IGUS

The Industry 4.0 era calls for a rethink of traditional processes in quite a number of areas.
One example is using predictive maintenance based on continuous condition monitoring
rather than checking machine tools at fixed intervals. These tools then only need to undergo
maintenance or be replaced when the system signals this is necessary. Comparing status data
with target parameters on an ongoing basis also measurably reduces unscheduled stoppages
and therefore downtime costs. igus GmbH has achieved these benefits by using smart
plastics to develop various sensors and monitoring modules for everything from energy
chains and cables to plain, linear and slewing ring bearings. Networking these products with
the new igus communication module (icom.plus), which igus is soon to showcase at the
upcoming EMO Hannover 2019, ensures direct integration into the customer’s own IT
infrastructure – into production management systems such as SCADA and MES, for
instance, or online into cloud solutions that are used throughout a company.

Once programmed with initial service life algorithms using igus online configurations,
icom.plus can also be operated offline if the customer wishes. This gives users flexibility
when it comes to decisions about how the module is connected, how its data is managed and
how to balance run time maximization against IT security. As long as icom.plus is online, the
service life data is continuously compared with the igus cloud to maximize machine run
times and minimize the risk of a failure. The data in the cloud includes details of the ten
billion energy chain and cable test cycles performed each year in the company’s own 3,800
square meter test laboratory. Based on this data, it is possible to predict with impressive
accuracy how long a component such as an energy chain will work reliably in the respective
machine tool application. Integrated isense components that factor in the current ambient
conditions provide additional reassurance by continually updating the service life. Machine
learning and AI produce extremely precise data that can be viewed on the machine control
system’s screen. If users opt for online connection, a text message or e-mail is also sent to
notify them of unexpected operating states and scheduled maintenance.