Superwise

Einleitung¶

With the superwise service, igus® offers a solution for intelligent condition monitoring and predictive maintenance of e-chain systems®. The aim is to avoid unplanned downtimes, increase plant availability and make maintenance processes plannable and efficient. 

superwise combines sensor technology, cloud technology and data-based analysis into an integrated system for condition assessment. All relevant information is centrally available via the superwise portal and dashboard – from current operating and status data to automated service and replacement messages. 

In addition to the mere provision of status and operating data, superwise is designed as part of an active system support by igus®. On the basis of the information available in the system, igus® assesses relevant changes in the condition, upcoming maintenance requirements and the achievement of the recommended service life of e-chain systems®. If action is required, information is provided at an early stage, combined with concrete recommendations for maintenance, replacement or suitable products and services. This provides a reliable basis for decision-making without the need for a detailed technical evaluation of the e-chain systems®. 

The superwise service is aimed at companies that want to operate their production facilities reliably and efficiently. Typical target groups are buyers, maintenance and service managers with a focus on reducing unplanned downtimes and optimizing maintenance processes, production and operations managers with requirements for high plant availability and predictable operating costs, as well as OEMs and machine builders who want to add additional value to their systems through intelligent condition monitoring. Its use is particularly relevant in industries with high downtime costs, including automotive production, container and bulk handling in port and handling facilities, packaging industry, food industry, logistics and conveyor technology. 

superwise Benefits¶

With superwise, operators of e-chain systems® receive a reliable, digital basis for predictable and efficient maintenance. The service combines sensor data, algorithms and igus®' expertise to create a practice-oriented solution that creates tangible benefits in daily operations. 

Higher system availability

Unplanned downtimes are among the most expensive events in plant operation. superwise detects deviations or critical changes in condition at an early stage and actively reports them. This allows maintenance or replacement to be planned in a targeted manner – before malfunctions occur. 

Longer system life

Thanks to individual service instructions and early detection of load peaks, the e-chain system® is not replaced unnecessarily early, but also not too late. This extends the service life and increases operational reliability. 

Clear decision-making bases 

All data is prepared in the superwise portal in an understandable way. igus® takes over the evaluation and provides concrete recommendations: 

• "Maintenance due" 

• "Exchange time reached" 

• "Sensor reports deviation" 

This allows informed decisions to be made. 

Reduced organizational effort 

SuperWise bundles: 

• Condition data 

• Histories 

• Maintenance appointments 

• Exchange cycles 

• Service contacts 

The operator does not have to maintain his own lists and does not have to update any data manually. 

Plannable maintenance and replacement processes 

Instead of acting according to rigid intervals, superwise is based on real usage and status data. 

This enables: 

• Maintenance measures at the optimal time 

• Clear budget and resource planning 

• Fewer spontaneous field assignments, less coordination effort 

Highest transparency across all locations 

Whether it's a single machine or a global machine park: superwise creates a uniform, central view of all assets. 

This makes it easier: 

• Benchmarking 

• Comprehensive location comparisons 

• Central maintenance planning 

Überblick about service levels¶

The superwise service is divided into four tiered levels - Basic, Silver, Gold, Platinum - to reflect different requirements for condition monitoring, connectivity and service. All levels offer access to the superwise portal, a central overview of the integrated e-chain systems® including structured recommendations for action. The scope of digitization and the depth of data integration differ depending on the level. 

Basic: For applications without sensor technology or online connection, where predictable, time-controlled maintenance is sufficient.	Silver: For applications that want to use sensor data but do not require a permanent online connection.
Gold: For investments where continuous online data and rapid response are critical.	Platinum: For operators who want to fully integrate superwise into their IT/OT environment

This classification serves as an initial aid – the following table shows the technical differences, hardware requirements and performance scopes of the respective levels in detail.

Grundlagen of the superwise service¶

The superwise service can be used for all igus® e-chain systems® over long and short travels, regardless of whether smart plastics sensor technology is integrated. As a result, the range of applications includes both purely mechanical systems and fully networked smart plastics solutions. 

Regardless of the selected service level, the following inclusive services are available: 

• Access to the superwise portal:

Central online platform for condition monitoring and service management. 

• Central System Overview:  

Uniform display of all integrated e-chain systems® and smart plastics components. 

• Service Management and Reminder Features:  

Automated notifications of upcoming maintenance and replacement appointments. 

• Exchange recommendations:  

Derivation of optimal replacement dates to avoid unplanned downtimes, based on usage and condition data (from level silver). 

• High IT security:  

Protect sensitive operational and asset data with advanced security measures, including two-factor authentication. 

The information provided in the superwise system not only serves to provide transparency for the operator, but also forms the basis for active support by igus®. 

igus® evaluates the status and usage data of the integrated e-chain systems® and derives concrete recommendations for action from this. In the event of any discernible deviations, upcoming maintenance or imminent replacement measures, information will be provided at an early stage. 

These basic functions form the basis of all service levels and ensure end-to-end transparency and clear control over the condition of the equipment. 

Registrierung and Login¶

To use the superwise service, a one-time registration via the my.igus.net portal is required. After registration, an e-mail with an activation link will be sent no later than the next working day. This link must be accessed within 72 hours to activate access. 

After successful activation, access to the superwise portal is available via the registered access data. 

superwise Portal¶

The overview page of the superwise portal presents all relevant information on the integrated e-chain systems® and functions centrally. 

Kontakt to the igus® contact person¶

The contact details of the responsible igus® contact person are stored in the portal. Contact can be made by phone, email or via Microsoft Teams chat. 

Übersicht of all assets with a health rating¶

The portal contains a tabular overview of all registered assets. A condition score is displayed for each asset. In addition, information such as name, location, system, installation date, status and assigned service level is available. 

Functional features

• The "Location" and "Plant" fields are editable and allow for structured assignment within the plant environment. 

• The asset list can be sorted and filtered according to defined criteria (e.g. asset name, installation date). 

• Selecting a single asset provides access to the associated dashboard with detailed health information, histories, and analytics. 

The superwise portal acts as a central platform for monitoring, managing and evaluating all integrated systems as well as supporting relevant service processes. 

Superwise Dashboard¶

The superwise dashboard provides the technical information required to reliably assess the condition of an e-chain system® and to plan maintenance and replacement decisions in a well-founded manner. The focus is on status representation, temporal classification and traceability over the entire system life cycle. 

Zustandsbewertung of the e-chain system®¶

The superwise dashboard displays the current status of an e-chain system® in a coherent overview. Central key figures, status curves and temporal classifications make it visible where the system is in the life cycle. 

The presentation combines the current state with a temporal perspective. This not only shows how the system is currently being evaluated, but also how this state is likely to develop. This creates a reliable basis for technical assessments and decisions during operation. 

Wartungs and exchange planning based on data¶

Upcoming maintenance dates and a recommended replacement period are explicitly shown and chronologically classified in the dashboard. This information is based on the operating and status data collected by the system and is continuously updated. 

Maintenance and replacement are thus planned on the basis of the actual system status. Maintenance measures can be scheduled in a targeted manner, replacement measures can be planned at an early stage and integrated into existing maintenance and budget processes. Unplanned downtimes are reduced because measures are not only triggered in the event of acute disruptions. 

Zustandsüberwachung and detection of deviations¶

The dashboard maps status curves, sensor data and events in a common context. Changes in operating behavior become visible over time and can be evaluated in their development. Individual events such as limit value violations or status changes do not stand alone, but are embedded in the overall process. 

In this way, stable operating phases can be distinguished from phases with increasing deviation. Changes in status are detected at an early stage before they lead to a restriction of function or availability. 

Ereignis and service history¶

All relevant system events, status messages and service-related information are historically recorded in the dashboard. In addition, maintenance and measures carried out are documented and assigned to time. 

This continuous history enables a comprehensible evaluation of the system behavior over the entire operating life. Technical decisions can be made on the basis of documented condition developments and measures that have already been implemented. 

System and component overview¶

The dashboard provides a complete overview of the components belonging to the e-chain system®. Modules are clearly identifiable and assigned to their respective system context. In addition, technical status information, for example on software or firmware versions, is displayed. 

This means that it is transparent at all times which components the system consists of and what technical condition they are in. System changes, maintenance measures or updates can be planned and tracked in a targeted manner.  

Level¶

The following sections give a detailed overview of the individual superwise levels. The respective characteristics and performance characteristics of the individual levels are presented. 

Basic¶

Erforderliche Hardware¶

An igus® e-chain system® is required to use superwise Basic. Additional hardware is not necessary. The optional use of i.Sense sensors for shutdown condition monitoring is possible, but is not a prerequisite for the use of superwise Basic.  

Funktionsweise¶

The expected, risk-free service life of the e-chain system® is determined on the basis of the known application parameters and the underlying test and experience values of igus®. From this, time-controlled service instructions and a recommended replacement period are derived. 

With optionally used i.Sense sensors, local alarms are triggered if limit values are exceeded (e.g. chain breakage, excessive tensile and shear forces). These alarms support operational safety on site, but are not linked to the superwise portal. 

Konnektivität and cloud service¶

In the Basic service level, there is no direct connection between the chain system® and the superwise portal. 

An internet connection or cloud connection is not required for this level. 

Service and exchange notifications¶

Maintenance and inspection recommendations are issued on a time-controlled basis, for example at annual intervals. The actual movement profile is not taken into account. Before the optimal exchange time is reached, appropriate information is provided. 

Kosten¶

The use of the superwise Basic Service is free of charge. 

Einordnung of service level¶

superwise Basic is suitable for applications in which plannable maintenance and transparent service life derivation are desired without providing an online connection to the e-chain system®. The service offers a structured entry into condition-based maintenance and can be expanded as needed with higher service levels with data transmission and real-time assessment.  

Silber¶

Erforderliche Hardware¶

To use superwise silver, an igus® e-chain system® with integrated i.Sense technology is required. This includes sensors for condition monitoring: 

• EC. P for monitoring tensile and thrust forces 

• EC. B for fracture monitoring 

• CF. P for monitoring the cable tensile force 

• The central component of the Silver service level is the ComBox. It enables the sensor data to be transmitted to the superwise portal 

Funktionsweise¶

For superwise silver, a status report is transmitted once a day, which contains summarized characteristic values of the measured parameters. This data enables early detection of deviations in the load profile. 

If the sensor is triggered, for example by exceeding defined force limits or a chain breakage, an immediate message is also sent to the superwise portal. This will allow necessary measures to be initiated promptly.  

Konnektivität and cloud service¶

The superwise Silver Service enables the automatic transfer and evaluation of sensor data via a unidirectional MQTT protocol to the superwise portal.  

The scope of services includes: 

• Access to the superwise portal 

• Data transfer via the SIM card integrated in the ComBox for 10 years 

• Cloud service for storage and analysis of sensor data 

• Individual notification via SMS and/or e-mail  

All necessary services, including mobile communications and cloud services, are fully included in the ComBox. 

Beginn of service life¶

The integrated SIM card has a term of 10 years and is activated before delivery. This means that data transmission is immediately ready for use. If the ComBox is stored for a longer period of time before commissioning, the remaining running time is shortened accordingly.  

Verlängerung of useful life¶

After the 10-year term, the use can be extended for another 10 years. This extension is subject to a fee.  

Verwendung your own SIM card¶

The ComBox is equipped with a permanently integrated SIM card. Operation with your own SIM card is not possible. The integrated solution provides reliable data transmission over a period of 10 years. 

Artikelübersicht¶

Mobilfunkabdeckung¶

The SIM card integrated in the ComBox enables worldwide data transfer in over 170 countries and regions.  

It can be used within the coverage area without additional roaming or usage costs. Data transmission takes place automatically and independently of a customer's Internet infrastructure. 

Vollständige Länderübersicht 

Service and exchange notifications¶

On the basis of the status and usage data available in the superwise system, upcoming maintenance and the recommended replacement time of the e-chain system® are determined. The maintenance appointments are issued according to the stored maintenance plan depending on usage. The corresponding information appears in the superwise dashboard and can optionally be supplemented by an e-mail or SMS notification. 

In the event of relevant changes in status or sensor triggering, active information is provided by igus® to classify the need for action. The evaluation is based on the cyclically transmitted sensor data as well as event-related messages from the system. This allows measures to be planned at an early stage and integrated into existing maintenance and operating processes. 

Kosten¶

For superwise silver, there are one-time acquisition costs for the necessary hardware, while mobile and cloud services are fully included in the ComBox for the included term. There are no ongoing fees within this period. 

Einordnung of service level¶

superwise silver is suitable for applications where sensor-based condition monitoring with automated data transmission is required without requiring a permanent online connection of the system. The service provides a reliable basis for usage- and condition-based maintenance and replacement decisions and extends the pure condition representation with a structured, data-based assessment. 

Gold¶

Erforderliche Hardware¶

For superwise Gold, an igus® e-chain system® with a long travel, an i.Sense system and an i.Cee module are required. In addition, permanent online access is required, for example via a modem provided by igus®.  

At least one of the following sensors must be used for condition monitoring: 

• EC. P for monitoring tensile and thrust forces 

• EC. B for fracture monitoring 

• CF. P for monitoring the cable tensile force 

Other sensors for service life assessment - such as EC. W for sliding or EC.IT for rolling e-chains® - can be supplemented, but are not required for superwise gold.  

Funktionsweise¶

The sensors integrated in the e-chain system® continuously record condition, load and service life parameters. The data is transmitted via the i.Cee module in high temporal resolution to the superwise portal and processed there. 

The continuously available measured values enable a detailed analysis of the system behavior over the entire life cycle. Changes in the stress profile become visible at an early stage and can be assessed in their development. The data collected by the service life sensors is directly incorporated into the calculation of the expected risk-free service life of the e-chain system®. 

In the event of limit values being exceeded or sensor triggering, an event-related message is sent in real time. 

Konnektivität and cloud service¶

To make it as easy as possible to get started and get up and running, superwise Gold comes with a 6-month starter package as standard. This package includes: 

• Physical SIM card 

• Activation and data usage for the first 6 months 

• Access to the superwise online portal 

Beginn and duration of use¶

The start of the service life depends on the known commissioning time of the application. If no information is available, the determination is made on the basis of empirical values. After the starter package has expired, the use can be extended for a fee, either via an annual subscription or as a flat rate for the entire product service life. 

Artikelübersicht¶

Mobilfunkabdeckung¶

When using the igus® SIM card, a worldwide mobile connection is available in several tariff zones.  

Alternatively, an M2M SIM card provided by the customer can be used. The prerequisite for this is the transmission of the associated mobile phone number to igus® in order to ensure remote support and system assignment. 

Link to full list!  

Service and exchange notifications¶

On the basis of the status and usage data available in the superwise system, upcoming maintenance and the recommended replacement time of the chain system® are determined. The corresponding information appears in the superwise dashboard and can optionally be supplemented by an e-mail or SMS notification. 

In the event of relevant changes in status or sensor triggering, active information is provided by igus® to classify the need for action. The evaluation is based on high-resolution online data as well as event-related messages from the system. This allows measures to be planned at an early stage and integrated into existing maintenance and operating processes. 

Kosten¶

In addition to the one-time acquisition costs for the hardware, there are ongoing costs for connectivity and cloud service. These services can be billed either via an annual subscription or as a flat rate for the entire product service life. 

Einordnung of service level¶

superwise Gold is suitable for applications with increased requirements for transparency, data resolution and speed of response. Thanks to the continuous online connection and the integration of lifetime sensors, the service provides a precise basis for maintenance and replacement decisions based on the condition and use, and extends sensor-based monitoring with in-depth, continuous analysis.  

Platin¶

Erforderliche Hardware¶

For superwise Platinum, an igus® e-chain system®, an i.Sense system and an i.Cee module are required, which will be integrated into the customer network. In addition, a secured return channel is required for the transmission of the sensor data. 

At least one of the following sensors must be used for condition monitoring: 

• EC. P for monitoring tensile and thrust forces 

• EC. B for fracture monitoring 

• CF. P for monitoring the cable tensile force 

Other sensors for service life assessment - such as EC. W for sliding or EC.IT for rolling e-chains® - can be supplemented, but are not required for superwise platinum. 

Funktionsweise¶

The sensor data is transferred to the superwise dashboard via the i.Cee module. The values recorded by the service life sensors are continuously evaluated. They are included in the assessment of the expected risk-free service life of the e-chain system®. Changes in operating behavior can thus be detected at an early stage. Maintenance and replacement times can be derived in a well-founded manner. 

Konnektivität and cloud service¶

The connection at the Platinum service level is carried out entirely via the customer's network. i.Cee and i.Sense will be integrated directly into existing IT/OT systems. Among other things, the following are supported: 

• Connection to customer systems such as CMS (Customer Crane Management Service) 

• Integration into the PLC/PLC incl. display of messages, recommendations and sensor data 

• Integration into SCADA and MES systems 

• Local access to the i.Cee dashboard via static IP in the customer's network (LAN) 

The exact design is carried out on a project-specific basis on the basis of existing IT specifications and security requirements. 

Artikelübersicht¶

The nature and extent of the SOFT. XXXXX are defined within the framework of the respective project. 

Service and exchange notifications¶

On the basis of the status and usage data available in the superwise system, upcoming maintenance and the recommended replacement time of the e-chain system® are determined. The corresponding information appears in the superwise dashboard and can optionally be supplemented by an e-mail or SMS notification. 

In the event of relevant changes in status or sensor triggering, active information is provided by igus® to classify the need for action. The evaluation is based on high-resolution online data as well as event-related messages from the system. This allows measures to be planned at an early stage and integrated into existing maintenance and operating processes. 

Kosten¶

For superwise Platinum, there are one-time costs for the required hardware, as well as project-specific software and system adjustments. In addition, there are ongoing fees for the cloud service. The cloud service is billed either annually or as a flat rate for the entire product service life. 

Einordnung of service level¶

superwise Platinum is suitable for applications with the highest requirements for integration, data availability and individualization. The service is designed in particular for complex systems, safety-critical applications or environments with defined IT and OT specifications. Thanks to its complete system integration, superwise Platinum provides a comprehensive basis for end-to-end, data-based plant monitoring and maintenance strategy.  

Service Packages¶

The superwise service creates transparency, provides early information and supports the determination of optimal times for maintenance and replacement. 

The service packages add an operational component to the digital offering and enable implementation in the field. This makes superwise a building block of a holistic support concept in the sense of continuous and proactive system support by igus®.  

The service packages define the extent to which igus® assumes responsibility. The range of services ranges from the mere reminder of upcoming measures to comprehensive all-round service including maintenance, repair and material provision. 

All packages are designed for long-term support over the entire product service life and logically build on each other. 

During operation, there is clear added value. The internal coordination effort is reduced. Planning reliability increases and unplanned downtimes are avoided. 

The service packages combine the data intelligence of superwise with the service expertise of igus®. The result is higher plant availability, lower organizational effort and long-term reliable plant support. 

Service Care¶

Entry-level package for maximum transparency with minimum effort. 

igus® automatically informs about upcoming inspections and the end of the recommended service life of the system. The condition of the components remains traceable at all times, and service calls can be scheduled at an early stage. 

Included services: 

• Automatic reminder during inspections 

• Indication of the upcoming replacement date 

Service Care Plus¶

Expansion to include operational maintenance services. 

In addition to the reminders, igus® takes care of carrying out maintenance on site. Travel and working hours are included. All necessary maintenance work is carried out professionally and on time. 

Included services: 

• Automatic reminder 

• Maintenance by igus® service personnel 

• Travel and working hours included 

Service Care Complete¶

Increased planning security in the event of repairs. 

In addition to reminders and maintenance, necessary repair work is also covered. In the event of a necessary intervention during the period of use,

Included services: 

• Automatic reminder 

• Maintenance including travel and working hours 

• Repair work (work) 

Service Care All-in¶

Comprehensive service package for maximum system availability. 

All services incurred in the company are included. This includes reminders, maintenance, repairs and the provision of required spare and wear parts. The complete service responsibility lies with igus, with full cost transparency. 

Included services: 

• Automatic reminder 

• Maintenance incl. travel and working hours 

• Repair work 

• Required spare and wear parts 

Ihr Advantage¶

Regardless of the package chosen, all services are based on the findings from the superwise system. Maintenance, repair and replacement are condition- and data-based. Measures are carried out neither too early nor too late, but at the technically and economically optimal time for the respective plant. The operator benefits from condition-based and plannable maintenance, while the continuous evaluation and early derivation of necessary measures is carried out by igus®

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