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Complete indoor crane automation thanks to the i.Sense monitoring system

smart plastic package drastically reduces operating costs in Polish panel warehouse

The TLF is a fully automated warehouse for wooden panels of the Polish-based company Nowy Styl Sp. z o.o. Due to the immense size of 15m x 65m, an automatic crane, which travels along the entire length of the warehouse, is an elementary component of the supply warehouse.

Profile

Fully automatic indoor crane with i.Sense system

Problem

The main task of the new TLF bearing is to ensure the continuous supply of production. The cutting plans are drawn up in advance so that the bearing can prepare the optimum plate feed, taking into account the remaining pieces.

The biggest challenge was to plan and install a reliable and predictive power supply that could fulfil the dynamic requirements in the often very hot and dusty warehouse. With a travel of over 60 metres and acceleration values of over 1 m/s², only a few technologies are suitable for this.

As significant savings in operating costs and maximum operational availability were also required in the subsequent utilisation of the system, only a future-oriented energy supply system that can map automatic operability in real time could be chosen.

Solution

As part of the modernisation of the automatic crane's power supply, igus® supplied a "readychain®" - a prefabricated 4040C series guide system equipped with separators and a set of appropriately placed cables and the pre-assembled cables: power, control system, signal, network and pneumatics.

As the operation of the crane is fully automatic, a i.Sensemonitoring system has been implemented, equipped with the EC.P tensile / shear force sensor for chains and CF.P cables and an EC.B breakage monitoring sensor. In order to maintain complete control over the operating conditions and predictive maintenance information at all times, the innovative i.Ceemodule was also installed, which enables real-time measurement of the speed, acceleration and environmental parameters and issues maintenance forecasts to the system operator on a daily basis by comparing them with historical service life data from the huge igus® test laboratory.

Mounting bracket with i.Sense EC.B for breakage monitoring

Mounting bracket with i.Sense EC.B for breakage monitoring

All i.Sense modules in the control cabinet to save space

All i.Sense modules space-saving in the control cabinet

i.Sense CF.P cable monitoring

i.Sense CF.P Line monitoring

"The complete smart plastic package offers the option of controlling the operation of the energy supply in real time and provides advance notification when an inspection is required. This eliminates the risk of an unplanned outage that would bring the entire plant's production to a standstill."

Grzegorz Michalski, Nowy Styl Sp. z o.o.

Everything from one source ...

... igus® Engineering Service
igus® carried out measurements, the selection of a new solution, the implementation of the readychain® system, the prefabrication of control cabinets with the modules EC.P, EC.B. CF.P as well as i.Cee and a comprehensive installation in the factory. In addition, the commissioning and calibration of the complete i.Sensesystem and the harnessing of cables as an intermediate connection between the guidance, which supplies the crane runway, and the guidance, which supplies the cross lift, was also ensured by the igus® service team.

igus engineering service
Protected chainflex® cable package

ASI Automatikk AS Distributor+47 9006 1100