igus launches the TR.P system - intelligent condition monitoring for robotics

igus has developed a new i.Sense TR.P sensor designed to monitor tensile forces in triflex robotic cable carrier systems. The solution is intended for use in industrial robots, where power, signal and data cables must operate under conditions of high dynamics, torsion and tension. The manufacturer points primarily to automation in the automotive industry, where unplanned downtime generates high costs. The system is intended to detect potential damage at an early stage, increase operational safety and support commissioning through condition monitoring of the cable carrier. According to the company, the sensor responds to critical tensile forces acting on the cable guidance system.

Industrial robots are an integral part of automotive production, where they perform tasks including welding, bonding and painting. Three-dimensional cable carriers from the igus triflex series ensure cable movement even under high torsional and tensile loads. In combination with flexible chainflex cables, they supply the robot with power, data and signals. According to Richard Habering, head of the intelligent plastics division at igus, the costs of stopping a robot in a car factory can be very high: "It costs 600 euros per second if a robot cannot do its job in a car factory."

Monitoring tensile forces in the carrier

The i.Sense TR.P system measures tensile forces acting on the robot head by means of a load cell. If predefined maximum values are exceeded, it triggers an action via a potential-free contact. This may be, for example, a message to the operator or stopping the robot. The sensor has been developed specifically for the three-dimensional triflex cable carrier.

"With the help of our i.Sense module and the modular sensor system on the moving triflex arm, users can detect critical movement patterns and identify and prevent damage such as excessive bending, overstretching or jamming at an early stage," explains Habering.

Support during robot commissioning

igus points to the system’s potential particularly during robot commissioning. TR.P can act as a measuring system to identify problematic movement patterns when dress packs are used during programming. This makes it possible to look for solutions before damage occurs to cable guidance components.

In addition to monitoring tensile forces, igus has offered the TR.B crack detection system since 2022, which is used in many applications worldwide. If a carrier link breaks, the system detects a change in the length of the cord installed in the carrier and sends a digital signal to the plant control system. Immediate detection of a break enables maintenance actions to be taken and therefore helps avoid unplanned downtime and complete failures in the event of carrier link breakage.

The i.Sense TR.B sensor is connected directly to the PLC without additional hardware costs or complicated programming. A simple alarm is also optionally possible, for example via a signal light.

The superwise concept for intelligent plastics

In the area of after-sales service, igus also offers the superwise concept for its intelligent plastics. It combines digital condition monitoring of i.Sense sensors with predictive maintenance. The aim is to avoid unplanned downtime, reduce the workload of maintenance teams and extend the service life of machine components without high investment.

For this purpose, customers’ i.Sense data is securely connected to the igus CRM system. The igus service team gains transparent access to information and can initiate targeted measures, such as early contact in the event of conspicuous sensor values, maintenance or cleaning recommendations, planning and coordination of inspections and replacements, as well as direct ordering for rapid stock replenishment.