Robot energy chain monitoring for automotive automation

Industrial robots used in automotive manufacturing depend on reliable cable management systems to maintain continuous operation across welding, gluing and painting processes. In this context, igus introduced the i.Sense TR.P sensor for monitoring triflex energy chain systems used in robotic applications.

Monitoring tensile loads in robotic cable management systems
The i.Sense TR.P sensor is designed to monitor tensile forces acting on triflex^® multi-axis energy chain systems that guide cables supplying power, data and signals to robotic end effectors. The system uses a load cell to measure tensile stress and detect deviations from predefined limits.

If force thresholds are exceeded, the sensor can trigger predefined responses through a potential-free contact, such as sending alerts to operators or initiating controlled robot stops. This approach supports condition monitoring strategies intended to reduce the risk of mechanical failure in automated production environments.

Such monitoring is particularly relevant in the automotive sector, where robot downtime can result in significant production losses. igus indicates that unexpected robot stoppages in automotive plants can result in costs of approximately €600 per second.

Supporting commissioning through motion pattern analysis
Beyond operational monitoring, the i.Sense TR.P sensor can also be used during robot commissioning. During programming and dress pack installation, the system can function as a measurement tool to identify problematic robot movements before production deployment.

Installed as part of the triflex sensor system on the robot arm, the device enables detection of abnormal bending, excessive tensile stress or jamming conditions that may lead to premature wear or failure. This allows engineers to adjust movement sequences and routing layouts before damage occurs.

Break detection through complementary sensor systems
igus also offers the i.Sense TR.B sensor for detecting chain or cable breakage. This system monitors changes in cable length within the energy chain and transmits signals directly to the PLC when anomalies are detected.

Immediate detection allows maintenance teams to intervene before failures propagate into larger system disruptions. The TR.B sensor can be connected directly to PLC architectures without additional hardware or complex programming, and can be combined with visual alert systems such as warning indicators.

Linking condition monitoring with predictive maintenance services
The igus superwise service integrates condition monitoring data from i.Sense sensors with predictive maintenance workflows. Sensor data is connected to igus service systems to support maintenance planning, inspection scheduling and replacement coordination.

This service model is intended to reduce maintenance workload and extend component service life by enabling early intervention based on sensor data. The approach reflects the growing adoption of predictive maintenance and digital condition monitoring in industrial automation environments.

Edited by industrial journalist Aishwarya Mambet, with AI-assistance.

www.igus.com