Condition monitoring system with smart sensor technology for machine data acquisition

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).

With guided chainflex® cables, the modern sensor technology from smart plastic the tensile forces on the cables are monitored (i.Sense CF.P), the cable quality (i.Sense CF.Q) and the data transmission rate (i.Sense CF.D) are measured. All i.Sense Sensors for condition monitoring can also be subsequently integrated into the energy supply or energy chain.

i.Sense evaluation module
All the sensor data supplied can then be analysed during operation with the i.Sense Module II analysed which is mounted in the control cabinet of the system to be monitored. In active fault management, all movement anomalies are recognised there and reported directly to the user or the machine control, e.g. Siemens PLC, reported.

With the latest generation, up to Four condition monitoring sensors for energy chain and cable simultaneously can be connected to just one control cabinet module, which means considerable space and cost savings. The new module 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
In addition to the direct integration into the PLC system control in order to be able to prevent total machine failurethe i.Sense module offers even more network options. One is location-independent alerting with the optional SMS module. Another is that all acquired sensor data can be output to an online dashboard.

Some Condition Monitoring Dashboard visualises the remaining service life of components equipped with smart technology online or locally at a glance. 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.

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

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 the condition and remaining service life of your energy supply for just a few hundred euros. can be displayed.

What is included in a condition monitoring solution and which components are used? Various sensors or access to existing data sources in 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 stored in a gateway / edge device such as the i.Sense module aggregated, analysed and prepared for further distribution or dashboard presentation.

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

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