igus develops new sensor for condition monitoring of tensile forces in robotic energy chain systems

Unplanned downtimes in automation not only cost time, but also money – especially in the automotive industry. With the new TR.P sensor, igus is launching a smart solution for industrial robots that actively monitors triflex energy chain systems and reacts immediately to critical tensile forces. The system recognises potential damage at an early stage, increases operational safety and provides support during commissioning through condition monitoring. igus will present the new solution at the SPS in Nuremberg (Hall 4, Stand 310).

Industrial robots have become an integral part of automotive production. They weld, glue and paint. Three-dimensional energy chains from the triflex series from igus ensure that your cables move safely even under extreme torsional and tensile loads. With the appropriate highly flexible chainflex cables, they supply the robot with power, data and signals. However, unplanned downtime can quickly become expensive. “It costs €600 per second if a robot can’t do its job in an automobile plant,” says Richard Habering, Head of smart plastics at igus. This is why the motion plastics specialist has now developed a new sensor for monitoring tensile forces specifically for its three-dimensional triflex energy chain. The i.Sense TR.P system measures the tensile forces acting on the robot head using a load cell and triggers an action via a potential-free contact if predefined maximum values are exceeded – this can be a message to the operator or even a stop of the robot, for example.

Condition monitoring: detecting faults during commissioning

“With the help of our i.Sense module and the modular sensor system on the moving arm of the triflex, users can recognise critical movement patterns and identify and prevent damage such as excessive bending, overextension or jamming at an early stage,” explains Habering. igus sees great potential for the system, particularly in robot commissioning. The TR.P can act as a measuring system to identify problematic movement patterns when dress packs are used during programming, finding solutions before damage occurs. In addition to monitoring tensile forces, igus has been offering the TR.B system for breakage detection since 2022, which is already being used successfully in many applications worldwide. If a chain link breaks, the system detects the change in length of the rope installed in the chain and sends out a digital signal to the plant’s control system. Instant breakage detection allows for immediate maintenance measures and helps avoid unplanned downtime and total failure in the event of individual chain link breakages. The i.Sense TR.B sensor is connected directly to the PLC control system without additional hardware costs or complicated programming. A simple alarm, for example via a signal light, is also possible as an option.

superwise: increase operational reliability and relieve customers

With superwise, igus also offers an after-sales service concept for its smart plastics. It combines the digital condition monitoring of the i.Sense sensors with predictive maintenance. The aim is to avoid unplanned downtimes, reduce the workload of maintenance teams and significantly extend the service life of machine components – without high investments. To this end, the i.Sense data of the customers is securely linked to the igus CRM. The igus service team gains complete transparency and can initiate targeted measures, such as early contact in the event of conspicuous sensor values, suggestions for maintenance or cleaning measures, scheduling and coordination of inspections and replacements as well as a direct ordering function for fast replenishment.

Find out more about the TR.P sensor under Condition Monitoring TR.P