Flexibility meets safety: First monitoring system for robot e-chains from igus

Intelligent condition monitoring is now also possible with the new i.Sense TR.B sensor on the 3D energy chains triflex R from igus. (Source: igus GmbH)

Robots have long been an integral part of many areas of industrial manufacturing – and their range of tasks continues to expand with digitalization. Whether welding, painting, soldering, or palletizing: industrial robots work dynamically. A flexible 3D energy chain like the triflex R from igus makes it possible to safely guide robot cables. To detect potential chain breaks caused by extreme loads in a timely manner and prevent unplanned machine failures, igus introduces with i.Sense TR.B the world's first break monitoring system for 3D energy chains at automatica 2022.

Increasing material and energy efficiency, compensating for supply bottlenecks through domestic production, and alleviating the skilled labor shortage: According to the 2022 Trend Index of the world's leading trade fair automatica, these are some of the most cited reasons why industrial robots are important for the German economy. However, for an industrial robot to operate reliably, one thing is essential above all: a secure cable management. Robot cables must withstand numerous bending cycles as well as torsion and tensile stresses. With the triflex R, igus has developed a round energy chain with a defined bending radius specifically for industrial robots, thus protecting the cables even during dynamic rotary and pivoting movements. Because a chain break can be devastating: plant downtime, production stoppages, and delivery delays cost time and money. To detect a chain break instantly and prevent costly consequential damages, motion plastics specialist igus has developed a new and cost-effective solution: i.Sense TR.B – a real-time break monitoring system for the three-dimensional triflex R energy chain.

Smart real-time condition monitoring – also for 3D applications

With i.Sense TR.B, the proven i.Sense break monitoring from igus smart plastics now also makes dynamic, three-dimensional applications possible. Customers can thus increase the safety of their robot systems with an investment of only a few hundred euros. The i.Sense TR.B sensor is directly connected to the customer’s PLC control system – without additional software costs. If a chain link breaks, the system detects the length change of the cable embedded in the chain and can accordingly output a digital signal to the plant control system. The lightning-fast break detection enables immediate maintenance actions and can thus prevent unplanned downtimes and total failures due to individual chain link breaks. "Especially in applications like automotive manufacturing lines with extremely high output, any downtime can cost several hundred thousand euros. Real-time condition monitoring of energy management in industrial robots thus offers users significant added value," explains Richard Habering, Head of the smart plastics business division at igus.

Sustainable maintenance with smart plastics

With numerous test series in the industry's largest testing laboratory, igus continuously works to optimize the quality and durability of its products. The combination of the flexible triflex R 3D chain with high tensile capacity and the i.Sense TR.B sensor makes it possible to safely guide and protect robot cables – significantly increasing their lifespan. Condition-based maintenance using the TR.B sensor also makes maintenance more sustainable, as users can avoid unnecessary or premature part replacements. And if a chain break does occur, the sensor can be reused after proper emergency shutdown of the system.