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Condition monitoring system with smart sensor technology for machine data acquisition
“Trust is good. Control is better”
Smart plastics combine igus® high-performance plastics with advanced sensor technology - giving you complete control over your system.
Our i.Sense condition monitoring system for energy chains and cables uses sensors to track both mechanical factors (like push/pull forces) and electrical conditions (such as cable quality). The connected i.Sense module evaluates this data, enabling real-time actions, integration with machine controls, and remote monitoring via an online dashboard.
e-chain® condition monitoring equipment
Condition monitoring equipment for chainflex® cables
Condition monitoring equipment and systems from i.Sense in detail:
Collect data - analyse data - distribute data
Applications with smart plastics
Condition monitoring solutions that utilise e-chain®, chainflex® cables and bearings.
Frequently asked questions regarding condition monitoring solutions
Condition monitoring is the process of continuously or periodically tracking the health and performance of machinery and components using sensors and data analysis. It helps detect early signs of wear, damage, or failure.
A condition monitoring system is crucial for understanding the behaviour of machines and integral to equipment reliability.
Condition monitoring systems helps prevent unexpected breakdowns, reduces maintenance costs, improves safety, and extends the lifespan of equipment by enabling timely interventions before serious issues occur.
- Optimising production output
- Increased service life
- Reduced maintenance costs
Condition-based maintenance (CBM) is a strategy where maintenance is performed only when indicators show that equipment performance is deteriorating, or a failure is likely. It’s more efficient than routine or time-based maintenance.
In maintenance, condition monitoring involves using real-time data to assess the state of equipment. This allows maintenance teams to act based on actual equipment condition rather than relying on fixed schedules.
Yes. i.Sense systems are designed to be compatible with existing igus® energy chains, allowing for easy retrofitting without major modifications.
Yes. i.Sense systems can integrate directly with machine PLCs, enabling seamless data exchange and automation within your existing control architecture.
Yes, with the smart condition monitoring sensor i.Sense EC.W you can continuously monitor and display the condition and estimated remaining service life of your energy supply system for just a few hundred euros.
Various sensors or access to existing data sources belonging to the system are required for condition monitoring. This allows both mechanical and electrical factors as well as external environmental parameters to be recorded. All machine data is aggregated, evaluated and prepared for further distribution or dashboard display in a gateway/edge device such as the i.Sense module.
All signals from the individual condition monitoring components create the necessary data basis for predictive maintenance concepts; also called preventive maintenance. At igus, everything related to predictive maintenance is summarised under the term i.Cee ("see" = I see ahead).
A smart condition monitoring system for energy chains is required when...
- Regular maintenance work requires complete production shutdown.
- Plants or machines need to be monitored frequently or continuously.
- Maintenance work poses a health or safety risk.
- Motion anomalies cannot be detected by humans in time.
- Energy supply system travels are difficult to access or view.
- Maintenance costs are to be reduced and service life extended.
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