predictive maintenance system provides an optimum maintenance plan for the built-in components.
EC.M motion sensor, EC.W abrasion sensor, EC.B breakage sensor, i.Cee:plus for the evaluation of sensor data, i.Cee:net for the transfer of data to the i.Cee dashboard
Why is it used?
The purpose of condition monitoring of the built-in components is to ensure that, if damage occurs, the machine is shut down, whereby the predictive maintenance system provides an optimum maintenance plan for the built-in components.
More about the train washing station
Operation without surprises: smart energy chains for the most modern train washing station in Europe
Free case study
This case study talks about how CFL, Luxembourg's state railway company, uses several energy chains from igus® together with intelligent sensors from smart plastics to overcome numerous challenges:
- How exactly are failures prevented?
- Which components were to blame for the failure?
- How was the whole project approached and with what tools ?
- And how is it going at the moment?
Go to the PDF download
Smart plain bearing bushings
Intelligent bearings in agricultural machinery
Which smart plastics technology is used?i.Sense bushing
Why is it used?
Due to heavy loads and the additional effects of dirt, vibration and weather, a huge amount of stress is placed on bearing points, but they are sometimes maintained irregularly as well or, due to the difficulty of access, are sometimes badly or only partly maintained. This is where the smart bearing is of help as it always reports the current condition of components and how worn they are.
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