Smart maintenance solutions for energy chain systems and bearing technology from igus

Prevent downtime ... Extend product service life ... Save costs for maintenance ...
with smart plastics

With i.Sense continuous condition monitoring, you can keep an eye on your systems at all times. i.Cee allows you to connect your production plant to the Internet of Things (IoT) or your local network and offers you the option of predictive maintenance.

With smart plastics - energy chain systems, chainflex cables, linear guides and plain bearings equipped with smart sensors - we want to make complex automation solutions as compatible with Industry 4.0 as possible.

Make an appointment now for your introduction to smart maintenance!

What you would like to know about smart maintenance:

CFD sensor shows a sensor chain in the cable carrier system with wireless signal to the control unit.

Condition monitoring + predictive maintenance = smart maintenance

Smart maintenance infographic with sensors, cloud service, secure connection, and PLC link.

Condition monitoring (i.Sense)

Condition monitoring is the fastest and simplest way to turn a wide range of igus products into self-monitoring smart plastics products. By attaching sensors, operators can measure forces during operation. If the measured values exceed predefined limits (e.g. sudden peaks caused by a blockage or chain break), the system issues an alarm or at least a notification. Based on this information, a decision can be made about the next steps, (maintenance or shutdown). If required, values outside defined limits can trigger a system shutdown to avoid expensive damage. At igus, we use the term "i.Sense" to refer to condition monitoring.

To the condition monitoring system - i.Sense

Predictive maintenance (i.Cee)

Predictive maintenance utilises the elements of condition monitoring and, with the help of sensors and software, creates a system that enables a dynamic service life calculation and optimum maintenance times for igus products. This makes predictive maintenance the next step in achieving a comprehensive concept for smart energy supply and bearing technology. This system offers a wide range of designs and a high degree of customisation. The goal is always to maximise system and user safety as well as product life. We at igus call our predictive maintenance system i.Cee (derived from "I see ahead").

To the predictive maintenance system - i.Cee

These igus products can be equipped with smart plastics technology

iSense monitoring module and colored cables in a cable chain with radio symbols.

smart energy supply + cables

igus i.Sense system with sensor ring, control unit and plain bearing for condition monitoring.

smart bearing technology

Smart maintenance: industry examples

Cranes

Machine tools

Agricultural engineering

Explore all smart plastics applications

i.Cee sensor on a plastic part in an automotive factory with data transmission symbols.

Automotive production

In automotive production, the assembly lines never stand still. Smart production concepts in the style of predictive maintenance have long been established in these production lines.

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Crane industry

Heavy loads, long periods of use, and a wide variety of weatherconditions – all reasons why cranes must fulfil very stringent performance requirements. To ensure this at all times, reliable condition monitoring concepts are needed.

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Cable carrier at a wastewater plant guides cables along a concrete edge.

Wastewater and sewage treatment plants

Wastewater treatment plants demand a lot from the components used: continuous operation, weather and dirt. Our intelligent energy chain systems are designed for fail-safe operation at all times under all conceivable conditions.

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Knowledge base

Here you will find:

current news in the blog
Manuals/operating instructions
3D CAD models of smart components
i.Sense assembly instructions
Online seminars / video tutorials
EPLAN data for CAE software

To the knowledge base

Bread packaging machine

isense module and GHD Hartmann machine for condition monitoring in a production line.

Bread-packaging machine:

Avoid broken cables with smart plastics

Smart prevention of cable breaks

Sensors monitor energy chains in engine plants in the automotive industry

Industrial system with igus energy chains on several machine guides.

The Austrian automotive supplier therefore relies on smart plastics from igus® to avoid unplanned breakdowns and plant downtime.

Smart maintenance in the automotive industry

Predictive maintenance in train-washing stations

Train washing system with sensor and vehicle in the wash station.

The complete smart plastics package, which optimally combines condition monitoring and predictive maintenance

Predictive maintenance in train-washing stations

Güdel relies on condition monitoring for the energy chains on linear robots

Güdel robot system with two vertical axes on a trade fair wall.

Güdel avoids failures on its linear robots by measuring the movement, temperature and wear of the energy chains in real time.

Güdel relies on condition monitoring for the energy chains on linear robots

Treatment tank at a plant with railings and a water surface.

Condition monitoring in the sewage treatment plant

The smart plastics prevent the plant from stopping in the event of a fault, in order to avoid expensive consequential damage

Condition monitoring in the sewage treatment plant

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

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

This case study illustrates how EMO B.V. achieved over 375,000km on its STS cranes with igus chains for cranes®.

To PDF download

What new products are there?

Industry 4.0: new smart plastics products

igus banner for HMI 2023 with various industrial applications on colorful columns.

3D CAD portal for smart plastics

Design intelligent energy chain systems faster. CAD models for all smart components.
Our intelligent e-chain systems already operate reliably in many hundreds of thousands of applications around the world - from beverage machines and CNC machines to steelworks. Unsupported lengths can be bridged with ease and long travels can be realised in a wide range of industries.