Engineering news
Factory equipment supplier Igus has introduced “Industry 4.0” functionality to its range of linear cable, energy chain and linear bearing products.
German firm Igus supplies plastic components such as the articulated housings for cabling used in moving machinery across several different industries.
Igus said that the embedding of sensing, monitoring and communications in its products, also known as Internet of Things (IoT) technology, will enable better condition monitoring and predictive maintenance.
Cables, chains and linear bearings equipped with the sensing, monitoring and communications technology, which Igus calls “isense”, are available now and enable local data collection and analysis. The communications module, which the firm calls “icom” and enables data from the machines to be transmitted over the internet for viewing and analysis offsite, is in beta testing phase and will be available in 6-12 months.
Matthew Aldridge, managing director of Igus UK, said: “This takes the black art out of maintenance, and turns it into a science.
“We have real life data about chains, cables and bearings and can compare that to data built up over the years to give proactive advice and supply parts just before they fail.
“We can reduce maintenance costs, prevent premature replacement and eliminate unplanned downturns, it will have a big impact on financial performance. This will maximise the life of the products and the efficiency of the equipment, saving time.”
Aldridge added that the data will also enable the Igus engineers to give design advice, such as if bearings need spacing out more. “These are real life products based on existing products we’ve been selling for years, with added intelligence,” he said. “We already outlast a metal chain. We also analyse stroke rate and other engineering data when we supply a product to give an estimated lifetime. But monitoring all the time allows us to give an account for a specific application, for example customers often modify equipment after it is installed.”
The technology can measure wear in chains and linear bearings via RFID sensors. The RFID sensors work in pairs, one positioned under the other. Under normal operation, the moving part passes through and triggers both sensors. When the bottom sensor is destroyed, at 80% wear, only one RFID chip registers and an alert is made.
Other sensing technologies include a strain gauge to monitor push/pull forces and, a potentiometer to detect breakages, and a device that measures the conductive value of cables to check their lifetime.
The cost of the IoT features was not revealed at the launch, and there are no figures on return on investment yet. Aldridge said the cost of the units is “negligible” and that there are no plans to charge for ongoing consultancy advice and predictive maintenance services.
Some of the sensor technology can be retrofitted, but the company advises supplying the systems from new.