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Smart condition monitoring systems for data, measuring system, and bus cables

Drastically reduce failure costs for heavily used cables ... with i.Sense CF.D

The new, protocol-independent measurement method determines the data transmission characteristics of the cable during operation using high-frequency technology. This means that there is no longer any need for additional sacrificial veins. The latest generation can monitor cables without any contact at all.

If the transmission characteristics start to deteriorate, cables can be replaced in good time. System downtimes are also minimised by this intelligent condition monitoring of the entire moving cable including plug connector prevented.

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Advantages of our smart plastics Solution:

▲ Tech up
  • Smart monitoring of the entire cable incl. plug-in connectors
  • Extension of the maximum service life
  • Integration into Industry 4.0/IIoT concepts


▼ Cost down
  • Saves on additional measuring cores
  • Contactless design allows quick retrofitting​
  • Reduce maintenance costs through early warnings

The system components of i.Sense CF.D

Collect data - evaluate data - visualise data

CF.D Sensors

Sensor technology & evaluation in one
The new measuring method determines the data transmission properties of the cable during operation using high-frequency technology. This means that there is no longer any need for additional sacrificial veins. The CF.D module monitors the performance of heavily loaded Ethernet cables that are at risk of failure and directly displays the current status. In addition, the Distance to the recognised hazard area of the cable, which avoids lengthy and costly troubleshooting.

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i.Cee dashboard

Dashboard
At a glance, the dashboard shows the remaining service life of components equipped with smart technology. In addition, the current status of the intelligent energy supply system is displayed in colour using a traffic light code. This gives the system operator the following at first glance a clear picture of the condition of the system and can plan the upcoming maintenance intervals in advance.

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i.Sense EC.P - intelligent line monitoring successfully realised

  • Wastewater treatment plants and wastewater operations
  • Harbour and container cranes
  • Conveying and bulk handling

    • "Avoid costly failures"

    i.Sense CF.Q in use

    "The machine works with really high stroke rates in a relatively small installation space. For this reason, we needed cables with high flexural strength. Furthermore, a preventive warning system had to be found to avoid a possible cost-intensive failure of this machine with its high output."

    Dipl.-Ing. Oliver Tausch, electrical engineering conductor, who GHD Georg Hartmann Maschinenbau GmbH

    Customer applications worldwide

    Overview of i.Sense examples

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

    Click here for the application overview

    Other smart solutions for cable monitoring

    No additional module is required for condition monitoring (i.Sense) using chainflex® cable. The system can be operated without additional software during integration and networking. In these cases, chainflex® cable takes over 3 possibilities of condition monitoring.

    • Tensile and shear force measurement via the cable (CF.P)
    • Measurement of the electrical specification of a cable (CF.Q)
    • Measurement of the transmission quality (CF.D)
    Sensors for smart energy chains and cables

    CF.P

    CF.P
    • Condition monitoring
    • measures pull forces acting on cables
    • If there is a fault, the contact closes, and a notification is sent to the machine

    CF.Q

    CF.Q
    • Condition monitoring
    • Indicates changes in the electrical properties
    • If there is a fault, notification is with contact and a signal
    "smart plastics" brochure

    Overview of smart plastic

    Insight into the complete product portfolio for Industry 4.0

    Table of contents:

    • Condition monitoring (i.Sense)
    • Condition monitoring products
    • Application examples of condition monitoring
    • predictive maintenance (i.Cee)
    • Application examples for predictive maintenance
    • How does the data flow with predictive maintenance?
    Download brochure
    i.Cee

    How does predictive maintenance work at igus®?
    Only the intelligent networking of individual components creates a solid basis for predictive maintenance concepts, also known as predictive maintenance. At igus®, predictive maintenance is summarised under the term i.Cee.

    The central element in this area is the i.Cee software. This software, in conjunction with sensors on the energy chain, the plain bearing bush or a linear slide, turns the products available from stock into smart products. This upgrade makes it possible to determine the maximum service life of your igus® product and the i.Cee system also indicates the perfect service time. Algorithms adjust the service life and the service time according to usage. With the software we provide, a few sensors and the new communication module i.Cee:plus II, standard products available from stock can be transformed into smart energy supply or storage technology in no time at all.

    All about predictive maintenance

    i.Sense CF.D - The most important facts at a glance

    Tech up

    Tech up

    • The transmission properties are measured during operation using protocol-independent measurement methods​
    • Small feed-through adapters are looped into the cable to be monitored at both ends
    • i.Cee:plus II module connected via USB for predictive maintenance information
    • Smart monitoring of all moving cables, including plug-in connectors
    Cost down

    Cost down

    • Saves on additional measuring cores
    • Small type enables quick retrofitting in case of cable replacement
    • Indicator for timely cable replacement – prevent unplanned plant shutdowns
    Proof

    Proof

    • Ongoing test series in the largest Test laboratory  the industry for dynamic energy transmission systems
    • Try it out in your own application in order to see for yourself; igus® is offering free samples in the beta test phase
    Sustainability

    Sustainability

    • No extra cores needed
    • Predictable service intervals save resource-intensive emergency operations

    Smart project planning

    Project planning

    Request expert support and customised solutions directly.

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    Smart consulting tool

    smart tool

    With just a little information about your application, you can make the right choice of smart plastics.

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    Smart white paper

    White paper

    This short white paper provides a quick overview of all igus activities relating to Industry 4.0 and the Internet of Things. 

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    Contact us

    Contact details

    Seán Ryan
    Seán Ryan086 0329555Submit form

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