Industry 4.0 in real-time crane monitoring technology

Extend product runtimes efficiently with smart condition monitoring solutions

Heavy loads, long periods of use, and a wide variety of weather conditions – cranes in port facilities must perform at their best. The fields of application include, amongst others: ship-to-shore cranes, bulk cargo handling cranes, RTGs, RMGs, Goliath cranes, spreaders and reach stackers. Where there is deadline pressure and safety must be guaranteed, intelligent concepts in the form 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.

Advantages of our smart plastics solutions:

▲ Tech up

Extension of the maximum service life
Simple integration into Industry 4.0 / IIoT concepts
Enables safe remote control and automatic operation

▼ Cost down

Reduce maintenance costs through early warnings
Eliminate unplanned downtimes and expensive production losses
Space-saving design - lower installation height & no cable loop station

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Different areas of application in the harbor

always the right solution at hand with smart plastics from igus®

Ship-to-shore cranes (STS)
Energy chains with integrated rollers reduce the friction of movement and thus reduce wear. In the latest development stage of the igus rol e-chains, use of maintenance-free, tribo-polymer plain bearings considerably lengthens the service life. Also, the new P4HD can be equipped with smart monitoring sensors. The sensor is integrated into a standard side part of the chain, which does not lead to any restrictions in the usable inner width. Our energy chain systems can be installed on all types of Ship-to-Shore cranes, whether it is a double trolley, shuttle boom or gooseneck design.

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Gantry cranes (RTG / RMG)
For a long time now, igus has been driving the changes in the cable guidance systems of RTGs. Today the energy chain system is a well established cable guidance system for trolley travel, in use on numerous RTGs around the world. The heavy-duty series 4040(R)HD chain, as a gliding or roller chain version, is the preferred choice. Also the igus chainflex cables, with TPE outer jackets, have proved to be long lasting in this demanding environment. And if you want to be on the safe side, you can use the new i.Sense CF.D for the continuous condition monitoring of cable specifications.

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Automated Stacking Cranes (ASC)
Since the crane operator's workplace is moving away from the crane to the office and being responsible for several cranes at the same time - due to crane automation - the ever more modern automatic stacking cranes not only require a reliable cable guidance system, but also the possibility of being able to report the current operating status from anywhere and at any time. This is ideally achieved with the new i.Cee dashboard which can be integrated online in the Internet or on site in the local network. This means that the current operating data can be accessed either via a display on the crane, via a cloud solution or an IoT dashboard, via the REST API interface or even directly via SMS or e-mail.

Condition monitoring (i.Sense)

Condition monitoring is the fastest, simplest way to combine many igus® products to form a self-monitoring smart plastics product. Sensors are mounted to measure values (such as temperature, forces and sound waves/vibrations) within predefined limits. Values outside the limits result in an alert or notification. This information provides the basis for taking subsequent steps, such as maintenance or shutting down the system. Values outside defined limits can directly trigger a system shut-down to prevent costly damages and repairs. At igus®, we use the term "i.Sense" (i feel) to refer to condition monitoring.

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Predictive maintenance (i.Cee)

Predictive maintenance uses sensors, software, and the elements of condition monitoring to create a system that allows dynamic service life calculation and determines the best times for the maintenance of igus® products. This makes predictive maintenance the next step in achieving a comprehensive concept for smart energy supply and bearing technology. This predictive maintenance system is called "i.Cee" (i see ahead) and is available in a wide variety of designs. The goal is always to maximize system and user safety and product service life.

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You determine the access of data transfers

i.Cee:local

Your data never leaves your corporate network, since the i.Cee software communicates only within the networks you want it to. The options range from an e-chain® within a single machine to a machine park and your own output interface.

i.Cee:cloud

This online solution has two options. In the first, your data is transferred directly to the cloud, where it is made available in a protected area that can be accessed with a browser dashboard. In the second, the data go to an intermediate location on the i. Cee.net: a so-called data concentrator allowing you to stop or adjust data exchange in the cloud.

Real-Time Crane Monitoring Software

i.Cee LIVE Dashboard Demo!

The i.Cee Dashboard visualizes all information and movement data of our smart trade show machine online and in real-time at the igus® virtual-real trade show stand in Cologne.

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Application examples with smart plastics

smart examples with e-chain®, chainflex® cables and bearings.

Industry: Automotive

Intelligent Breakage Monitoring in 22 Ton 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.

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Industry: Crane

Longest travel with smart roller chain system

Which smart plastics technology is used?
i.Sense EC.P for permanent monitoring of the system

Why is it used?
The system includes intelligent sensors for monitoring the pull/push forces, which can be used for an emergency shutdown in the event of increased forces.

Industry: Crane

Smart shipyard cranes in successful use for years

Which smart plastics technology is used?
Roller energy chains with the iSense EC.P pull/push force detectio.

Why is it used?
To avoid system damage and failures through preventive maintenance or remote intervention.

Industry: Crane

Complete smart plastics package on RMG crane

Which smart plastics technology is used?
EC.P for push/pull forces, EC.B for chain breaks, CF.P for measuring tensile force on cables, EC.M for movement data and EC.W for measuring abrasion and a predictive maintenance system.

Why is it used?
The customer now has full control, overview and safety.

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.

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Industry: Transport

Predictive maintenance 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 to evaluate data, i.Cee:net to transfer to dashboard.

Why is it used?
The built-in components ensure that, if damage occurs, the machine is shut down to provide an optimum maintenance plan.

Bread wrapping machine with smart plastics

Industry: Packaging

"igus® 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 isense sensors with CF.Q module detect core ruptures before they occur and save the user high downtime costs.

Güdel measuring machine with smart plastics

Industry: Robotics

Predictive maintenance planning for linear robot

Which smart plastics technology is used?
EC.M sensor for motion data and EC.W sensor for the measurement of abrasion along the energy chain

Why is it used?
The two sensors transfer the measured values via the i.com module (now i.Cee module) directly to Güdel's condition monitoring system, which evaluates the data and makes maintenance predictable.

Industry: Mining

Smart plastics in aluminum oxide production

Which smart plastics technology is used?
EC. P System as a cleaning or maintenance reminder.

Why is it used?
The heavy dust arising during the movement of bauxite is an enormous stress, especially for moving machine components.

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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: Agriculture

Smart bearings in agricultural machinery

Which smart plastics technology is used?
i.Sense bushing

Why is it used?
The smart bearings reports the current condition of components and how worn they are.

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Smart e-chain® and cables

Use smart plastics to stay abreast of how your chain is doing.
Our intelligent e-chain® systems are already reliably in use in hundreds of thousands of applications.

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Smart bearing technology

Don't let a defective plain bearing ruin your day.
Smart plain bearings are great for sensitive or hard-to-reach spots on a machine, since they allow the bearing's condition to be assessed at any time.

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Smart Applications

Customer application examples with smart plastics
Whether a new project for Industry 4.0 or efficiency-driven retrofitting - our smart plastics solutions can be individually adapted to any system.

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Download the smart plastics brochure

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Contact a smart e-chain® expert

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