Fixed flange bearings with i.Sense igubal®

The intelligent fixed flange bearing from smart plastics constantly monitors the condition of the bearing point and immediately reports the first signs of wear in order to avoid serious bearing damage.

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

The CFL train washing station uses igus® energy chains and igubal® fixed flange bearings in the washing trolleys. Previously used metal bearings have been replaced with plastic bearings to reduce maintenance requirements. A "smart" bearing that monitors condition is being tested to prevent unforeseen damage. The aim is to receive an immediate notification if the bearing properties deteriorate. This is intended to prevent expensive disruptions and failures.

The CFL's maintenance manager, Mike Feinen, emphasises the importance of avoiding downtime, as this is costly and the contracts call for regular cleaning of the trains. Failure to comply will result in penalties. In collaboration with igus®, a solution was found to ensure optimal performance of the system. After initial adjustment problems, the system now runs smoothly and the smart fixed flange bearing has saved a lot of maintenance time.

Tech up

Continuous condition monitoring of heavy-duty two- and four-hole fixed flange bearings
Early anomaly detection
Comprehensive connectivity for optional integration into the predictive maintenance concept with i.Cee

Cost down

Identical design can replace metallic counterparts 1:1
Avoidance of unplanned downtime thanks to condition-based alarm messages

Proof

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

Minimal material requirements for the integrated sensor
Use-based product replacement reduces unnecessary material costs

Intelligent condition monitoring implemented successfully

i.Sense from smart plastics in practice

Wastewater treatment plants and wastewater operations |
Port and container cranes |
Conveyor and bulk handling

"Less effort, greater availability"

"Less maintenance effort, greater availability, the capability of guiding all different cables and hoses in a single system, intelligent i.Sense condition monitoring … I would definitely choose the intelligent igus energy chains again!"

Dipl.-Ing. Fabian Wilhelm, Project Manager for AOS Stade GmbH

Customer applications worldwide

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

To the application overview

Case study on i.Cee in CFL train washing station

Operation without surprises: smart energy chains for the most modern train washing station in Europe

Free case study

This case study talks about how CFL, Luxembourg's state railway company, uses several energy chains from igus® together with intelligent sensors from smart plastics to overcome numerous challenges:

How exactly are failures prevented?
Which components were to blame for the failure?
How was the whole project approached and with what tools ?
And how is it going at the moment?

Go to the PDF download

When do I need a smart condition sensor like the i.Sense igubal?

When regular maintenance work requires complete production shutdown ...

When motion anomalies cannot be detected by humans in time ...

If plants or machines need to be monitored frequently or continuously ...

If energy supply system travels are difficult to access or view ...

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

If maintenance costs are to be reduced and service life extended ...

Live condition monitoring in every bearing

i.Sense BRG for everyone

A defective bearing point can ruin the day, not only for farmers, but for any machine operator. Machine failures and downtimes are among the biggest cost drivers in industry. It is therefore important for maintenance personnel to act in good time to prevent unplanned stoppages.

igus smart bearing products are great for especially sensitive or hard-to-reach spots on a machine, since they allow the bearing's condition to be assessed at any time. The sensor can be used to monitor each machine wear part remotely – and this could benefit many other motion plastics applications in the future.

More about our smart dry-tech products

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

Integration into your network environment

Since the new i.Sense BRG mini-sensor is part of the smart plastics i.Sense condition monitoring system, all of its data can also be evaluated in the i.Cee control cabinet module. These data can then be used to digitally control the system's alarm and escalation management.

The i.Cee module can be integrated into predictive maintenance concepts in a number of ways, from preventive service management, which schedules regular maintenance depending on use, to location-independent fault management, which immediately reports any unforeseen change via various mobile channels. All information is collated in a modern dashboard, online or offline in the local network, depending on the customer's requirements.

Predictive maintenance