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i.Sense EC.P

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Reduce machine downtime with smart pull/push force detection for e-chains

i.Sense EC.P infographic

i.Sense EC.P - Save a lot of money and trouble with little cost or effort thanks to igus smart technology

You have to master immense push/pull forces on energy chains or drag chains. Because: where travels and forces increase, so does the risk. Full control including switch-off recommendation is guaranteed by our i.Sense EC.P from smart plastics. Can be used on any e-chain® - unsupported or gliding - these intelligent sensors even work with changing loads and fluctuating environmental parameters. This significantly reduces your downtime costs and continuously increases overall system effectiveness.

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Information ...

i.Sense EC.P manual

Learn all the details about i.Sense EC.P installation, setup, and troubleshooting here in the manual.

Service, Help & FAQs

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i.Sense EC.P 3D data

Download free design data in all common 3D formats directly and start designing.

... Buy it

Buy i.Sense EC.P in the igus online shop

Configure ready-to-install i.Sense EC.P systems for detecting push/pull forces directly in the igus® online shop and order them online.

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Case study on smart aluminium production with smart plastics

Difficult environment, reliable energy supply - energy chain systems from igus® defy dust and dirt in aluminium oxide production

Free case study

This case study discusses the question asked by almost all design engineers who have to guide hoses, power and data cables in moving applications with long travels of over 100m:

Which energy supply system is the most efficient - in terms of reliability, ease of maintenance and future security, among other things? A motorised cable reel? Or an energy chain?

Go to the PDF download

What is i.Sense EC.P, and what are its benefits?

What practical i.Sense EC.P success stories are there?

What are the technical components of i.Sense EC.P?

At what point does purchasing an i.Sense EC.P pay off for me?

What is on-site i.Sense EC.P assembly like?

How does i.Sense EC.P fit into predictive maintenance concepts?

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i.Sense EC.P functional principle and advantages explained in 70 seconds

What is i.Sense EC.P, and what can it do for me?

Functionality and advantages

The EC.P (EC = e-chain P = pull force) sensor is mounted on one end of the e-chain,
where the sensor continuously measures push/pull forces acting on the e-chain, then transmits them via cable to a DIN top-hat rail module installed in the switch cabinet.
The vast majority of failures are preceded by an increase in force due to such factors as foreign bodies, snow/ice, misalignment, and deformed or loose guide troughs.
If the acceptable forces are exceeded, the i.Sense EC.P System detects that fact, reports it, and switches the system off quickly in order to prevent expensive consequential or total damage.

What are the technical components of i.Sense EC.P?

The technology for push/pull force monitoring in detail

i.Sense EC.P sensors

Sensors

There are two EC.P sensor unit variants that can be used depending on application environment:

Strain gauge force sensors
Load cell in the FTA/floating moving end

In the first variant, the EC.P sensor unit consists of a sensor block and a dummy block screwed to the mounting bracket. This variant is a suitable standard for most applications. Then there the variant with load cell, which is usually part of a complete engineering project. The sensor is integrated as a load cell into the floating moving end (FTA, or floating tow arm).

i.Sense EC.P system evaluation module

Evaluation module

Subsequently, all supplied push/pull force sensor data are continuously evaluated with the i.Sense Module II, which is mounted in the control cabinet of the system to be monitored and connected with chainflex cables. The module detects all movement anomalies immediately and transmits them directly to the user or the machine control system, such as Siemens PLC, via an NC contact. This new generation can connect up to four condition monitoring sensors at the same time with just one switch cabinet module, saving lots of space and costs.

i.Sense EC.P online dashboard

Connectivity

The module also offers many typical Industry 4.0 use cases, such as remote resetting or an SMS/e-mail alarm function. The i.Sense module offers other network options besides direct integration into the PLC plant control system to prevent total machine failure in an emergency.

One is location-independent alerting with the optional SMS module. Another is that, in connection with an i.Cee module, all acquired sensor data can be output to an online dashboard.

How are i.Sense EC.P sensors mounted on the chain?

Mounted i.Sense EC.P sensor

EC.P force sensors mounted on a plastic mounting bracket

Download the sensor data sheet now

i.Sense EC.P sensor with load cell mounted on the FTA

EC.P sensor implemented as load cell on the floating moving end (FTA)

Download the load cell data sheet

i.Sense EC.P sensor with load cell mounted on the FTA

You can mount the EC.P yourself, whether it has force sensors or a load cell

Download installation instructions

How is the i.Sense EC.P module connected?

In addition to the installation instructions, there are also detailed operating instructions for all our smart plastics systems. These guide you step by step through all the relevant aspects of operation:

Safety instructions
Installation and connection planning
Configuration and calibration
Operating conditions
Troubleshooting

Download the operating instructions

i.Sense operating instructions

Intelligent push/pull force monitoring implemented successfully

i.Sense EC.P in practice

Wastewater treatment plants and wastewater operations |
Port and container cranes |
Conveyor and bulk handling

"Less effort, greater availability"

i.Sense EC.P in use

"Less maintenance effort, greater availability, allows guiding all the different cables and hoses in a single system, electronic i.Sense EC.P. push/pull force detection … I would definitely choose intelligent igus energy chains again!"

Dipl.-Ing. Fabian Wilhelm, Project Manager for AOS Stade GmbH

Customer applications worldwide

i.Sense EC.P examples in the overview

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

To the application overview

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

When do I need a smart condition monitoring system like i.Sense EC.P?

Condition monitoring instead of production downtime

When regular maintenance work requires complete production shutdown ...

Condition monitoring system for very small deviations

When motion anomalies cannot be detected by humans in time ...

Condition monitoring for continuous monitoring

If plants or machines need to be monitored frequently or continuously ...

Condition monitoring for hard-to-reach areas

If energy supply system travels are difficult to access or view ...

Condition monitoring for security areas

If maintenance work poses a health or safety risk ...

Condition monitoring for reducing costs

If maintenance costs are to be reduced and service life extended ...

At what point does it pay to purchase i.Sense EC.P?

The financial benefits of safety systems are often difficult to assess, especially because the initial investment in a modern condition monitoring system increases costs instead of reducing them. So we performed a break-even analysis for the entire utilisation period based on practical experience in an automotive production hall.

Given the average cost per working hour for all typical maintenance expenses in the German manufacturing industry (EUR 41.60), an EC.P system reaches its benefit threshold in just the third year of use, even by a conservative estimate (regular case).

View the full break-even analysis

i.Sense EC.P break-even analysis

Various scenarios were examined in detail in a break-even analysis

smart plastics expert Richard Habering demonstrates i.Sense EC.P

You are guaranteed personal advice

Do you have a crane or system for which you would like to monitor e-chain tensile forces to enhance system reliability?
If so, feel free to contact me.

I am looking forward to your message!
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► Expert support by phone or with the video chat function

i.Sense EC.P as the basis for predictive maintenance

Always the optimum maintenance solution with igus smart plastics

For a solid foundation for predictive maintenance concepts, you need a smart network of individual condition monitoring systems, such as i.Sense EC.P. At igus, everything related to predictive maintenance falls under the term i.Cee. Similarly, i.Sense encompasses all condition monitoring systems.

The central element here is the i.Cee software, which, combined with i.Sense condition monitoring sensors on the energy chain, the plain bearing bushing, or a linear carriage, transform stock products into smart ones. This upgrade creates the capability of determining maximum service life and optimal maintenance intervals in real time based on real usage data.

More about predictive maintenance with smart plastics

i.Sense EC.P systems as the basis for predictive maintenance

All condition monitoring systems at a glance in the brochure

General smart plastics overview

Insight into the entire igus Industry 4.0 product portfolio

Table of contents for this free brochure:

Condition monitoring (i.Sense)
Condition monitoring systems
Advantages of condition monitoring systems
Condition monitoring application examples
Predictive maintenance (i.Cee)
Systems for predictive maintenance
Advantages of predictive maintenance systems
Application examples for predictive maintenance
Data flow in modern smart factory concepts

Download the smart plastics brochure

EC.P infographic

Back to the i.Sense condition monitoring systems overview

Consulting

I would be happy to answer your questions

Dan Seeney

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