Condition Monitoring Sensors for Energy Chains and Cables

Identify and prevent failures before they occur

igus® energy chains and flexible cables can be integrated with smart condition monitoring sensors from the i.Sense product line. By using these sensors, early signs of potential downtime can often be identified well before a failure occurs. The i.Sense solutions enable monitoring across a range of parameters, including detecting breakage of individual e-chain® links, tracking environmental conditions, and measuring wear both within the pin bore and on the outer surfaces in sliding applications. These sensor systems not only allow for early detection of potential machine failures but also help extend the overall service life of machines.

Smart energy chains;

P4.1 roller chain
E4 chain series for the high load range
E2 chains for the medium load range

i.Sense condition monitoring sensors;

Sensor for movement (EC.M)
Non-contact wear measurement (EC.I)
Sensor for abrasion (EC.W)
Position-sensitive pull/push force measurement (EC.P)
Pulling and pushing force measurement via the lines (CF.P)
Measurement of the electrical properties of a line (CF.Q)
Transmission quality measurement (CF.D)

Smart e-chains® using condition monitoring

igus cable carrier module with moving segments and a sensor graphic for condition monitoring.

P4.1 rol e-chain®

Longer service life due to maintenance-free tribo-polymer plain bearings in conjunction with the chain links
For the heavy duty applications
Travel distance up to 800m and speed higher than 5m/s

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E4 e-chain® for heavy loads

Gliding, unsupported, and suspended applications possible
For robust, challenging areas of use
Inner height from 21 to 350mm
Each link consists of four individual parts
Openable along inner and outer radius

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E2.1 cable carrier accessory with orange handle and pink wave marker.

E2 e-chain® for medium loads

Inner height: 26 - 48mm
Openable from both sides along the outer or inner radius
Weight to dimension ratio improved on comparable predecessor series
55% faster assembly time than predecessor

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Conditioning monitoring sensors for energy chains

EC.W

EC.W cable carrier with guided travel path for a moving machine.

Sensor for energy chain abrasion

Measures wear on crossbar, pin/bore, or liner (design-dependent)
Compares algorithms with real usage data
Can operate as a standalone sensor

EC.PP

Position-sensitive push/pull force sensor

Integrated into the e-chain positioning system
Provides real-time, position-dependent force data
Position data can be used for additional applications

Conditioning monitoring sensors for cables

CF.P Pushforce Detection shows a cable chain with a sensor for detecting pull forces.

CF.P

Measures pull forces acting on cables
If there is a fault, the contact closes, and a notification is sent to the machine

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CF.Q cable carrier with i.com indicator for cable quality.

CF.Q

Indicates changes in the electrical properties
If event of a fault, information about contact and notification to the machine

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CF.D bus cable monitoring with chain and sensor indicator.

CF.D

Integrated in the cable, no extra measuring cable needed
Package losses are detected in good time
Alarm via LED, NC contact or the network

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Smart solutions with chainflex® cables

Condition monitoring (i.Sense) with chainflex® cables requires no additional module.
The system can be integrated and networked without additional software.
In these cases, cables have three options for condition monitoring.

Cable push/pull force measurement (CF.P)
Cable electrical property measurement (CF.Q)
Transmission quality measurement (CF.D)

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