Flange assembly in the gasket industry faces challenges that are not only technological but also economic in nature. Incorrectly tightened bolts can not only lead to overloaded assemblies or leaks in flange connections, but also cause considerable costs. In this context, monosIQ and accensors present a pioneering solution that not only ensures the required bolt force, but also makes a decisive contribution to cost efficiency in assembly and operation.
Innovative foil sensors: Revolutionary technologies for reliable screw connections
monosIQ and accensors are pooling their extensive expertise to reshape flange assembly in the gasket industry. monosIQ is not only providing its expertise in the gasket industry, but also an advanced software platform in the future. This platform plays a crucial role in guiding, monitoring and documenting the assembly process. In addition, accensors is contributing its expertise in the development and production of foil sensors. These sensors are used to monitor the bolts of the flange connections. The sensor technology required for this is similar in design to a normal washer. Together, these companies are creating an innovative solution that not only revolutionizes assembly processes, but also sets a new standard for safety, efficiency and cost effectiveness in the sealing industry.
Cost reduction in the sealing industry – increase efficiency, minimize downtime costs
The focus is on the question of the benefits in relation to the intrinsic value of this new technology. Installation with intelligent sensor technology involves practically no additional time expenditure, with manageable additional costs.
The average downtime costs due to a defective flange connection are €84,5593.54 (internal calculation based on various statistics on the subject of “Downtime costs of systems in the chemical industry due to leaks”). To prevent these costs, manual flange checks are currently being carried out. These inspections cost €62.92 per flange, which means average regular costs of €30,200 per year for larger plants.
With more than 70% of leaks occurring due to an incorrect assembly process, accensors and monosIQ’s innovation offers a cost-effective solution to ensure that every bolt is correctly assembled. In the best-case scenario, a leakage at the flange connection causes costs of only €500; in the worst-case scenario, damage claims of up to €100,000,000 can arise (based on 20 years of experience as an expert witness). By monitoring the assembly process, companies focus on avoiding assembly errors with too little (leaks) or too much assembly force (destruction of one or more parts of the sealing system).
Service beyond the assembly process
The plans of monosIQ and accensors go far beyond pure sensor technology, as specialists in the sealing industry and related sectors are offered a comprehensive solution. The intelligent foilsensor technology enables more efficient monitoring on the one hand and a rapid response to potential problems, such as the loosening of a screw connection, on the other. In addition, the monosIQ platform uses artificial intelligence (AI) in the monosIQ Cloud to provide insights that are intended to increase the safety and availability of flange connections (currently in progress). In addition, the platform is working on predictive maintenance by generating warnings, alarms and status information from flange connections (also in progress). The organization of assembly and maintenance is optimized through the assignment of fitters, flange identification and localization. This holistic service platform promises both effective monitoring and proactive maintenance and organization for maximum efficiency and safety in flange assembly.
Precise screw force monitoring using foil sensors
The screw force sensors developed by accensors are characterized by their innovative realization of foilsensors, which are created by the clever combination of different materials and elements. Unique features define these sensors: Their remarkable flexibility allows easy adaptation to a wide variety of mounting environments, while their flat design ensures minimal interference with the overall system. These sensors offer the possibility of bolt force monitoring with individual layouts, allowing them to be seamlessly integrated into various applications.
As a fascinating glimpse of the future, not only the flange but also the gasket itself could be “sensored”. The continuous development of the technology leaves room for the possibility of monitoring not only the assembly, but also the medium flowing through the gasket. This innovative approach could help to increase the efficiency of bolted joints, as well as gaining an additional level of control over the transported medium. This potential opens up new horizons for applications in various industries and underlines the continuous research and development for advanced and versatile sensor solutions.
A future with safety and cost savings in the sealing industry
The partnership between monosIQ and accensors will provide professionals in various areas of the sealing industry with an innovative technology to overcome the challenges of flange assembly. The cost reductions and increased efficiency achieved will help to strengthen competitiveness in the industry, sustainably improve the safety of bolted and flange connections and drive Industry 4.0 forward.
