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The LOCC-Box is widely known for load monitoring – but it is surprising how much added value companies can gain by tracking data as part of a comprehensive monitoring concept.

In many control cabinets, it’s become the go-to standard for intelligent overload and short-circuit monitoring: the LOCC-Box (Lütze Overload Current Control). It is a popular choice for the flexible protection of 24 V circuits.

One customer that uses the LOCC-Box extensively in its production and special-purpose machinery is Metz Connect. One reason: some of their own supplier products are part of the module – like a push-in terminal. But what is really exciting is what they are extracting from the LOCC-Box: data – the raw material of Industry 4.0.

The rich stream of data is tracked with a dual purpose: for energy monitoring and predictive maintenance.

The family-run company in the southern Black Forest specializes in products for building and industrial automation and networking. So they already have a strong sensitivity to information flows – especially internally. Using the LOCC-Box, they monitor the energy consumption of machines and systems across five plants in Blumberg. Each individual 24 V circuit can be monitored with characteristics set via IO-Link.

Take small conveyor belts as an example: they run for long periods, so bearing damage is a recurring issue. By monitoring the nominal current, they can detect mechanical problems early on: a sharp deviation and current spike might indicate a stiff bearing or another issue – prompting maintenance before the belt comes to a halt. The LOCC-Box picks up on such anomalies even before it trips – for instance, in the case of clogged fan filters.

“We track all kinds of data – from axle mileage and main operating times, to control cabinet temperatures,” says Lukas Schultz, Electrical Design Engineer. “It’s great that the LOCC-Box helps deliver this entire wealth of data.” This opens up valuable insights, especially for 24/7 operations. Maintenance teams, for example, can access this info directly via the HMI (Human Machine Interface), without needing an interface. One practical takeaway: noticing that a specific cylinder tends to fail every two million cycles – a clear sign it is time to look for a more durable solution. “This shifts us away from relying on gut feeling and towards solid data, allowing us to plan and replace components before they fail,” summarizes Johannes Lohberger, Head of Automation.

Energy monitoring can be just as impactful – especially in times of climate crisis and high energy costs. And momentum is only increasing with growing documentation requirements, energy audits, and -management systems. "At first, it’s easy to shave off a few percent in energy use each year. But eventually, you’ve sealed the biggest leaks and swapped out all the fluorescent lights,” says Lukas Schultz. That is when you really need to pinpoint where there is still room to improve. At Metz Connect, they break down the hall-wide energy logging to individual consumers. “That’s where the LOCC-Box really shines – it’s a cornerstone of our monitoring system. Especially thanks to its fieldbus interface, which lets us pull a lot of process data,” says Schultz. Even for non-intelligent components like small electric motors, their condition becomes trackable. Patterns start to emerge: “We can spot early when something in the process begins to change,” adds Johannes Lohberger. They can even see cost savings in real numbers – for example in pneumatics: if air consumption drops by 20 percent after maintenance, that saving can be weighed against the maintenance cost to determine the payback period.

When it comes to collecting production data, Metz Connect relies entirely on Lütze. And this is where more of the LOCC-Box’s strengths come into play. “We found the LOCC-Box to be very cost-effective considering all the functions it offers,” says Lukas Schultz. Their own systems and special-purpose machines are designed to be extremely compact – and space was becoming a real constraint. That is where the LOCC-Box fits perfectly, with its slim 8.1 mm width. On top of that, it is modular and expandable as needed: up to 15 LOCC-Box Net modules can be linked via an IO-Link gateway.

Metz Connect’s special machine division is currently building a complex assembly line for a new product. With no space for one large machine, they have designed a setup made of several individual machines. There are no freestanding control cabinets – everything is built directly into the machine frames. The result: the system fits within space limitations and the smaller machines can be easily relocated between the company’s five local sites if needed.

Metz Connect is ahead of the game when it comes to data logging. They practice in-house what they aim to expand into the market with their products. And this is set to be a real growth area, especially as regulations, like those for ESG/CSRD reporting, become more relevant for a growing number of companies in the coming years. In many ways, this is a glimpse into the future of mechanical engineering.

Lütze and Metz Connect share a partnership that spans decades, with their roots in PCB connection technology. A few years ago, Metz developed the now well-known push-in spring terminal for DIN rail devices at Lütze’s request – specially angled to allow the circuit board to fit neatly into the ultra-slim LOCC-Box. Today, this collaboration extends to Lütze Transportation, with IRIS-certified components now in use in the demanding railway industry. And Metz has ambitious plans to further grow its stake in the bus and rail sector – an area increasingly driven by digitalization, including applications like passenger data tracking, which is emerging as a key market. There are plenty of reasons to be curious about what else this close-knit customer-supplier duo might roll out in the future.

Autor: Jessica Stoll, sales engineer at Friedrich Lütze GmbH