iComm Box: All-in-One System for Next-Generation Condition Monitoring

Optimizing operations and minimizing downtime: the new iComm Box from igus helps with that. The communication module seamlessly integrates the i.Sense sensors for monitoring the condition of igus motion plastics into the superwise service. Intelligent algorithms provide detailed condition analysis of the monitored machines and equipment. The superwise dashboard delivers real-time information, enabling optimal monitoring and control. A key advantage: the cost of data transmission is already included in the product price.

Instantly stopping a machine before a mechanical defect leads to costly damages works best when technology supports human monitoring. For several years, igus has been offering intelligent sensors of the i.Sense series that monitor the condition of moving machine components such as energy chains, cables, linear guides, plain and pivot bearings, and slewing ring bearings. In the event of an anomaly, they immediately trigger a notification or an automatic system shutdown to prevent costly damages. “The new communication module now provides a cost-effective and easy way to extend the functionality of these sensors,” explains Richard Habering, Head of the smart plastics division at igus. It connects the sensors to the igus superwise service, enabling fast and reliable data transmission. All notifications, along with measurement values, are stored in the i.Cee portal of igus and can be analyzed later for diagnostic purposes. Additionally, intelligent algorithms calculate, for example, the movement profile of an energy chain using the sensor data. Based on the detailed analysis, precise predictions about its condition can be made. The superwise dashboard clearly displays real-time information on service life, maintenance recommendations, or alerts for anomalies. “This ensures that no potential service life is wasted while minimizing the risk of failures,” says Habering.

Quick Return-on-Investment with Maximum Safety

Potential users of the communication module include companies in process industries such as wastewater treatment plants and concrete plants, container cranes in ports, and the manufacturing industry, including automotive manufacturers. The new solution enables a quick return on investment by optimizing maintenance management and preventing costly downtimes. “One minute of system downtime can cost up to 10,000 euros in the automotive industry. If we can prevent even a few seconds with the iComm Box, which is quickly achieved, the investment has already paid off,” emphasizes Habering. The iComm Box works as follows, illustrated using the i.Sense EC.P sensor, which measures tensile and compressive forces in the energy chain: The measurement 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 shutdown in case of emergency, such as when a guide channel loosens. The new feature now allows this evaluation module to be connected to the iComm Box via another cable. The communication module then sends the data over the cellular network to the superwise dashboard—encrypted, separate from the customer’s TCP-IP network, ensuring maximum security. There are no costs for this transmission. When purchasing the module, the user acquires a data flat rate for ten years.

igus Takes Responsibility for Monitoring

In the personalized dashboard, the customer can always see the remaining service life of the connected components in percentage terms and the optimal time for the next maintenance. “The dashboard is intuitively understandable, easy to operate, and makes monitoring a breeze,” says Habering. If companies still do not have time to monitor the systems themselves, igus takes responsibility for the applications as part of the superwise service. The i.Cee portal is directly connected to the igus CRM system. This means that the sales staff are always informed of all notifications and automatically receive corresponding tasks, such as in the event of a system shutdown, to initiate rapid deliveries. They proactively reach out when something needs to be done, so the customer doesn’t have to check the dashboard. “With this service, we strengthen our customers’ personnel resources and thus their productivity in times of a skilled labor shortage,” explains Habering. “With the iComm Box, we offer an all-in-one system to prepare them optimally for the challenges of Industry 4.0.”

For more information, please visit: https://www.igus.eu/?C=DE&L=en