Igus Unveils iComm Box for Integrating Condition Monitoring

Igus, a leader in motion and control solutions, has recently announced its latest innovation: the iComm Box communication module. Designed to improve on the capabilities of the company’s intelligent sensors in the i.Sense series, the new module facilitates the integration of these sensors with the ‘superwise’ service, all from one small unit. The new solution offers fast and reliable data transmission for operational health monitoring.

The new iComm Box communication module for i.Sense sensor and superwise service integration. Image used courtesy of igus

Seamless Integration and Real-time Data

The new iComm Box allows for reliable and fast transmission of data between the i.Sense sensors and the superwise system, a proactive monitoring and maintenance solution offered by the company. Said to offer a cost-effective monitoring solution, the system also features a user-friendly dashboard that offers real-time data monitoring and control, displaying aspects like service life in percentages, system anomalies, and maintenance recommendations.

Through the superwise service, igus can leverage their i.Cee portal to help companies should they be unable to monitor their systems. The portal is linked to the customer relationship management (CRM) system of igus, ensuring that users are updated on all reports and automatically assigned relevant tasks.

Equipped with smart algorithms, the iComm Box delivers detailed analysis of a machine or the systems being monitored for more accurate predictions of their conditions. Using data that is already acquired from sensors, movement profiles of components such as energy chains, plain and spherical bearings, linear guides, slew ring bearings, and cables can be calculated by these smart algorithms.

Capable of automatically stopping systems or triggering messages in the event of system anomalies, the smart sensors in the i.Sense series can send data through a cable to the evaluation module that integrates the PLC and the iComm Box via separate cables. One sensor is the i.Sense EC. P sensor that measures the shear and the tensile forces in energy chains and sends the values to the evaluation module, where it's later sent to the superwise dashboard through the iComm Box. Buying the module comes with a 10-year data plan offering no running costs.

Cost-Effective and Secure Transmission Solution

When it comes to security in data transmission, the new iComm Box communicates through an encrypted mobile network that is secure and separate from the TCP-IP network of the user. The new module also comes with secure data management options like the secure cloud-based (i.Cee:cloud) data transfer and local network data transfer (i.Cee:local) that offer flexibility and security to the company regarding transfer and access of any sensitive data.

According to Richard Habering, the Head of the smart plastics Business Unit at igus, the iComm Box offers a cost-effective and simple choice for enhancing the functionality of the sensors in the i.Sense sensor series. Promising a faster return on investment, Habering emphasized that the new communication solution can save precious seconds of system downtime, which may not sound like much, but in the automotive industry, a minute of system downtime can cost up to $50,000. Additionally, the iComm Box comes with all its data transmission costs included in its price.

When it comes to industry sectors where the iComm Box can potentially find its use, the communication module can offer condition monitoring solutions for sectors like concrete works, sewage treatment plants, automotive industries, and container cranes.

Condition Monitoring for Industry 4.0

As industry technologies improve, the emergence of technologies like the iComm Box offers an all-in-one innovative solution for condition monitoring and predictive maintenance, handling some of the industry 4.0 challenges. By optimizing the process of maintenance and cutting down on downtime costs, the communication solution stands out as a potential choice for companies seeking enhanced productivity with no worries of limitations resulting from a shortage of skilled labor and costly damages.