Energy chain
An energy chain with IoT sensors continuously reports the condition of the cable management on moving machinery. Operators learn about overload, blockages or chain breakage before the machine stops, and plan chain replacement according to actual use.
Energy chain at a glance
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Verified projects featuring Energy chain
Extending the service life of energy chains in RMG cranes – with condition monitoring and predictive maintenance
Safe bulk material conveying with energy chains and sensors in bucket wheel excavator
Energy chains ensure continuous operation of container cranes under extreme conditions
Intelligent break monitoring in 22-tonne automotive driving simulator
Complete indoor crane automation thanks to the i.Sense monitoring system
Agricultural technology: 60% water savings with energy chains and sensor technology
Smart energy chain: report overload and breakage before a standstill
In the solution examples, the sensors come from igus and are called smart plastics. i.Sense EC.P measures the push and pull forces at one end of the chain, because most failures are preceded by a sudden rise in force, caused for example by foreign objects, snow or ice. i.Sense EC.B detects a broken chain via a tensioned cord that registers every change in length. If limit values are exceeded, the system can shut down immediately. The i.Cee module adds temperature, speed and distance travelled and uses them to calculate service life and the next maintenance date, either within the company network or via the cloud.
The examples come from the automotive, energy, rail, horticulture and logistics sectors. Mercedes-Benz monitors the energy chains of its driving simulator in Sindelfingen with breakage detection that identifies chain breaks early and shuts the system down automatically. At the Talwandi Sabo coal-fired power plant in India, a monitored roller energy chain with a travel distance of 670 metres replaces an unreliable cable drum. Luxembourg's railway company CFL runs its train washing plant with monitored energy chains, avoiding unplanned downtime.
Podcast episodes featuring Energy chain
Smart energy chains: frequently asked questions
How is an energy chain monitored with IoT?
Sensors on the energy chain continuously measure the forces acting on the chain and cables and report a break in the chain links. The data flows into a module in the control cabinet that is connected to the machine control system. If a limit value is exceeded, the operator is notified or the machine stops. An additional maintenance module uses usage and environmental data to calculate when the chain should be replaced.
How can a broken e-chain be detected in time?
A broken e-chain can be detected immediately with integrated breakage detection, rather than only being discovered during a visual inspection. With igus i.Sense EC.B, a tensioned cord or polymer wire runs through the chain and reports every change in length to the sensor. Mercedes-Benz uses this in its driving simulator in Sindelfingen. At an Austrian engine plant, the modules received an “Innovation of the Month” award.
Is a drag chain suitable for very long travel distances?
Yes, roller energy chains with sensors can reliably supply very long travel distances. At the Talwandi Sabo coal-fired power plant in India, a roller energy chain guides the cables of a bucket wheel machine over 670 metres. It replaces a cable drum that frequently failed and damaged the exposed high-voltage cable. Sensors along the chain measure push and pull forces and shut down if a limit value is exceeded.
How does predictive maintenance work for energy chains?
In predictive maintenance, software calculates the remaining service life of the energy chain from its actual use. The igus i.Cee module evaluates forces, temperature, travel speed and distance travelled and compares them with service life data from tests. Luxembourg's railway company CFL uses i.Cee in its train washing plant and learns in advance when damage will occur and how it can be prevented.
More assets in “Components & Devices”
Filter
Filter monitoring with IoT measures the differential pressure across a filter and shows how dirty it is. Operators change filters when it is actually necessary, avoid clogged filters and downtime, and save energy and material.
Lighting
Commercial lighting control with IoT adjusts the lighting in offices, halls, shops and advertising installations according to occupancy, brightness and schedules, and monitors every luminaire remotely. Operators cut electricity consumption and learn about failures immediately.
Electricity meter
Automatic meter reading means that electricity meter readings reach a platform via radio, cellular network or pulse adapter, with no on-site reading. Operators bill more accurately and see where energy is consumed in a building or in production.
Charging station
Commercial EV charging relies on load management that distributes the available power across all charging stations at a site and monitors them remotely. Operators avoid overloading the grid connection, integrate photovoltaics and storage, and bill sessions automatically.
Piping network
Pipeline monitoring with IoT reports pressure drops, pressure peaks and moisture under insulation in a piping network before they turn into failures. Operators maintain pipes according to their condition and avoid inspection rounds to hard-to-reach measuring points.
Power tool
Connected tools bring rivet tools, screwdrivers and cordless power tools into the networked factory. Every work step is documented, failed attempts are detected, and the data feeds into quality assurance and production control.
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