CCM Chain elongation monitoring maintenance iwis

Chain Condition Monitoring
The iwis chain elongation monitoring system

Chain Condition Monitoring (CCM) from iwis measures the wear elongation of chains in operation and gives maintenance staff timely warning when wear elongation has reached the point where the chain needs to be replaced.

CCM can be integrated quickly and easily in machinery – and even retrofitted without any special additional components – in numerous chain applications in many industries. Measurement is precise, contact-free, and requires no direct interference in the chain drive. Or simply transfer results to a computer via a USB interface.

CCM Chain elongation monitoring maintenance iwis

Intelligent chain monitoring

CCM offers users a number of benefits: it not only gives maintenance staff time to (re)act, but also prevents long plant or machinery downtimes, thus helping to safeguard promised delivery deadlines to your customers. Predictive maintenance prevents downtimes and unnecessary costs!

iwis CCM chain Wear Status is shown

Chain Wear Status

Chain wear status is shown on a finely graduated LED display.

iwis CCM Display of measurement results


Measurement results can be transferred to a computer via USB connection and displayed on a special interface.

iwis CCM different speed ranges


Different speed ranges and changes of load direction are not a problem for CCM.

iwis CCM for simplex duplex and triplex chains in different pitches

Chain sizes

The CCM is equally effective on simplex, duplex and triplex chains.

iwis CCM contact-free measurement


Precise, contact-free measurement with no direct interference in the chain drive.

iwis CCM quick and easy integration in chain applications


CCM is quick and easy to integrate - with no need for any special additional components - in numerous chain applications in every industry.

With CCM, iwis has implemented one of the crucial aspects of Industry 4.0: intelligent data analysis enables maintenance teams to actively prevent future malfunctions in chain applications. During the Hannover Messe trade fair in 2016, iwis was awarded the “Best of 2016” prize in the category Production Technology and Mechanical Engineering for its CCM system.

The greatest customer benefit of CCM is that it enables maintenance staff to react in good time. No long downtimes for machinery or plant, no risk of missing promised delivery deadlines, no disruption of the logistics chain – the ideal way to prevent financial loss caused by lost production. In addition, the system ensures constant monitoring of your high-precision chain applications.

Frequently Asked Questions (FAQ)

Work on our FAQ page is in progress: we will try to answer frequently asked questions quickly and post the results here.

The wear status LED display is graduated in 0.5% steps. The measurement results of the CCM system are a combination of measured and calculated values i.e. the result shown is a calculated value that can be displayed to an unlimited number of decimal places. Deviations between the results of static (test bench) chain elongation measurements and the results obtained using the CCM system can be expected. Trials have revealed that measurement results are not affected by non-magnetic contamination. We nevertheless recommend the regular cleaning, inspection and maintenance of your CCM system, because magnetic particles such as metal shavings, swarf etc. definitely affect measurement results.
Chain wear status, device functionality and any error messages are displayed primarily by LEDs. A secondary display of measurement results - via a USB software connection - is also possible on a PC, laptop etc. A subsequent development step is planned in which the CCM system will be expanded to enable it to be supplied with an industry-standard digital interface such as Profinet or Profibus.
Wear elongation measurement by the CCM system is independent of chain speed. Reversal of chain direction or variations in chain speed have no effect on the function or results of the CCM system. Measurement results will be affected in the event of changes to the tensile force of the chain that cause load elongation and stretching of the chain. However, this effect normally (at a load of approx. 15% of chain breaking strength) lies within a range of 0.18-0.22% elongation. A change of chain temperature also results in a change of length. In short: the CCM system displays an elongation value composed of wear, load elongation and temperature elongation. Longitudinal oscillation is a relative speed change and is not a problem for CCM system measurement.
The CCM system is compatible with chain sizes: 06B to 20B; ANSI chains: 08A to 16A Each chain size requires its own CCM system. The system is supplied ready for use and calibrated to the respective chain size. . The CCM system detects wear on one chain strand only, so it can be used independently of whether simplex, duplex or triplex chains are installed. Measurement of roller chains with attachments on one side or both sides is possible, but a technical feasibility assessment by iwis must be carried out beforehand. Flat-top chains, hollow pin chains and so-called “mesh belts” (made of magnetically conductive material) can also be measured with the CCM system. Leaf chains cannot be measured using the CCM system; please use our wear gauges for this purpose. The CCM system can be used with JWIS CR chains; in the near future, it should also be possible to measure double pitch chains (mid-2016) and accumulation chains (mid-2016). JWIS CF chains are incompatible with the CCM system due to their magnetic properties. The compatibility of other stainless steel chains must be assessed on a case-by-case basis.
The CCM system is installed as a stationary testing device. Its use as a mobile testing device is currently being investigated.
Normal operating temperature range from 0°C to 70°C. Extension of lower temperature limit to -20°C possible following specific alterations. Use at temperatures above 70°C cannot be guaranteed due to the electronic components. The CCM system should be installed as specified in the operating instructions; it is important for the chain to be fitted with guides on both sides where it runs through the device to ensure that the measurement results obtained are meaningful and reliable. All metal parts of the CCM system are made of anodized aluminium (EN AW 6082). Chains should be measured on the tight side because the greatest possible defined load status is present here. The CCM system cannot be used as a safety-relevant component. It fulfils an exclusively informative function, and can neither prevent, nor reliably predict the probability of, a chain drive failure. The CCM system has been designed and built to give the longest possible service. The statutory warranty conditions apply.


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