Condition Monitoring and Predictive Maintenance Solutions for Energy Chains & Bearings

Industry: Automotive

Intelligent breakage monitoring in a 22-ton automotive driving simulator

Which smart plastics technology is used?
P4.1 roller chain, i.Sense EC.B, chainflex cables

Why is it used?
Increase in plant safety and availability; complete project implementation from a single source; smart early warning system.

Industry: Crane

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 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.

Industry: 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.

Industry: Automotive

Austrian automotive parts supplier uses smart plastics

Which smart plastics technology is used?
EC.B sensor for breakage monitoring + EC.W for measurement of the abrasion along the e-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.

Industry: Wastewater and sewage treatment plants

Smart sensors in sewage treatment plant pipelines prevent failures before they occur.

Which smart plastics technology is used?
EC. P pull force monitoring system for the energy chain.

Why is it used?
The EC. P module is used to shut down the plant in an emergency so that the damage can be rectified or total damage is avoided.

Industry: Transport

Condition monitoring 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.

Industry: Packaging

CF.Q condition monitoring can prevent failure of machines with high output

Which smart plastics technology is used?
E4.1L e-chains® and chainflex® cables pre-assembled as a readychain, CF.Q isense sensors, Module Connect connector.

Why is it used?
The i.Sense sensors with CF.Q module detect core ruptures before they occur and save the user high downtime costs.

Industry: Crane

Complete indoor crane automation thanks to i.Sense and i.Cee

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.

Industry: Gantries and linear robots

Smart maintenance planning for linear robot

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.Cee module directly to the Güdel condition monitoring system, which evaluates the data, making maintenance predictable.

Industry: Cranes

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 extreme adverse environmental conditions.

Industry: Cranes

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.

Industry: Cranes

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.

Industry: Bulk handling

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."

Industry: Bulk handling

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.

Industry: Bulk handling

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.

Industry: Composting and incineration plants

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.

Industry: Composting and incineration plants

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 is 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."

Industry: Bulk handling

Safe bulk material conveying 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.

Industry: Composting and incineration plants

Predictive maintenance solutions 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.

Industry: Automotive

i.Cee predictive maintenance in automotive industry

In automotive production, the conveyor belt never stops. Collaborating robot arms for assembly and welding work are in continuous use, as are all the components that supply them with energy and data. It is precisely in such environments that intelligent concepts in the style of predictive maintenance make the most sense. Whether a new project for Industry 4.0 or efficiency-driven retrofitting - our smart plastics solutions are available as universal modular systems and can be individually adapted to any system.