igus develops new sensor for condition monitoring of tensile forces in robot energy chain systems
Unplanned downtime in automation costs not only 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 in the event of critical tensile forces. The system detects potential damage at an early stage, increases operational safety, and supports condition monitoring right from the start-up phase.
Industrial robots have become indispensable in automotive production. They weld, glue, and paint. To ensure that their cables move safely even under extreme torsion and tensile loads, three-dimensional energy chains from the triflex series from igus come into play. 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 euros per second when a robot in an automotive plant cannot do its job," says Richard Habering, Head of the smart plastics division at igus. That 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 occurring at the robot head using a load cell and triggers an action via a potential-free contact when the predefined maximum values are exceeded – this can be, for example, a message to the operator or a stop of the robot.
Condition monitoring: Detecting faults as early as during commissioning
"With the help of our i.Sense module and the modular sensor technology on the triflex carrier arm, users can detect critical movement patterns and identify and prevent damage such as overbending, overstretching, or even pinching at an early stage," explains Richard Habering. igus sees great potential for the system, especially in the commissioning of robots. The TR.P can serve as a measuring system to identify problematic movement patterns in the use of hose packages during programming and find solutions before damage occurs. In addition to monitoring tensile forces, igus has been offering the TR.B system for break 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 a digital signal to the system control. Lightning-fast break detection enables immediate maintenance measures to be taken, thus avoiding unplanned downtime and total failures in the event of individual chain link breaks. The i.Sense TR.B sensor is connected directly to the PLC control system without additional hardware costs or complex programming. A simple alarm, for example via a signal light, is also available as an option.
superwise: Increase operational reliability and reduce customer workload
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 downtime, relieve maintenance teams and significantly extend the service life of machine components – without high investments. To this end, the customer's i.Sense data is securely linked to the igus CRM. The igus service team has complete transparency and can initiate targeted measures, such as early contact in the event of abnormal sensor values, suggestions for maintenance or cleaning measures, scheduling and coordination of inspections and replacements, and a direct ordering function for fast replenishment.
Learn more about the TR.P sensor at Condition Monitoring TR.P.