Fixed flange bearings from igus become intelligent

New generation of igubal spherical bearings is equipped with predictive maintenance system

Expensive machine and vehicle failures due to undetected faults in heavy duty fixed flange bearings will soon be a thing of the past thanks to a new generation of two- and four-hole fixed flange bearings. Their special feature is that the bearings, which are made of lubricant-free high-performance plastic, are equipped with miniature wireless sensors that enable condition monitoring and predictive maintenance.

A technician looks at his smartphone: a conveyor of a beer bottle disposal system contains a fixed-flange bearing whose wear limit is approaching. In the past, the problem might have gone undetected and caused an expensive system failure. Today, however, the technician can simply replace the bearing during an interruption in production - secure in the knowledge that the hundreds of other bearings are also communicating with him. "This scenario is no longer science fiction. As part of our smart plastics range, we are gradually equipping plain bearings made of high-performance plastics with networked sensors," says Roy Snellens, Product Manager Business Unit Linear and Bearing Technology igus. "Our two- and four-hole fixed flange bearings from the igubal series now also enable condition monitoring and predictive maintenance to prevent unforeseen damage."

Flange bearings transmit their status wirelessly

And this is how the new Industry 4.0 bearings work: igus integrates a wear sensor into the spherical polymer ball: a thin circuit board close to the raceway. There is also a battery for power supply without cables. This means that the bearing for spherical leveling can continue to move independently. Wear and tear interrupt the circuit board's guide tracks. When the electronics lose the signal from a guide path, it knows that wear has reached a certain level. The sensor transmits a digital signal over a long-range network (LoRa), a wireless standard for the Internet of Things (IoT) known for its energy efficiency. The receiver is the i.Cee switchgear module, which analyzes the data. The associated software now knows that the guide path is worn out and calculates the percentage of wear. Over time, the sensor itself wears away layer by layer - parallel to the tread of the bearing. It continues to send signals from which conclusions can be drawn about the condition of the bearing. Users can see the remaining life and when maintenance is needed on a Web-based dashboard, which they can access from anywhere in the world with a PC, tablet or smartphone.

Luxembourg railroad company is first pilot customer for smart fixed flange bearings

The new fixed flange bearings are currently in the prototype phase. However, they have already convinced one pilot customer: the Société National des Chemins de Fer Luxembourgeois (CFL). Luxembourg's national railroad company has a 200-meter long washing system that cleans local and long-distance trains every day. In the past, failures in the washing system's gearing repeatedly led to costly system failures. So the operator moved away from lubricated standard ball bearings and instead used igus' networked spherical balls in the UC bearing housings. The advantage is that the high-performance plastic balls are corrosion-free, resistant to chemicals and, thanks to their built-in solid lubricants, allow for low-friction, maintenance-free dry operation. "The other bearings have to be lubricated every few weeks, which is very time-consuming," says CFL Maintenance Manager Mike Feinen. "So we have eliminated this maintenance problem." Says Roy Snellens: "The new network function is the icing on the cake. Thanks to continuous condition monitoring, CFL can prevent breakdowns, plan maintenance work optimally and make full use of the life of the polymer bearings."

Read more about smart condition monitoring and predictive maintenance in CFL's train washing system here:

https://www.igus.nl/info/smart-plastics-train-washing