Energy chain cable
Cable break detection with IoT lets operators spot a failing energy chain cable before it breaks. Sensors measure tensile forces and electrical values of moving cables and report incipient conductor breaks, so replacement can be planned.
Energy chain cable at a glance
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Cable break detection for energy chain cables
In the solution examples, igus uses i.Sense CF.Q to monitor an additional, identical cable from the same production batch, because two such cables fatigue in the same way under load. From push and pull forces and the electrical properties of two measuring cores, the system detects a conductor break at a very early stage. On cranes, i.Sense CF.P measures the tensile force on the cables. IMS Connector Systems and MP-SENSOR use an M12 connector with measuring electronics and Bluetooth, which measures voltage, current and power and calculates the line resistance from them. A gateway translates the data into Profinet or Profibus, and it can also be sent to the cloud via MQTT.
The examples come from mechanical engineering, packaging and port logistics, as predictive maintenance and condition monitoring. GHD Georg Hartmann Maschinenbau has built CF.Q into its GBK 440 bread packaging machine as standard. The user operates the cables well beyond the end of the warranty and saves several thousand euros in maintenance costs per year. At the Port of Hamburg, EUROGATE monitors the tensile forces on the cables of its rail loading cranes with i.Sense CF.P.
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Energy chain cable monitoring: frequently asked questions
How can a cable break in an energy chain be detected early?
A cable break is detected early by running a reference cable alongside and measuring it permanently. With the igus i.Sense CF.Q system, the measuring cable is complemented by a second, identical cable because both age in the same way. The device monitors two additional cores as well as push and pull forces. If the electrical properties change, it reports an incipient conductor break before the actual cable fails.
How long does a drag chain cable last?
How long a drag chain cable lasts depends on bending radius, load and the number of movements, because the cable fatigues with every bend. With monitoring, there is no need to guess: igus software compares the readings with data from load tests and predicts how many working cycles remain. At GHD Hartmann, the cables therefore run well beyond the end of the warranty.
Why monitor the tensile force on continuous flex cables?
If the tensile force on a continuous flex cable rises, the cable is overloaded and can be damaged. The risk is particularly high on cranes with many heavy cables and long travel distances. On EUROGATE's rail loading cranes and on a rail-mounted gantry crane, igus i.Sense CF.P therefore continuously measures the tensile forces on the cables and reports deviations directly to the crane control system.
Can an M12 connector report the condition of a cable?
Yes, with built-in measuring electronics, an M12 connector reports the condition of the connected cable. The SmartMod module from IMS Connector Systems and MP-SENSOR continuously measures voltage, current and power and calculates the line resistance from them. Each connector has a unique address, so faulty wiring can be located quickly. The data is sent via Bluetooth to the controller or a gateway.
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