Evaluate machine data with new communication module from igus

icom.plus module enables predictable maintenance with flexible data integration for higher IT security

Predicting and planning maintenance is the goal igus pursues with its intelligent plastic solutions. For example, intelligent sensors measure the wear of cable tracks, slewing ring bearings and linear plain bearings. With the new icom.plus communication module, customers can now decide in what form they want to integrate the data collected from the sensors. From an offline version for restrictive environments to connecting the values to the igus server, or for automatic spare parts ordering. The user chooses how he wants to integrate and read his data.

Under the name isense, igus supplies various types of sensors that monitor the condition of igus components, such as cables or cable tracks. Among other things, they measure wear during use and alert the user in time to schedule repair or replacement. Networking with the icom communication module transmits the data to an intelligent system. The module can be connected to any of igus' specific sensors. For example, to sensors for measuring the wear of links, or wear measurement of the pin/hole connection of cable tracks, but also to sensors for detecting breaking, pushing and pulling forces and for cable monitoring. Once the measured values from a sensor are sent to the icom module, they must be interpreted, i.e. understood to generate sound instructions. Until now, this was possible via the igus cloud connection. However, due to increasingly important IT security, more and more companies are relying on developing their own SCADA systems. That is why igus has now upgraded its data concentrator to icom.plus. The new module allows customers to integrate data in the way that best suits their equipment.

Flexible data connection via new 3-in-1 module

The icom.plus is programmed via online igus configurations with initial life algorithms. The special feature: after online installation without update functionality, the new communication module can be operated offline upon customer request. In this "semi-offline" case, during the initial "learning phase," the device requires a temporary and short secure IoT access to the igus server to match the calculation algorithms to the current motion and environment profile of the customer application. In highly restrictive environments, the update can also be performed from the beginning, completely offline via a storage medium. In this way, the user can flexibly design the connection of the module and its data and achieve a balance between maximizing runtime and IT security. The motion profile required to calculate the maintenance recommendation is read directly from the control system via the machine's bus system. Similarly, information about the number of days until the next recommended maintenance and freely definable warning messages about unusual changes in sensor data are sent to the PLC control. User information is provided directly from the system monitor or from customer-specific SCADA systems.

Predictable maintenance through connection to the igus server

With icom.plus's online connection, the lifetime statement is continuously synchronized with the igus cloud to enable maximum system runtimes with minimal risk of error. The cloud data is based on 10 billion test cycles of cable backs and cables performed in the company's own 3,800-square-meter test lab. Thanks to machine learning and AI, igus can provide accurate information about the durability of the applied solutions and thus inform the user in advance of a required replacement.