Intelligent breakage monitoring in 22-ton automotive driving simulator

Smart igus e-chains reliably guide energy, data and media in highly dynamic applications

Moving driving simulators have been used in the German automotive industry for 35 years. The world's most modern driving simulator now impresses with the following key data: 2.2MW of electric drive power, "22 tons of agility" and a total value of over euro 25 million.

Profile

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Requirements: high dynamics of up to 10m/s as well as enormous loads, safe guidance of power, data and other media in one, intelligent accident prevention
Industry: automotive
Success for the customer: increase in plant safety and availability; complete project implementation from a single source; smart early-warning system

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Problem

With its 360° screen, high-speed electric drive and twelve-metre rail for "air-bearing motion", the plant is one of the most powerful systems in the automotive industry. Therefore, it is necessary to safely guide and protect all required cables for the power supply, control system, network technology as well as cooling water and pneumatic hoses in the most efficient way possible.

Solution

Energy chains are like an umbilical cord, supplying energy, data and media, all the while remaining in constant motion.To further increase plant safety and availability, those responsible decided to install new energy chains of the P4.1 series, including a breakage detection system.Should an unforeseen difficulty arise during actual operation in such a highly dynamic application, this can be identified directly with the unique breakage detection i.Sense EC.B from smart plastics. This detects chain breaks at an early stage and avoids high costs due to downtime of the entire plant.

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

Smart plasticsfor e-chain

Our intelligent e-chain® systems are already reliably in use in hundreds of thousands of applications worldwide - from beverage machines and CNC machines to steel mills.

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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

Application examples

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.

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Download the smart plastics brochure

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Contact a smart e-chain® expert

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