igus GmbH, based in Cologne, develops and produces motion plastics. These innovative products made of high-performance plastics are primarily used in industry. With the concept "improve what moves", igus has set itself the goal of improving the motion sequences of machines and devices worldwide.
For igus, the focus is on innovative thinking in product development - for example through the use of "smart plastics", i.e. intelligent sensors, for Industry 4.0. Sensors already installed in the plastic can transmit real-time data and prevent high costs through the efficient control of maintenance work and the occurrence of damage.
.avif)
"We have been working on smart plastics since 2016 and have implemented applications in a wide range of industrial sectors around the world. Smart plastics are intelligent plastic components that are equipped with sensor systems," says Richard Habering, Head of Business Unit at igus. These can be used in various systems, for example in machines in sewage treatment plants.
Durable and robust systems are particularly important in wastewater treatment plants, as these facilities operate 365 days a year and a plant shutdown can be very problematic. Downtime in the piping systems must therefore be avoided at all costs. This is exactly what condition monitoring using smart sensors makes possible: The sensors in the components can trigger an alarm or even cause the system to shut down completely via the machine control system—all before costly damage occurs. Data is transmitted in real time using M2M SIM cards and cellular networks. Cellular networks are an ideal, established technology for seamless monitoring of the plant, as the infrastructure is available almost everywhere.
Habering explains exactly how the system works: "With our i.Sense EC.P tension and thrust force monitoring system, we use sensors to continuously measure the force required by the system to move the cable carrier. If these forces change due to external influences such as ice, an animal or a tool forgotten during maintenance, the sensor detects this change and switches the system off. This solution prevents expensive consequential damage and lays the foundations for the maintenance of the Smart Factory. Of course, we and our customers have to be able to rely on the reliable and permanent transmission of data."
As sewage treatment plants largely run without the presence of people, malfunctions during operation may not be detected for long periods of time. This makes remote access by igus customers to status information in real time all the more relevant.
“Theoretically, our smart plastics modules could also be connected via cable; however, for years we have observed a growing demand from our customers for direct remote capability and standalone connectivity. Connecting via mobile routers with M2M SIM cards enables a simple, standardized connection to the Internet of Things—exactly what our customers want from us.” Operation is designed to be as simple as possible: SIM cards are managed through the portal provided by WhereverSIM, or—if desired—via API integration into the customer’s own system.
Data security is a top priority, especially when accessing data remotely. WhereverSIM offers its customers several options to protect against unauthorized access, such as using an IPSec VPN(Internet Protocol Security). This ensures that data is transmitted via a virtual, encrypted connection.
If access to the data is not a priority, the use of a private APN is recommended as an alternative. This creates a closed system in which the data is forwarded directly to the company's data network without any detours
Given its international customer base, the global applicability of the technology used was particularly important to igus when selecting an IoT partner. With WhereverSIM and access to all mobile networks in Germany as well as networks in over 190 countries, this requirement is met. In addition to affordable and transparent plans with included data allowances and an easy-to-use dashboard, professional customer support was the deciding factor in choosing WhereverSIM.
“We were impressed not only by the product lineup, which was a perfect fit for us, but also by the personal dedication of our contact at WhereverSIM. Even after we signed the contract, he was always available to us, answered every question we had, and advised us on new, suitable rate plans,” says Habering.
The increasing demand for smart plastics shows that igus is on the right track with its confidence in innovative products: not only are more and more "standard" products from igus being equipped with smart technology, but international demand is also increasing. igus now has over 2,500 systems worldwide that are equipped with smart modules - and the trend is rising.
