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Extremely light, but always in the picture ... Now also for flange bearings with i.Sense igubal®

The intelligent flange bearing from smart plastic permanently monitors the condition of the bearing point and immediately reports the first signs of wear in order to prevent serious bearing damage.

i.Sense igubal® sensor

The i.Sense igubal® sensor in practical use in the gearbox of Luxembourg's largest train wash system.

CFL's train wash system uses igus® energy chain and igubal® flange bearings in the wash trolleys. Previously used metal bearings have been replaced by plastic bearings to reduce maintenance costs. An "intelligent" bearing that monitors the condition is tested to prevent unforeseen damage. The aim is to receive an immediate message if the bearing properties deteriorate. This should prevent expensive malfunctions and breakdowns.

CFL's maintenance manager, Mike Feinen, emphasises the importance of avoiding downtimes, as these are associated with costs and the contracts stipulate regular cleaning of the trains. There are penalties for non-compliance. In co-operation with igus®, a solution was found to ensure the optimum performance of the system. After initial adjustment problems, the system is now running smoothly and the smart flange bearing has saved a lot of maintenance time.

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Tech up

Tech up

  • Continuous condition monitoring of highly loaded 2 and four hole flange bearings
  • Early anomaly detection
  • Comprehensive connectivity for optional integration into predictive maintenance concept with i.Cee
Cost down

Reduce costs

  • Identical in construction, and can therefore be used 1-1 instead of metallic representatives
  • Avoidance of unplanned downtimes thanks to condition-based alarm messages
Proof

Proofs

  • First successful pilot application on site at customer CFL in Luxembourg
  • Ongoing test series in the industry's largest test laboratory  for high-performance polymers
Sustainability

sustainability

  • Minimised material costs for integrated sensor
  • Usage-dependent product replacement reduces unnecessary material costs
Our colleague Julian explains in detail the functionality, advantages and application criteria of smart igus products in train washing systems.

Intelligent condition monitoring successfully realised

i.Sense in practice

  • Wastewater treatment plants and wastewater operations
  • Harbour and container cranes
  • Conveying and bulk handling
    • i.Sense EC.P in use

    "Less effort, higher availability"

    "Less maintenance, higher availability, the ability to manage all the different cables and hoses in one system, intelligent condition monitoring i.Sense ... I would always use intelligent energy chain from igus® again!"

    Dipl.-Ing. Fabian Wilhelm, project manager at AOS Stade GmbH

    Overview of i.Sense examples

    Worldwide customer applications

    Whether in international automotive production, the global crane industry or in regional wastewater treatment plants: i.Sense systems are used successfully wherever maintenance costs are saved and machine downtime is prevented.

    Click here for the application overview
    Train washing station case study

    Predictive operation without surprises: smart energy chain for the most modern train wash in Europe

    Free case study

    This case study discusses how CFL, Luxembourg's national railway company, uses several energy chains from igus® together with intelligent sensor technology from smart plastic to overcome numerous challenges:

    • How exactly are failures prevented?
    • Which components were to blame for the failure?
    • How and with which tools was the entire project approached?
    • And how is it currently going?
    Go to the PDF download

    When do I need a smart status sensor like i.Sense igubal®?

    Maintenance work

    When regular maintenance work requires a complete production shutdown...

    Finder

    If movement anomalies cannot be recognised by humans in time...

    smart plastics

    If systems or machines need to be monitored frequently or permanently...

    Offshore

    If the travel paths of the energy supply are difficult to access or visible...

    NFPA130

    If maintenance work poses a health or safety risk...

    Runtime

    If maintenance costs are to be reduced and running times extended...

    There are no limits to the application possibilities for the new mini-sensor.

    Live condition monitoring in any position(s)

    i.Sense BRG for everyone
    Not just for farmers, but for every machine operator, a defective bearing can spoil the working day and the mood. Machine failures and downtimes are among the biggest cost drivers in the industry. It is therefore important for maintenance staff to prevent unplanned downtime in good time.

    Smart bearing products from igus® are therefore particularly suitable for particularly sensitive or hard-to-reach areas of a machine, as the condition of the bearing can be checked at any time. With the help of the sensor, every wear-resistant part of a machine can be monitored remotely - from which many other motion plastics also benefit.

    More about our smart dry-tech products
    News catalogue: 2023 smart plastics news

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