Smart, reliable energy supply in the smallest of spaces

i.Sense ES.B: Intelligent breakage detection on theatre e-spool® guarantees safe movement at all times

theatre e-spool with smart function monitoring

The new theatre e-spool now comes with various smart features: The force of the three springs included is monitored using an inductive sensor. If the force falls below the specified value, the IM5132 sensor with correction factor 1 prompts the user to replace the spring. If the force is exceeded, there is a blockage that must be removed.

A rotation sensor monitoring system can also be installed, which counts the drum revolutions and determines the position of the chain. As further protection to increase system safety, i.Sense EC.P could also be installed on the chain's moving end in the future for intelligent push/pull force monitoring.

Tech up

Increased system safety through permanent function monitoring
Extension of the maximum service life of the theatre e-spool®
Measurement and display of the current extension length
Remote access to real-time status information of the energy supply system

Cost down

Avoid system downtimes and expensive follow-up costs thanks to integrated breakage detection
Reduce maintenance costs thanks to immediate warning messages in the event of anomalies in the e-spool
Space-saving design without additional monitoring equipment

Proof

Ongoing test series in the industry's largest test laboratory for dynamic energy transfer systems
Numerous successful energy supply applications
with i.Sense condition monitoring

Sustainability

Avoid resource-intensive emergency operations
Have your energy chain recycled at the end of its life cycle in the igus® Chainge Recycling programme. Irrespective of the manufacturer.

3D illustration of the new theatre e-spool® with spring force monitoring

The e-spool® system ...

... the alternative to the cable drum without slip ring
Safely guide many different cables in a confined space with e-spool. e-spool uniquely combines two different energy supply systems: One standard energy chain is guided by a roller, providing the correct length and tension of the energy supply system through an integrated retaining spring. In the home position, the energy chain is completely rolled up to save space. The twisterband connects the roller with the shaft end block, serving as an interface to the supply side cables.

Learn everything about the entire e-spool® system here

Intelligent condition monitoring successfully realised

i.Sense from smart plastics in practice

Sewage and wastewater treatment plants

Ports and container cranes

Conveying and bulk handling

"Less effort, higher availability"

"Less maintenance work, higher availability, the ability to manage all the different cables and hoses in one system, intelligent status monitoring i.Sense ... I would always use intelligent energy chain from igus again!"

Dipl.-Ing. Fabian Wilhelm, Project Manager at AOS Stade GmbH

Worldwide customer applications

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

Click here for the application overview

When do I need a smart status sensor like i.Sense BRG?

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 ...

Smart machine data acquisition as the basis for predictive maintenance concepts

As part of the i.Sense condition monitoring system from smart plastics, all data from the i.Sense Wonderbox can also be analysed in the i.Cee switch cabinet module. This can then be used to digitally control the entire alarm and escalation management of the system.

The i.Cee module also offers numerous integration options in predictive maintenance concepts. From preventive service management, which schedules regular maintenance depending on usage, to location-independent fault management, which immediately reports any unforeseen changes via various mobile channels. All information is aggregated in a modern dashboard, online or offline in the local network, depending on the customer's requirements.

Predictive maintenance with smart plastics | i.Cee

White paper on optimising the overall equipment effectiveness OEE

Differentiates condition monitoring from predictive maintenance

In this white paper you will learn

What does condition monitoring (i.Sense) mean at igus
What does predictive maintenance (i.Cee) at igus include?
What technology is behind both systems
What do both systems offer for energy supply in industry

Go to download

24/7 push/pull force monitoring

Condition monitoring system i.Sense EC.P
Additional protection for the energy chain is provided by the smart plastics i.Sense EC.P system (EC = e-chain P = pullforce), which continuously measures the e-chain's push/pull forces. If force thresholds are exceeded, the sensor recognises this, reports it and, if necessary, switches off the system to prevent potentially expensive consequential damage to or total destruction of the system.

i.Sense EC.P condition monitoring