Cleaning system
An industrial cleaning system with IoT records forces, consumption and process data and reports them to maintenance, production control or cost calculation. This keeps cleaning systems available and makes every wash cycle traceable.
Cleaning system at a glance
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Verified projects featuring Cleaning system
SECS/GEM interface FabLink® in the backend of the semiconductor industry
Predictive maintenance of train washing stations
Intelligent container services for cleaning facilities in Hamburg
Industrial cleaning system: keep it running, measure every wash
At CFL's train washing plant, force sensors of the igus i.Sense EC.P system measure the push and pull forces on the energy chains of the washing carriages. If defined limits are exceeded, the system shuts the plant down. The i.Cee software adds temperature, travel speed and distance travelled and uses them to calculate service life and service dates. Data either stays in the company network or goes to the cloud via a data concentrator. In Hamburg, sensors record electricity and gas consumption, water temperature, water pressure, washing time and the amounts of water and cleaning agent, with Revolution Pi units as pre-processing and IoT gateway. In semiconductor manufacturing, the SECS/GEM interface FabLink from Kontron AIS connects the system to the MES.
The examples come from transport and logistics and from plant engineering, for predictive maintenance, consumption tracking and audit reporting. According to igus, unexpected breakdowns of the washing plant are a thing of the past at Luxembourg's railway company CFL. Thanks to erminas, a service provider in the Port of Hamburg sees water, energy and chemical consumption per container, and an app selects the most economical wash programme. SYSTRONIC commissioned its cleaning system in a semiconductor fab on schedule with Kontron AIS and now handles follow-up projects itself. In episode #88, CFL maintenance manager Mike Feinen reports.
Podcast episodes featuring Cleaning system
Industrial cleaning systems: frequently asked questions
How can breakdowns at a train wash be prevented?
Breakdowns at a train wash are prevented by continuously monitoring the energy chains of the washing carriages. At CFL, four washing carriages travel along 66-metre sections on each side of the train, and their energy chains carry lines for power, compressed air, water and cleaning agents. Most failures are preceded by a sudden rise in force from foreign objects, snow or ice. igus sensors detect it and shut the plant down before a train gets stuck in the hall.
How does IoT make shipping container cleaning more efficient?
IoT makes shipping container cleaning more efficient because every wash cycle is recorded with its consumption and duration, and the right programme can be derived from this. For a service provider in the Port of Hamburg, erminas developed an app that always selects the most economical wash programme for an object. It adapts the programme to outside temperature and humidity. The project manager sees water, energy and chemical use per container, and washers can add their own notes.
What data does digitalised industrial tank cleaning provide?
Digitalised industrial tank cleaning provides electricity and gas consumption, water temperature, water pressure, washing time and the type and amount of cleaning agents. In the Hamburg project, the sensors had to withstand high temperatures, humidity and chemicals, and erminas selected them after an on-site analysis. Three Revolution Pi Connect+, three Revolution Pi DI and one Revolution Pi AIO forward the data to the cloud. This enables accurate billing and lays the groundwork for pay-per-use models.
How does a stencil cleaning system get integrated into a semiconductor fab?
A stencil cleaning system is integrated into a semiconductor fab via a SEMI-compliant interface to the manufacturing execution system. For SYSTRONIC, Kontron AIS supplied its SECS/GEM component FabLink and helped with the roughly 100-page specification containing more than 300 requirements. A workshop clarified data points, material flow and status models, and the GEM manual enabled the end customer to integrate the system. A dedicated test system shortens commissioning in the fab.
More assets in “Machinery and Equipment”
Pump
Pump monitoring with IoT records vibration, temperature, pressure and energy consumption of running pumps. Operators detect damage and faults before a pump fails and plan maintenance by condition rather than at fixed intervals.
Compressor
With IoT, compressor maintenance follows actual condition: sensors record current consumption, pressure, temperature and running times. Operators detect creeping damage and unused running time early and cut energy and service costs.
Electric motor
Motor condition monitoring with IoT continuously measures the vibration, temperature and current draw of electric motors. Operators detect imbalance, bearing damage or winding faults early and replace motors based on condition rather than after a failure.
Packaging machine
OEE software automatically records run times, downtime, speed and rejects on packaging machines from the machine signals. Operators see where their lines lose performance, and machine builders use the same data for remote access and digital services.
Refrigeration system
A refrigeration monitoring system makes service plannable: temperatures, refrigerant circuit pressures, compressor status and energy consumption flow into a platform in real time. Operators and service partners detect faults early, avoid unnecessary site visits and reduce excess consumption.
Air conditioning system
Commercial air conditioning systems in offices, retail branches and data centres can be monitored remotely with IoT. Operators see energy consumption, temperatures and faults in one place, detect failing compressors or refrigerant shortages early and plan service visits precisely.
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