Author: SD

Smart products made of tribo-polymers increase the service life of machine tools by digitally monitoring their status

“Industry 4.0”, “Internet of Things” and “Smart Factory” – these concepts are no longer a vague promise of what is to come. Companies are already able to benefit from the use of intelligent systems and products. At EMO 2019, igus will be showing how machine tool manufacturers and customers can raise their maintenance to a new level and, at the same time, reduce costs by using smart machine components.

Maintenance in the era of Industry 4.0 means a clear change of paradigm. Instead of personnel carrying out maintenance at fixed intervals or merely reacting to a failure or a fault, so-called “predictive maintenance” makes it possible to continually monitor the status of the machine tool. Repair or replacement is only carried out when really necessary. Maintenance tasks can be planned precisely. At the same time, unscheduled shutdowns and therefore the costs of failure can be reduced due to condition monitoring. In order to make this possible, igus has developed sophisticated smart plastics, by using diverse sensors and monitoring modules for energy chains, plain bearings, linear bearings and slewing ring bearings. For example, sensors for the measurement of abrasion or wear of the pin/bore connections of energy chains as well as sensors for the detection of breakages and the push/pull forces being applied. Due to networking with the new igus communication module (icom.plus), the sensors are integrated into the customer’s own IT infrastructure, for example into production management systems such as SCADA and MES, or online into cloud solutions throughout a company.

Flexible data integration with new icom.plus
The icom.plus is programmed with initial service life algorithms on the basis of igus configuration tools and, at the customer’s request, can be operated offline without an update function after online installation. The user can therefore decide how the module is connected and how the data is managed, while establishing a balance between runtime maximisation and IT security. If online connection of the icom.plus is chosen, the service life information is continuously compared with the igus cloud in order to enable maximum machine run times with a minimum risk of failure. The data in the cloud inter alia draw on the 10 billion annual test cycles of energy chains and cables performed in the company’s own 3,800 square metre test laboratory. On the basis of these tests, the results of which are incorporated into the freely available service life calculator, it is possible to precisely predict how long an e-chain, for example, will work reliably in the respective machine tool application. Thanks to the isense components, the service life is continually updated, giving the customer additional reassurance. This is because each update takes into account the current ambient conditions of the application. Thanks to machine learning and continuous improvement, precise information on the durability of the individually used solutions in real applications can be obtained. This information can be viewed on the screen of the machine control system and, if online connection is chosen, an SMS or e-mail can provide the relevant details if unexpected operating states occur or maintenance is impending. At an early stage, users are informed if there is a need to procure replacement parts; a wide range of scenarios such as automatic initiation of maintenance work or the ordering of replacement parts as well as “e-chain as a service” can be implemented.

CONTACT: Vaibhav Taware Regional Manager igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT: Serish Gupta Product Engineer igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 8105058844 sgupta@igus.net Visit us on ww.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.

Intelligent igus sensor keeps track of the wear of linear plain bearing liners, increasing the reliability

Detecting the wear of liners in linear systems at an early stage was the goal of the engineers at igus, who have now developed a new, intelligent linear guide. A sensor in the bearing liners measures the individually determinable wear limit and sounds an alarm when it is reached. This allows maintenance to be planned in advance and avoid unexpected system failure.

When should I change my bearing? This question is posed by operators of systems that use linear robots and linear systems around the clock. From the packaging machine and the glass processing industry up to machine tools. Linear guides must withstand extreme loads. In order to detect early wear of the sliding lubrication-free bearings made of high-performance plastics and to plan the maintenance in advance, igus has now developed a new smart system for its drylin linear systems. The new smart plastics technology measures the wear of dirt and dust-resistant bearings and gives the user a signal when the wear limit is reached.

Patented technology for wear monitoring
A new intelligent and patented technology ensures the measurement of the wear of a bearing in all directions. To do this, igus integrates a sensor in the bearing, which sends the measured data to the icom. The communication module collects the data of all smart plastics sensors, processes them and forwards them. The user can take over the monitoring with the terminal device of his choice and therefore always carry out maintenance, repair and replacement.

Fast replacement directly on the rail
If a bearing change is needed, it is quite simple, because this is where igus banks on its smart bearing replacement technique. The linear axis or the multi-axis gantry with toothed belt drive no longer has to be disassembled, because the replacement takes place directly on the rail. Similar to a pit stop in Formula 1, the linear plain bearing can be changed in no time at all and thanks to a free tool, it reduces downtimes to a minimum. The system can be put back into operation within a few minutes.

CONTACT: Vaibhav Taware Regional Manager igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT: Serish Gupta Product Engineer igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 8105058844 sgupta@igus.net Visit us on www.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.

icom.plus module enables predictive maintenance with flexible data integration for high IT security

Being able to predict and plan maintenance is the goal pursued by igus with its smart plastics solutions. Intelligent sensors, for example, measure the wear of energy chains, slewing rings and linear guides. With the new communication module icom.plus, the customer can now decide in which form they would like to incorporate the acquired data from the sensors. From an offline version for restrictive environments up to the connection of the values to the igus server for automatic spare parts ordering, the user is free to integrate and read their data.

Under the name isense, igus carries sensors of various kinds that detect the condition of igus components such as cables or energy chains. They measure among other things the wear during the operation and alert the user early enough to plan repair or replacement. By networking with the icom communication module, the data is transmitted to an intelligent system. The module can be connected to all igus specific sensors. For example, with sensors for the measurement of abrasion, or the wear measurement of the pin-bore connection of the energy chain, as well as sensors for the detection of break and push-pull forces and for cable monitoring. Once the measured values from a sensor have been transferred to the icom module, they have to be “interpreted”, i.e. understood in order to generate instructions from the same. So far, this has been possible via the connection to the igus cloud. Due to the increasing importance of IT security, however, many companies are increasingly relying on the development of their own SCADA systems, which is why igus has now advanced its data concentrator into icom.plus. With the new module, the customer can integrate the data in the way that best suits their equipment.

Flexible data connection through new 3-in-1 module
The icom.plus is programmed via igus online configurations with initial service life algorithms. The special feature: the new communication module can be operated offline upon customer request, after online installation without update function. In this “semi-offline” case, during an initial “learning phase”, the device requires a temporary, short-term secured IoT access to the igus server to match the calculation algorithms to the actual motion and environmental profile of the customer application. In very restrictive areas, the update can also be performed from the beginning via a storage medium completely offline. In this way, the user can flexibly design the connection of the module and their data to establish a balance between maximising the runtime and IT security. The motion profile required for the calculation of the maintenance recommendation is read directly from the control system via the bus system of the machine. In the same way, the information about the number of days until the next recommended maintenance and freely definable warning messages about unusual changes in the sensor data are transferred to the PLC control. The user information is provided directly via the system monitor or via customer-specific SCADA systems.

Predictive maintenance by connecting to the igus server
With the online connection of the icom.plus, a continuous matching of the service life statement with the igus cloud takes place in order to enable maximum system runtimes with minimal failure risk. The data in the cloud draws on the 10 billion test cycles of energy chains and cables performed in the company’s own 2,750 square metre test laboratory, and thanks to machine learning and AI, igus can provide precise information on the durability of the solutions used and inform the user about a necessary replacement beforehand.

CONTACT:   Vaibhav Taware Regional Manager   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT:   Serish Gupta Product Engineer   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone :+91 8105058844 sgupta@igus.net Visit us on www.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.

Simple automation and low cost: the igus delta robot makes this possible by the use of lubrication-free components made of tribo-polymers. At the 2019 Motek show, the motion plastics specialist presented a new version with a 10 times larger work space volume compared with the proven model. This lightweight system for easy pick & place tasks, is delivered as a pre-assembled kit or ready to install product. This guarantees quick operation and saves costs immediately.

Lightweight, cost-effective and with a larger range – that’s the new delta robot drylin DLE-DR from igus. Using lubrication-free tribo-polymers, it is not only very cost-effective when buying, but also low maintenance when in use. This reduces maintenance and downtime costs. Thanks to a modular system, users can choose between a compact self-assembly modular kit or pre-assembled version in a transport frame. The robot consists of three maintenance-free drylin ZLW toothed belt axes with NEMA23 XL encoder stepper motors, lubrication-free igubal coupling joints and matching adapter plates for grippers and motors. This ensures the quick handling of up to 5 kilograms with a precision of ± 0.5 millimetres. The new delta robot offers a 10 times larger working space with 660mm diameter at 180mm height, which significantly increases the range. A calibrating pin allows the robot to be positioned at the zero point. It is directly fixed to the mounting hub.

Simple automation available from 5.9 Lakhs
The use of the delta robot is very apt for simple assembly activities, pick and place tasks, as well as applications in inspection technology. As a construction kit, it can be set up in just 30 minutes and is extremely cost-effective from 5.9 lakhs. “Even a smaller or medium-sized company can venture into automation for a few lakhs”, says Stefan Niermann, Head of Low Cost Automation at igus. “At the same time, the operator benefits very quickly from their new automation solution. The payback period is less than six months for most applications.” Depending on the customer’s requirements, the new drylin DLE-DR can be delivered within 2 weeks as a pre-assembled construction kit with assembly instructions in a box, or as a ready-to-install system in a transport frame. As an option, the customer can use their own software and control system, or the intuitive and easy-to-use dryve D1 control system from igus.

Build your own robot with just a few clicks
With the drylin DLE-DR delta robot, igus is expanding its broad selection of robotics components. Based on its tribo-polymer expertise, the company has been developing cost-effective automation solutions for order picking, feeding, quality assurance and assembly for many years. These include robolink DP – a modular system that allows users to assemble articulated arms with a robust and lightweight plastic housing, gearboxes and motors into a robotic arm of their own. The offer also includes robolink DCi, a pre-configured, ready-to-use automation system. It consists of a 4 or 5-axis robot and a control system that is integrated at the base of the gripper arm in a space-saving manner. This year igus and its industry partners introduced the RBTX.com platform to enable customers to quickly assemble their own robot solution. With just a few clicks, you can put together your own low-cost robotic solution online. The basic electro-mechanical structure is thereby the articulated-arm robots, delta robots and linear robots. In the next step, the user supplements this basic structure by adding individual components of different manufacturers such as grippers, suction units, cameras, motors, sensors and control systems. The advantage: all components are compatible with each other. The user quickly receives a reliably operating overall automation package that meets their individual requirements and budget.

CONTACT:     Vaibhav Taware Regional Sales Manager-North   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, Dodda Nekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell      : (+91)9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT:     Serish Gupta Product Engineer   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, Dodda Nekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell      : (+91)81 0505 8844 sgupta@igus.net Visit us on www.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.

Low cost process automation with lubrication-free drylin linear robots from igus

Simple, precise, fast processes: these are the requirements of Cartesian robots. They are used for such things as pick-and-place applications, sorting systems and medical technology. igus has now developed a linear and room linear robot for large workspaces. The two new kinematics systems allow users to move up to five kilogrammes. Both linear robots are available directly from stock. They can also be customised to suit the customer application in question – no minimum order quantity.

To survive on the market, both large industrial players and small companies need automated solutions that will quickly pay for themselves. For years, Cartesian robots have been a means of choice in automation technology. They allow users to complete their tasks quickly, easily and cost-effectively. All that is required is a little bit of programming effort. igus’ lubrication-free linear axes developed in several stage. Depending on the application’s requirements, two-axis linear or flat linear robots and three-axis room linear robots can be selected. At Motek, igus introduced a new line robot and a new room linear robot with an enlarged workspace, which allows users to move even greater loads acrosslarger area.

Low Cost Automation with lubrication-free linear robot solutions
The two linear robots consist of pre-configured linear modules, aluminium linear axes, NEMA stepper motors and encoders. The new line robot can transport loads of up to 50 N in a workspace of 800x500mm at a maximum speed of up to 1 m/s. “The investment risk for the line robot is manageable, so that our automated pick-and-place applications for assembly tasks pay for themselves in less than six months. This means that decision makers have a low level of risk”, says Alexander Mühlens, Head of Automation Technology at igus. The new room linear robot is a good option for more complex tasks. It can transport loads of up to 50 N in a workspace of 800x800x500mm at a maximum speed of 0.5 m/s. Two ZLW toothed belt axes and one GRR gear rack axis ensure precise guidance and lubrication-free operation.

For fully automated sorting tasks
The new linear robot solutions are used in pick and place, bin picking and sorting tasks. Most of these processes have been moved to the end of the production line. This was also true at FachPack 2019 in the showcase of SSI Schäfer, the intralogistics specialist. The new drylin room linear robot automated the provision of sensitive products using a transport box with a thermoform insert. The specially developed packaging and the use of a linear robot allowed various coloured handles to be pre-sorted for the production of a household appliance. There are other linear robot use scenarios in microelectronics and automated testing.

Customise room linear robot design
In addition to the stock items, users can assemble their own linear robot with strokes of up to six metres at http://www.igus.in/robot-enquiry and request a quotation from igus. Depending on customer requirements, axis length and various motors can also be configured with such items as energy chains and cables from igus.

CONTACT:     Vaibhav Taware Regional Sales Manager-North   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell      : (+91)9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT:     Serish Gupta Product Engineer   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell      : (+91)81 0505 8844 sgupta@igus.net Visit us on www.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.

UR (Universal Robots) and robolink robots acquire a 5-times larger action radius thanks to a completely new solution

igus now offers a directly ready-to-connect 7th axis, so that a robot can move over a distance for several metres. The new complete system consists of a maintenance-free drylin ZLW toothed belt axis with corresponding adapter plate, switch cabinet, cables and software integration. For easy integration of the axis of the robot, igus has developed two adapter kits for robolink and UR robots. They enable fast and, above all, cost-effective low-cost automation.

Robots insert workpieces into a milling machine, dispense chocolate bars from vending machines and place crates on pallets, which are then stacked. But how can they move vertically, horizontally or overhead in a flexible manner? The answer is a 7th axis. Specifically, for linear adjustment, igus has developed a lubrication-free, lightweight flat axis with a stroke of up to 6m and a positioning accuracy of 0.5mm with the help of its drylin linear construction kit. To ensure that the axis can be easily combined with a robot, igus now offers overall solutions for UR3, UR5 and UR10 robots (Universal Robots), robolink DP robots and DCi robots. “A customer who acquires the new complete system receives, on the one hand, an adapter plate for easy attachment of the robot and the energy chain to the axis and, on the other, the corresponding integration solution, in other words the switch cabinet with cables, motor controller and the respective software solution”, explains Alexander Mühlens, Head of Automation Technology at igus GmbH. “If a robolink robot is used, the 7th axis can be easily controlled by means of the igus robot control software. For UR robots, we supply an UR-CAP as a direct integration solution, including all the electrical modules needed.” This means that the robot can be installed and put to work within just a few minutes.

Ready-to-connect 7th axis in desired length
The 7th axis is supplied by igus as a complete system that is ready to connect immediately, consisting of a drylin ZLW-20 toothed belt axis in the desired length exactly to the millimetre, plus the connecting cables, the switch cabinet, the power electronics, the software integration and the corresponding adapter set. Alternatively, the adapter set is separately available consisting of adapter plate and control system. 

CONTACT:     Vaibhav Taware Regional Sales Manager-North   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell    :(+91)9350922339 vtaware@igus.net Visit us on www.igus.in

CONTACT:     Serish Gupta Product Engineer   igus (India) Private Limited 36/1, Sy. No. 17/3 Euro School Road, DoddaNekkundi Industrial Area – 2nd Stage Mahadevapura Post Bangalore – 560048 Phone : +91 80 45127800 Cell    :(+91)81 0505 8844 sgupta@igus.net Visit us on www.igus.in

The terms “igus”, “Apiro”, “chainflex”, “CFRIP”, “conprotect”, “CTD”, “drygear”, “drylin”, “dry-tech”, “dryspin”, “easy chain”, “e-chain”, “e-chain systems”, “e-ketten”, “e-kettensysteme”, “e-skin”, “e-spool”, “flizz”, “ibow”, “igear”, “iglidur”, “igubal”, “kineKIT”, “manus”, “motion plastics”, “pikchain”, “plastics for longer life”, “readychain”, “readycable”, “ReBeL”, “speedigus”, “triflex”, “robolink”, “xirodur”, and “xiros” are protected by trademark laws in the Federal Republic of Germany and internationally, where applicable.