i.Sense TR.B Condition Monitoring

Intelligent monitoring for triflex® R energy chains to prevent unplanned downtime in robotic applications

Robots have long been indispensable in many areas of industrial manufacturing, bb welding, painting, soldering, and palletising: industrial robots are becoming dynamic. A flexible multi-axis energy chain such as the triflex® R from igus® makes it possible to guide robot cables safely. To detect potential chain breaks caused by extreme loads in good time and avoid unplanned machine breakdowns, igus has developed i.Sense TR.B, the world's first condition monitoring system for multi-axis energy chains.

Customers can increase the safety of their robot systems with an investment of just a few hundred pounds. The i.Sense TR.B sensor is connected directly to the PLC customer control system - without additional software costs. If a chain link breaks, the system detects the change in the length of the rope installed in the chain and can send out a digital signal to the system control. Instant breakage detection allows immediate maintenance measures and can thus prevent unplanned downtime and total failure when individual chain links break.

Intelligent condition monitoring successfully implemented across real-world applications:

Tech up

Real-time status detection of the robot's energy supply
Intelligent breakage detection allows for immediate maintenance measures
Service life extension of the protected cable packages

Cost down

Direct connection of the TR.B sensor to the customer's PLC without additional software costs
No unplanned downtimes
No total failures if individual links break

Proof

Ongoing test program in the industry's largest test laboratory for dynamic cable applications

Sustainability

Condition-based maintenance avoids unnecessary or premature chain replacement
Reusable after correct emergency shutdown of the system

Less maintenance, increased availability, the option of guiding all the different cables and hoses in one system, the electronic i.Sense EC.P push/pull force monitoring ... I would definitely choose intelligent igus energy chains again!

Fabian Wilhelm

Project Manager at AOS Stade GmbH

When do I need a smart condition monitoring system like i.Sense EC.P?

When regular maintenance work requires a complete production shutdown...

If movement anomalies cannot be recognised by humans in time...

If systems or machines need to be monitored frequently or permanently...

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

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

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

i.Sense in daily use on the triflex®

The i.Sense EC.B sensor (EC = e-chain, B = breakage detection) is mounted at the moving end of the triflex® energy chain.
Special mounting brackets enable the EC.B sensor to be securely installed on the moving end of the triflex® system.
A cable runs through the triflex® chain, continuously detecting any changes in length and transmitting this information to the EC.B breakage detection sensor.
If a chain breakage occurs, the sensor immediately detects the fault, triggers a system shutdown and helps prevent costly consequential damage.

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10 tips for energy supply on robots

This guide takes you through the complete process of selecting, installing, and commissioning an energy supply system for axes 3–6 on an industrial robot. From positioning the cable and hose package and selecting the right energy chain to choosing the appropriate retraction system, every stage is explained clearly. Practical installation tips and a final checklist ensure a smooth implementation, making the guide a valuable resource for both beginners and experienced professionals.

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