In even the smartest of Smart Factories, not many devices can measure — let alone predict — their own wear. Yet this is precisely what smart plastics can do.
Smart plastics integrate sensors and software to transform standard products, such as cable carriers and plain bearings, into intelligent systems with real-time condition monitoring and predictive maintenance capabilities. When integrated into energy chains — which are used extensively in industrial automation processes to guide and protect cables and hoses — for example, this solution helps operators monitor the condition of their cabling systems and receive alerts if maintenance or part replacement is required.
By unlocking condition monitoring and predictive maintenance capabilities, smart plastics enable manufacturers to create efficient and connected processes.
Condition Monitoring & Predictive Maintenance
Two examples of smart plastics include the i.Sense condition monitoring and i.Cee predictive maintenance platforms, which detect anomalies, predict failure and optimize maintenance schedules, enabling manufacturers to reduce downtime and extend the service life of their machinery.
The i.Sense monitoring system continuously records the operational state of machinery, using sensors to measure physical parameters like vibration, temperature and position. When these parameters exceed predefined limits, the system alerts operators to take corrective actions before a failure occurs. This proactive approach goes a long way toward preventing costly downtime and ensuring smooth manufacturing operations.
Users can integrate i.Sense directly into their PLC system to prevent total machine failure. The system is also available as an SMS module for location-independent alerting, while another option pushes all data to an online dashboard for users to view.
The i.Cee system takes these condition monitoring capabilities a step further by unlocking predictive maintenance. This platform uses data collected by i.Sense sensors to calculate the remaining service life of components and determine the optimal time for maintenance. This system uses algorithms to adapt maintenance schedules based on actual usage. The i.Cee system is also IIoT-friendly and can be integrated with local networks, offering flexibility in connectivity.
The i.Cee platform uses data collected from the igus testing facility to make accurate service life predictions, which account for how the equipment is being used in a particular application. Combining machine learning with predictive maintenance further enhances the efficiency of this smart plastics platform. For example, i.Cee provides a digital dashboard that visualizes all the information of connected sensors, eliminating guesswork and simplifying monitoring conditions for operators across entire systems.
Smart Plastics for Failure Analysis
In addition to providing condition monitoring and predictive maintenance solutions, smart plastics can detect points of failure and will send an alert or even shut down the system to prevent more catastrophic system damage.
For example, the i.Sense EC.B system detects link breakages on e-chain energy chain systems by monitoring push-pull forces and cable tension. A wire is fed through the e-chain and then tightened; any change in wire length, indicating a link break, triggers the system, causing the EC.B to alert personnel and automatically shut down the system to prevent damage to the energy chain and system at large. Fixing a cracked link only takes a few minutes and a few dollars versus damage that extends to multiple days if not addressed.
Automotive & Crane Applications
While smart plastics are beneficial in many applications, one that can particularly benefit from this technology is automotive manufacturing. Because automotive production lines include conveyor belts and robotic systems that operate continuously, the integration of smart plastics on cable systems ensures seamless operation while minimizing the risk — and hefty cost — of unexpected failures.
Case in point, a large automotive supplier in Austria has adopted smart plastics to enhance the reliability of its assembly lines. This company uses EC.B e-chain sensors to monitor breakage, as well as EC.W sensors to measure abrasion. Together, these solutions enable operators to stay ahead of any damage to the plant’s e-chain cable carriers, ensuring continuous production and reducing maintenance costs.
Smart plastics also play an important role in crane systems. The Port of Rotterdam, for example, uses the i.Sense condition monitoring platform to monitor push/pull forces on the cable carriers in ship-to-shore (STS) cranes. By providing early warnings of potential issues, this solution prevents equipment damage and downtime in an already demanding environment.
The Port of Rotterdam application involves three types of sensors to monitor the status of the energy chains: force sensors mounted on the e-chain’s moving and fixed ends measure tensile forces, while a wire inserted into the energy chain functions as a breakage sensor. These three devices send data to an i.Sense module, which determines if forces are within the normal range.
As soon as the data exceeds the normal range, the module sends an alarm message to the control system. This action stops the crane, enabling operators to repair the defect before a more serious malfunction occurs.
As manufacturers continue to look for innovative ways to improve their operations and reduce costs, the adoption of smart plastics technology is poised to grow, further solidifying its role in the future of manufacturing.
Learn more at www.igus.com.