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Condition monitoring system with smart sensor technology for machine data acquisition

Condition monitoring monitor for cable carriers with warning and approval symbols.

Eliminate unplanned downtime.
Increase machine availability.
With smart plastics.

"Trust is good, control is better" – this phrase aptly describes condition monitoring with igus smart plastics. These intelligent solutions give you full control over your systems. igus smart plastics combine high-performance polymers with innovative sensor technology to create solutions that make condition monitoring simple and effective.

The i.Sense condition monitoring system consists of several perfectly coordinated components. It offers various sensors that monitor mechanical factors such as push/pull forces or electrical parameters such as cable quality, depending on the application. The sensors continuously measure the condition of your igus products and transmit the recorded data to an i.Sense module in the control cabinet.

The module evaluates the sensor data and triggers follow-up actions as required. This can include integration into the PLC machine control system or the provision of the measured values in an online dashboard for location-independent monitoring. This gives you precise information about the condition of your system components in real time.

Condition monitoring creates the basis for condition-based maintenance and optimises processes in the smart factory. With i.Sense systems and igus smart plastics, not only are you on the safe side, but you also reduce costs and increase system availability in the long term.

The advantages of an intelligent condition monitoring system:

▲ Tech up

  • Increased machine availability and expected product service life
  • Direct input into the PLC machine control system for immediate action.
  • Better fault analysis thanks to real-time machine data acquisition
  • Easy integration into Industry 4.0 / Smart Factory concepts

▼ Cost down

  • Elimination of unplanned downtime or machine failures
  • Reduce maintenance costs through early warnings
  • Implementation of condition-based maintenance
Get to know i.Sense products in a live appointment

Condition Monitoring - Where can I find what on this page?

  • What components are used in a condition monitoring system?
  • How does smart plant monitoring work with i.Sense as a condition monitoring system?
  • When do I need a condition monitoring system?
  • What condition monitoring systems for energy chains are available from igus?
  • What condition monitoring systems for cables are available from igus?
  • What practical condition monitoring examples are there?
  • Where can I find further information?

    • Condition monitoring – questions and answers:

    Condition monitoring refers to the regular or continuous recording or monitoring of the condition of a machine (especially rotating components or moving applications), system or process.

    Condition monitoring systems are crucial for understanding the behaviour of machines and integral to equipment reliability.

    Most successful examples list the following benefits: maximisation of production, increased service life and reduction of maintenance costs.

    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).

    Condition monitoring technology and components from i.Sense in detail:

    Collect data - Analyse data - Distribute data

    igus isense sensors in a cable carrier system for condition monitoring.

    i.Sense sensors

    Condition monitoring sensors from i.Sense are used to permanently monitor the operating status of moving components. They can fulfil different functions depending on the application. In energy chains, they monitor the push/pull forces (i.Sense EC.P) and identify chain breakages at an early stage (i.Sense EC.B).

    In guided chainflex cables, the sensor technology from smart plastics can be used to monitor the tensile forces on the cables (i.Sense CF.P), measure the cable quality (i.Sense CF.Q) and the data transmission rate (i.Sense CF.D). All i.Sense sensors for condition monitoring can also be subsequently integrated into the energy chain.

    Learn more about the i.Sense sensors
    i.Sense module for cable condition monitoring.

    i.Sense evaluation module

    All sensor data supplied can be analysed during operation with the i.Sense Module II assembled in the switch cabinet. In active fault management, movement anomalies are recognised and reported directly to the user / machine control system, e.g. Siemens PLC.

    With the latest generation, up to four condition monitoring sensors can be connected simultaneously to just one switch cabinet module, which means considerable space and cost savings. The new module also offers a variety of typical Industry 4.0 use cases such as remote resetting via WLAN or SMS or also an SMS / e-mail alarm function.

    Learn more about the evaluation module
    Dashboard for monitoring smart plastics KI machine data on a laptop.

    i.Sense connectivity

    In addition to direct integration into the PLC control system to prevent total machine failure in an emergency, the i.Sense module also offers other network options. A location-independent alarm can be realised via the optional SMS module. Recorded sensor data can be displayed on an online dashboard.

    The condition monitoring dashboard visualises the remaining service life of the smart components online or locally at a glance. The current status is also displayed in colour using a traffic light code. This provides a clear picture of the condition of the system and allows preventative maintenance intervals to be planned.

    Learn more about the dashboard

    How does smart plant monitoring work with i.Sense as a condition monitoring system?

    Wie funktioniert Condition Monitoring mit i.Sense? Das Video zeigt die Möglichkeiten kurz und prägnant auf!

    When do I need a smart condition monitoring system for energy chains?

    ...regular maintenance work requires complete production shutdown.

    ...motion anomalies cannot be detected by humans in time.

    ...plants or machines need to be monitored frequently or continuously...

    ...energy supply system travels are difficult to access or view...

    ...maintenance work poses a health or safety risk...

    ...maintenance costs are to be reduced and service life extended...

    Condition monitoring systems for energy chain condition monitoring:

    Energy chain link with warning symbol and marked wear point.

    Push/pull force monitoring on e-chains with i.Sense EC.P

    • Measures the push and pull forces of the e-chain
    • Recommends switching off the system if a force limit is exceeded
    to the i.Sense EC.P product page
    Cable carrier with warning about an incorrect bending radius.

    Breakage detection on e-chains with i.Sense EC.B

    • Detects chain breakage in the early stages
    • Prevents overloading and subsequent system failures
    to the i.Sense EC.B product page
    i.Sense EC.W monitors an energy chain with signal module and status display.

    Low-cost condition monitoring with i.Sense EC.W

    • Real-time monitoring of the chain status
    • Direct, wired connection to machine control system
    to the i.Sense EC.W product page

    Condition monitoring systems for monitoring the condition of cables:

    Cable carrier with warnings about bend radius and cable routing.

    Tensile strength monitoring for cables with i.Sense CF.P

    • Measures the forces directly at the strain relief
    • Triggers a standstill via the break contact if the forces are too high
    to the i.Sense CF.P product page
    Cable carrier with warning about incorrect wiring and possible sensor interference.

    Cable quality monitoring with i.Sense CF.Q

    • Measures the quality of the cable cores
    • Emits a signal in the event of core rupture or stops the system via a normally closed contact if required
    to the i.Sense CF.Q product page
    Cable carrier for a gripper routes power and data between control and robot arm.

    Monitoring data transmission with i.Sense CF.D

    • Integrated in cable, no measuring cable required
    • Packet losses are recognised in good time
    • Alarm signalling via NC contact or network
    to the i.Sense CF.D product page

    Examples of condition monitoring with igus:

    GÜDEL gantry robot with two gripper axes above a trade show display.

    "Maximum reliability"

    "Thanks to the digital condition monitoring and networking of the system and products, it is possible to continuously record the condition of the components and report in advance as soon as a repair or replacement is required."

    Mr Daniel Bangerter, Customer Care Manager at Güdel Deutschland GmbH

    Güdel Germany GmbH
    Smart plastics for industrial applications with sensors and condition monitoring.

    Customer applications worldwide

    Whether in international automotive production, the global crane industry or in regional wastewater treatment plants: i.Sense condition monitoring systems are used successfully wherever maintenance costs are saved and machine downtime is prevented.

    Click here for the application overview

    Further examples of condition monitoring from the real world:

  • AOS GmbH
  • CFL SE
  • GHD Maschinenbau GmbH
  • Mercedes-Benz Group

    • Further information available for download:

    Robust and smart - how digitally networked energy chains strengthen STS cranes in the port of Rotterdam

    This case study illustrates how EMO B.V. was able to achieve running performances of over 375,000km on its STS cranes with igus chains for cranes®.

    To PDF download
    Brochure with a case study on digitalized cranes and port logistics on an orange background.

    Overview of smart plastics

    Insights into the complete product range for Industry 4.0

    In this brochure you will find comprehensive information on condition monitoring (i.Sense) and predictive maintenance as well as application examples, data flows in modern smart factory concepts and much more.

    Download the smart plastics brochure
    Cover of the smart plastics brochure 2025 with a magenta background and igus.eu logo.
    Digital Smart Plastics interface on a laptop with igus products and monitoring applications.

    Information ...

    A lot more information and news on Industry 4.0 with smart plastics

    smart plastics News
    Tablet with igus CAD configurator, where a part is viewed by touch.

    ... try it ...

    Free 3D data, operating instructions and much more in our smart plastic service area

    3D data
    igus cable carrier system with warning symbol and accessory modules on a laptop screen.

    ... realise

    Order a ready-to-install condition monitoring system directly in the igus online shop

    To the smart plastics shop

    Consulting

    I look forward to answering your questions

    Hennlich, d.o.o.+386 4 532 06 15Write e-mail

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