New monitoring sensors that developed by Igus check the electrical condition of chainflex cables in e-chain systems without contact or intervention in the existing harnessing.

The company’s i.Sense CF.D monitoring sensors allow real-time monitoring without extra cores and, in combination with the new i.Cee: plus II evaluation module, allow even more efficient predictive Source: IgusSource: Igus maintenance for protection against expensive system failures.

The latest CF.D generation facilitates the entry into predictive maintenance of chainflex bus and data cables in Igus e-chain systems. The smart system consists of two sensor units clipped onto the cable before and after the chainflex cable to be monitored. They are small enough to fit into the distribution box on the moving end side and into the control cabinet on the fixed end side. During operation, the sensors continuously check the cables’ transmission properties.

The monitoring sensor uses high-frequency technology that works without additional sacrificial cores and without contacting existing cores. “This technology allows the sensors to reliably measure even the smallest transmission deteriorations in cables and connectors,” said Richard Habering, head of the Igus smart plastics business unit. This allows effective predictive maintenance in moving industrial applications in which cables and connectors are subjected to continuous mechanical stress.

The new generation of CF.D sensors is compatible with most bus and data cables in the Igus chainflex cable range. When data and bus cables approach their wear limit, another innovation comes into play: i.Cee: plus II — a module that connects to the CF.D sensors. A CF.D sensor makes a USB connection to the predictive i.Cee maintenance module. Incipient deterioration of the transmission properties signals necessary maintenance work and adjusts the component service life calculation accordingly. It outputs the measurement results for each individual sensor to a dashboard that users can access through the local network or on the move on the internet with a PC, smartphone, or tablet. Workers responsible for equipment can keep up to date at all times and from anywhere in the world. It also allows them to react quickly to messages received via SMS or e-mail.

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