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Our new products from 2024 2023 2022

smart plastics new products 2024

The growing importance of smart condition monitoring and predictive maintenance

The integration of IIoT into industrial processes simplifies condition monitoring and predictive maintenance. With our new products, we are moving further in the direction of Industry 4.0. Sensor-based information enables us to make an exact statement about the expected service life of the products. Downtimes can be reduced and production efficiency increased. We are constantly developing our products to enable precise maintenance planning and to provide accurate information on the condition of the system at all times.

EC.IT ... Contactless transmission of data

EC.IT Contactless condition sensor ...

... for roller energy chains with direct superwise connection

The contactless EC.IT sensor collects data during operation virtually "on the fly". Thanks to the direct connection to superwise Service, the EC.IT sensor box can display valuable information on service life, provide maintenance instructions and draw attention to any irregularities. In addition, all relevant information can be viewed in a compact and clearly structured form on the dashboard.

To the EC.IT sensor box

superwise ... igus smart service

The OTA-capable i.Sense module ...

... with connection to the superwise service

The i.Sense GEN II NEW module now comes with over-the-air (OTA) updates for firmware and operating software, records movement profile data from your machines and enables an IoT connection to the superwise portal in addition to the proven push/pull force and breakage detection. Reliably prevents system failures caused by dirt and debris, misalignment or weathering effects.

To the OTA-capable i.Sense module

superwise ... igus smart service

i.Cee integrated superwise maintenance management

Plan service calls and retrofits intelligently. With the addition of a new maintenance management module to the firmware and the connection to the superwise system, a smart step can be taken in service management. The module enables optimised maintenance planning. Systems can be maintained more efficiently and unplanned downtimes reduced. Integrating the maintenance management module into the superwise system is a smart step towards improving maintenance processes.

To the superwise maintenance management

iComm box

The iComm box for all i.Sense modules

All sensors in one box ... Seamlessly integrated into the superwise system

With the iComm box, real-time information is seamlessly integrated into the superwise system. This compact solution combines all i.Sense sensors in a single device and offers optimal integration with the superwise condition monitoring service. The clear dashboard not only displays service life information and maintenance instructions, but also alarms in the event of anomalies to ensure efficient and proactive maintenance.

To the iComm box

CF-D module with DriveCliq

Quickly detect power failures with the CF-D module ...

... now with event log and Profinet Ethercat capability

The CF-D module can quickly detect cable failures and is therefore crucial for effective and accurate maintenance of Ethernet cables. With the new event log function and compatibility with Profinet Ethercat, the i.Sense CF.D module takes fault diagnostics to a new level: it precisely localises the location of transmission faults, allowing maintenance work to be carried out quickly and accurately.

To the CF.D module with DriveCliq extension

Status indicator ... igus smart service

Recognise the condition of the chain at a glance ...

... with the status indicator

The mechanical status display with coloured indicators (green, yellow, red). This is exposed by the abrasion of the wear additives of the chain links. The colour changes to yellow with increasing abrasion. The decreasing distance between the crossbars indicates the state of wear.

To the status indicator

igubal flange mounted bearing ... igus smart service

Smart igubal® flange mounted bearings ...

... equipped with abrasion sensor

The igubal® flange mounted bearings are equipped with an abrasion sensor that is integrated into the polymer spherical ball. Conductive elements are interrupted by wear. The resulting percentage status values are transmitted either to the local i.Cee system or to the superwise cloud solution via a long range network (LoRa).

To the smart igubal flange mounted bearing

Positioning system

The new travel measuring system ...

... with a measuring accuracy of up to 1mm

Precise positioning is no longer a problem. Positions can be determined with an accuracy of 1mm using the new travel measuring system.

To the travel measuring system

Spherical ball

Ball coupling without lubrication

With the intelligent trailer coupling, maintenance can be planned safely. A sensor measures the wear of the bearing and informs the user in good time when a bearing needs to be replaced. Failures and damage can lead to high costs in the agricultural sector. This can be prevented with the smart spherical ball.

For lubrication-free trailer coupling

Our new products from 2024 2023 2022

2023 smart plastics News

Moving energy made smart

Do you know how expensive an hour of plant downtime is for industrial companies? Please note: between 39,000 and 2 million US dollars, according to a study by Senseye, a UK-based maker of analytics software. These costs add up. The top 500 sales-volume companies in the world lose nearly $1.5 trillion a year to equipment failures. This massive drain on profits can't be ignored. Not even in small and medium-sized companies. So it is not surprising that more and more companies are implementing forward-looking concepts such as condition monitoring and predictive maintenance. This is an important step in minimising downtime and making maintenance work more economical.

Dive into the world of Industry 4.0 with smart plastics.

igus trade show stand 2023

smart plastics news overview:

superwise ... igus smart service

smart plastics meets orange service

superwise - igus® smart service

For the first time, the new "superwise" service combines the first-class igus® orange product service with the latest smart plastics technology in one package. Through the systematic as well as AI-supported evaluation of the customer's application or project data, igus® offers a whole host of advantages with "superwise". For example, we can actively inform you about price, delivery time and possible product improvements before an upcoming exchange.

2023 smart plastics News: i.Sense TR.B

Flexibility meets safety: i.Sense TR.B

First condition monitoring system for robot e-chains

Robots have long been indispensable in many areas of industrial manufacturing – welding, painting, soldering, and palletising: industrial robots are becoming dynamic. A flexible 3D energy chain such as the triflex® R from igus® makes it possible to guide robot cables safely. To detect potential chain breaks due to extreme loads in good time and avoid unplanned machine breakdowns, igus has developed i.Sense TR.B, the world's first breakage monitoring system for 3D energy chains.

Extremely light, but always monitoring ...

... the new i.Sense igubal® sensor

The intelligent smart plastics fixed flange bearing constantly monitors the condition of the bearing point and immediately reports the first signs of wear in order to avoid serious bearing damage. The aim is to receive an immediate notification if the bearing properties deteriorate. This prevents expensive disruptions and failures.

smart plastics News 2023: smart plastics MWS

Direct real-time monitoring easier than ever ...

... with the new smart plastics MWS

The smart plastics mini wear sensor (MWS) is used to record the percentage of abrasion on moving system parts in order to avoid possible operational failures at an early stage.

smart plastics innovations: new i.Sense CF.D

Now also with optical status display ...

Identify cable stress at an early stage with i.Sense CF.D

Until now, there have often been only two options for servicing and maintaining cables subject to high mechanical stress: either reactively replace them when they are already defective or replace functioning cables at specific intervals as a precaution.

The new smart plastics i.Sense CF.D module provides the first real alternative: predictive maintenance of data, bus, or Ethernet cables by intelligently monitoring data transmission quality during operation.

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Download a free case study

This case study illustrates how EMO B.V. is able to achieve over 375,000km on its STS cranes with igus chains for cranes®.

Go to the PDF download

smart plastics News 2022: smart i.Sense BRG mini-sensor

Full control with smart bearings ...

... with the new i.Sense BRG mini-sensor

The new i.Sense BRG mini-sensor gives you full control. Because with this innovation, you can make (almost) any plastic product from igus "smart"; i.e. as a user, you benefit from real-time condition monitoring including digital evaluation options for the recorded machine data. In combination with the i.Cee module, predictive maintenance recommendations or service life statements are then issued.

smart plastics DIY tools

Small but mighty: smart plastics DIY tools

The easiest entry into the world of sensors

In modern industry, sensors have become indispensable as data sources. With smart plastics, we have been consistently going in this direction for almost 10 years and develop new, intelligent monitoring systems for energy supply systems, cables and linear guides every year. Now we want to give even more users access to this and are entering the world of low-cost sensor technology with our smart plastics DIY tools.

AG5 smart sensor option

Intuitive tension monitoring for AG5

Cable tension indicator as smart sensor option

Carrying energy safely over long distances at a cost-effective price - that's the autoglide 5. The autoglide 5 energy chain system is designed especially for horizontal use in material handling and on crane systems. The energy supply system is quick to install as it requires no guide trough. Instead, it runs on a steel cable gripped by the e-chain contour. And that's what this new product, the AG5 smart sensor option, is all about.

smart plastics News 2023: EC.W in EKE

Extending service life made easy ...

... with the EC.W wear sensor in the e-chain online configurator

Quick and easy individual solution: with the help of the "e-chain expert", interested users can put together an individual energy chain system in just three steps. Price, service life and delivery time are displayed. For the first time, users now have the option of configuring their e-chain with the intelligent i.Sense EC.W wear sensor directly. This gives customers a complex, ready-to-connect e-chain system that includes real-time condition monitoring - in just a few clicks.

smart plastics News 2023: lean, green ... and smart

Lean, green ... and smart

Smart technology as standard in many e-chains® News

Digitisation on all travels: whether in the cleanroom, in the theatre or in rotary movements ... the demand for intelligent condition monitoring, safety and longer service life, is increasing. Therefore, this year there are again many new energy supply highlights, which are already equipped as standard with the proven smart plastics technology for intelligent condition monitoring and predictive maintenance.

Information ...

smart plastics info flyer 2023

Read all the information about smart plastics again in compact form in PDF format.

... Try it ...

smart 3D data

Free 3D data, operating instructions, and much more in our smart plastics service area

... Realise

Buy smart plastics news in the igus online shop

Order ready-to-install smart plastics directly in the igus online shop

superwise igus smart service

smart plastics meets orange service

superwise - igus® smart service

For the first time, the new "superwise" service combines the first-class igus® orange product service with the latest smart plastics technology in one package. Through the systematic as well as AI-supported evaluation of the customer's application or project data, igus® offers a whole host of advantages with superwise. For example, we can actively inform you about price, delivery time and possible product improvements before an upcoming exchange.

smart plastics News 2023: superwise® - igus smart service

i.Sense TR.B

Flexibility meets safety: i.Sense TR.B

First condition monitoring system for robot e-chains

Robots have long been indispensable in many areas of industrial manufacturing – welding, painting, soldering, and palletising: industrial robots are becoming dynamic. A flexible 3D energy chain such as the triflex® R from igus® makes it possible to guide robot cables safely. To detect potential chain breaks due to extreme loads in good time and avoid unplanned machine breakdowns, igus has developed i.Sense TR.B, the world's first breakage monitoring system for 3D energy chains.

2023 smart plastics News: i.Sense TR.B - condition monitoring for triflex® R 3D chains

Extremely light, but always monitoring ...

... the new i.Sense igubal® sensor

The intelligent smart plastics fixed flange bearing constantly monitors the condition of the bearing point and immediately reports the first signs of wear in order to avoid serious bearing damage. The aim is to receive an immediate notification if the bearing properties deteriorate. This prevents expensive disruptions and failures.

smart plastics News 2023: i.Sense igubal® sensor

smart plastics MWS

Direct real-time monitoring easier than ever ...

... with the new smart plastics MWS

The smart plastics "mini wear sensor" (MWS) is used to record the percentage of abrasion on moving system parts in order to avoid possible operational failures at an early stage.

smart plastics News 2023: smart plastics mini wear sensor

i.Sense CF.D module with optical status display

Now also with optical status display ...

Identify cable stress at an early stage with i.Sense CF.D

Until now, there have often been only two options for servicing and maintaining cables subject to high mechanical stress: either reactively replace them when they are already defective or replace functioning cables at specific intervals as a precaution.

The new smart plastics i.Sense CF.D module provides the first real alternative: predictive maintenance of data, bus, or Ethernet cables by intelligently monitoring data transmission quality during operation.

smart plastics SPS News 2023: i.Sense CF.D - Completely reworked condition monitoring for bus cables

i.Sense BRG

Full control with smart bearings ...

... with the new i.Sense BRG mini-sensor

The new i.Sense BRG mini-sensor gives you full control. Because with this innovation, you can make (almost) any plastic product from igus "smart"; i.e. as a user, you benefit from real-time condition monitoring including digital evaluation options for the recorded machine data. In combination with the i.Cee module, predictive maintenance recommendations or service life statements are then issued.

2023 smart plastics News: i.Sense BRG mini-sensor

smart plastics DIY tools

Small but mighty: smart plastics DIY tools

The easiest entry into the world of sensors

In modern industry, sensors have become indispensable as data sources. With smart plastics, we have been consistently going in this direction for almost 10 years and develop new, intelligent monitoring systems for energy supply systems, cables and linear guides every year. Now we want to give even more users access to this and are entering the world of low-cost sensor technology with our smart plastics DIY tools.

smart plastics News 2023: smart plastics DIY tools

Intuitive tension monitoring for AG5

Intuitive tension monitoring for AG5

Cable tension indicator as a smart sensor option

Carrying energy safely over long distances at a cost-effective price - that's the autoglide 5. The autoglide 5 energy chain system is designed especially for horizontal use in material handling and on crane systems. The energy supply system is quick to install as it requires no guide trough. Instead, it runs on a steel cable gripped by the e-chain contour. And that's what this new product, the AG5 smart sensor option, is all about.

smart plastics News 2023: smart sensor option for autoglide 5

EC.W wear sensor

Extending service life made easy ...

... with the EC.W wear sensor in the e-chain online configurator

Quick and easy individual solution: with the help of the "e-chain expert", interested users can put together an individual energy chain system in just three steps. Price, service life and delivery time are displayed. For the first time, users now have the option of configuring their e-chain with the intelligent i.Sense EC.W wear sensor directly. This gives customers a complex, ready-to-connect e-chain system that includes real-time condition monitoring - in just a few clicks.

Lean, grean ... and smart

Lean, green ... and smart

Smart technology as standard in many e-chains® News

Digitisation on all travels: whether in the cleanroom, in the theatre or in rotary movements ... the demand for intelligent condition monitoring, safety and longer service life, is increasing. Therefore, this year there are again many new energy supply highlights, which are already equipped as standard with the proven smart plastics technology for intelligent condition monitoring and predictive maintenance.

smart plastics News 2023: lean, green ... and smart

Our new products from 2024 2023 2022

2022 smart plastics news

Moving energy made smart – with innovation and sustainability

Our task is to continually develop innovations in the area of e-chains and cables. This enables us to reduce your costs while improving the quality of your machines and systems - in a nutshell, "Tech up, Cost down".

We at igus also take responsibility for contributing to reducing plastic waste and improving recycling: when energy chains reach the end of their service life, we have them processed in the igus recycling programme. You can also learn more about our investment in chemical recycling conducted by Mura Technology Limited.

Dive into the world of Industry 4.0 with smart plastics

2022 igus trade show stand

IMPS - igus motion plastics show

A 400m² physical-virtual trade show stand that you can visit whenever you like:

Tech up

Tech up

Cost down

Cost down

Proof

Evidence

Sustainability

Sustainability

You can explore the trade show stand on your own or with one of our experts:

Book a guided tour

smart plastics news overview:

smart plastics innovations: new i.Sense CF.D

NEW at SPS with optical status display ...

... Detect cable stress at an early stage with i.Sense CF.D

Until now, there have often been only two options for servicing and maintaining cables subject to high mechanical stress: either reactively replace them when they are already defective or replace functioning cables at specific intervals as a precaution.

The new smart plastics i.Sense CF.D module provides the first real alternative: predictive maintenance of data, bus, or Ethernet cables by intelligently monitoring data transmission quality during operation.

smart plastics news: i.Sense EC.W

Extending service life has never been this cost effective ...

... with the new i.Sense EC.W service life sensor

The new i.Sense EC.W sensor makes more system availability more cost-effective than ever before. Due to the direct connection of the PLC machine control via potential-free contacts, real-time status monitoring for your gliding energy supply systems is possible from EUR 248.00 (DE list).

This makes it easier than ever to avoid unplanned downtime and increase system availability.

2022 smart plastics News: i.Sense TR.B

Finally also for multi-axis and industrial robots ...

... i.Sense TR.B for intelligent condition monitoring

Robots have long been indispensable in many areas of industrial manufacturing – bb welding, painting, soldering, and palletising: industrial robots are becoming dynamic. A flexible 3D energy chain such as the triflex® R from igus® makes it possible to guide robot cables safely. To detect potential chain breaks due to extreme loads in good time and avoid unplanned machine breakdowns, igus has developed i.Sense TR.B, the world's first breakage monitoring system for multi-axis energy chains.

First non-contact system monitoring ...

... thanks to the new i.Cee wonderbox

With the non-contact system monitoring for gliding e-chain systems^® (with & without rollers), igus^® has achieved a technological sensation. The new i.Cee wonderbox measures the dynamic parameters of the "passing" chain without contact, similar to a speed trap on the motorway. By comparing with standard values from years of experience in the igus test laboratory, changes in condition can be detected at an early stage and precise service life predictions can be made for each individual chain link.

Arrange an individual news presentation

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Robust and smart – how digitally networked energy chains enhance STS cranes in the Port of Rotterdam

Download a free case study

This case study illustrates how EMO B.V. is able to achieve over 375,000km on its STS cranes with igus chains for cranes®.

Go to the PDF download

World premiere ...

... Predictive maintenance in the cleanroom with i.Cee EC.S

In this cleanroom highlight, the smart ultrasonic sensor technology is used to continuously monitor the current sag of the e-skin® flat with support chain. The e-skin® flat with support chain SKF.S is equipped with a defined bend radius and therefore enables unsupported lengths in cleanrooms. As soon as a critical condition of the energy supply system can be detected, predictive maintenance recommendations are issued.

Arrange an individual news presentation

2022 smart plastics news: e-spool theatre i.Sense ES.B

Reliable energy supply system ...

... thanks to i.Sense ES.B

The new theatre e-spool now comes with various smart features: the force of the three springs included is monitored with a load cell sensor. If the force falls below the specified value, the user is prompted to replace the spring. When the specified value is exceeded, there is a blockage that must be removed.

A rotation sensor monitoring system can also be installed to count the drum revolutions and determine the position of the chain. As a further safeguard to increase plant reliability, the proven i.Sense EC.P can also be mounted on the chain's moving end to monitor push/pull forces.

The new i.Cee:portal

All-in-one: new customer portal i.Cee:portal ...

... for all smart plastics components

In the new i.Cee:portal, numerous functions and use cases will be made possible in a single central location in the future:

Secure (VPN), authenticated access to local i.Cee dashboards
Overview of all customer assets (online and offline)
Remote configuration and reset for individual assets
Status report for all assets
Alarm & message overview

Arrange an individual news presentation

2022 smart plastics news: i.Sense online shop

Avoid unplanned downtime with just three clicks ...

... in the new i.Sense online shop

Following the smart plastics complete sets, the i.Sense EC.P systems for push/pull force monitoring and i.Sense EC.B for breakage detection can now also be configured in their entirety including pricing and ordered from the i.Sense online shop.

The individual system configuration for each application can be easily selected based on several selection criteria (chain series, length, control cabinet position, excess cable length). The bill of materials, price and delivery time are then generated. Further information such as EPLAN macros as well as operating and mounting instructions can also be viewed directly in the shop.

2022 smart plastics news: i.Cee in the FANUC FIELD

Intelligent plant monitoring ...

... in the smart factory from FANUC & igus

To evaluate data from machines and systems, FANUC, the international robot manufacturer, offers its "FIELD system", an open industrial IoT platform. The system uses local network topology to connect production machines from all manufacturers, allowing comprehensive data analysis for the entire process chain.

The infrastructure uses apps from both FANUC and third-party suppliers. The igus "smart plastics – i.Cee" app enables maintenance personnel to monitor the condition of their igus components at all times in the FIELD system and plan maintenance work predictively.

2022 smart plastics news: smart plastics in EPLAN

Draw electrical plans faster ...

... with the new smart plastics EPLAN macros

EPLAN Electric P8, one of the main EPLAN GmbH & Co. KG products, is considered one of the industry standards for electrical design. This provides support in plant project planning, from end-to-end planning to manufacturing, commissioning, servicing and maintenance. Various studies were used to determine that the time required for this project planning effort could be reduced by more than 50%.

2022 smart plastics news: Energy supply systems made smart

Digitisation on all travel types ...

... with many more smart chain highlights 2022

The E4.80R modular expansion now comes with the full i.Sense product range for intelligent condition monitoring (EC.B, EC.P, and CF.P).
The i.Sense EC.B smart breakage detection system can now be used in the new YE(HD) hybrid chain as well to protect against unexpected stoppages.
In the new AG5.RAIL design study, i.Sense EC.P and EC.W directly lay the foundation for a predictive maintenance concept.
Optionally, the e-dispenser also offers smart plastics rotation monitoring.

Request an individual news presentation

2022 smart plastics news: Cable condition monitoring

Cable monitoring made easy ...

... thanks to Cable Condition Monitoring from igus

The new, protocol-independent measuring method determines cable data transmission properties during operation using high-frequency technology. This eliminates the need for additional sacrificial cores. The latest generation can even manage completely contactless cable monitoring.

If the transmission characteristics start to deteriorate, cables can be replaced in good time. Intelligent condition monitoring of the entire moving cable, including the plug-in connector, also prevents system downtimes.

Arrange an individual news presentation

2022 smart plastics news: smart ReBeL

"Intelligent rebel of automation" ...

... smart plastics now available in the igus® cobot ReBeL®

For the latest generation of service robots with cobot function, igus has applied its motion plastics know-how to power electronics and for the first time developed an encoder using conductive plastic tracks. This allows the temperature, number of rotations and cycles to be measured precisely.

Thanks to a connection through the smart plastics systems, a dashboard displays all live data generated – and the customer can choose whether this is done via the cloud or on a local network. The customer receives full transparency about the smart ReBeL^® in operation for key indicators such as wear, cycle time and quantities.

Request an individual news presentation

smart plastics News 2022: smart i.Sense BRG mini-sensor

Full control with smart bearings ...

... with the new i.Sense BRG mini-sensor

The new i.Sense BRG mini-sensor gives you full control. Because with this innovation, you can make (almost) any plastic product from igus "smart"; i.e. as a user, you benefit from real-time condition monitoring including digital evaluation options for the recorded machine data. In combination with the i.Cee module, predictive maintenance recommendations or service life statements are then issued.

Information ...

News catalogue: 2022 smart plastics news

Read everything about 2022 smart plastics news again in a compact PDF format.

News catalogue PDF

... Try it ...

smart 3D data

Free 3D data, operating instructions, and much more in our smart plastics service area

... Realise

Buy smart plastics news in the igus online shop

Order ready-to-install smart plastics directly in the igus online shop

i.Sense CF.D

NEW at SPS with optical status display ...

... Detect cable stress at an early stage with i.Sense CF.D

Until now, there have often been only two options for servicing and maintaining cables subject to high mechanical stress: either reactively replace them when they are already defective or replace functioning cables at specific intervals as a precaution.

The new smart plastics i.Sense CF.D module provides the first real alternative: predictive maintenance of data, bus, or Ethernet cables by intelligently monitoring data transmission quality during operation.

smart plastics SPS News 2023: i.Sense CF.D - Completely reworked condition monitoring for bus cables

i.Sense EC.W

Extending service life has never been this cost effective ...

... with the new i.Sense EC.W service life sensor

The new i.Sense EC.W sensor makes more system availability more cost-effective than ever before. Due to the direct connection of the PLC machine control via potential-free contacts, real-time status monitoring for your gliding energy supply systems is possible from EUR 248.00 (DE list).

This makes it easier than ever to avoid unplanned downtime and increase system availability.

smart plastics news 2022: i.Sense EC.W service life sensor

i.Sense TR.B

Finally also for multi-axis and industrial robots ...

... i.Sense TR.B for intelligent condition monitoring

Robots have long been indispensable in many areas of industrial manufacturing – bb welding, painting, soldering, and palletising: industrial robots are becoming dynamic. A flexible 3D energy chain such as the triflex® R from igus® makes it possible to guide robot cables safely. To detect potential chain breaks due to extreme loads in good time and avoid unplanned machine breakdowns, igus has developed i.Sense TR.B, the world's first breakage monitoring system for multi-axis energy chains.

2023 smart plastics News: i.Sense TR.B - condition monitoring for triflex® R 3D chains

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