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System availability has never been as affordable as it is today | i.Sense EC.W

New low cost service life sensor enables cost-effective real-time condition monitoring with integrated potential output for direct machine connection for gliding e-chain systems from $500

A low cost service life: i.Sense EC.W More system availability at a cost-effective price: The new i.Sense EC.W service sensor
The new i.Sense EC.W sensor makes more system availability even more cost-effective than 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 starting around $500. 

For this purpose, the service life sensor is installed on one of the last crossbars on the fixed end side and records the current condition of the chain side parts with sensor technology from the in-house igus 3D printing; either directly for the PLC system control or via optional i.Cee module for comprehensive monitoring systems. This means that i.Sense EC.W makes it easier to avoid downtime and increase system availability. 

Part number: IS.EC.W.FIX.E4.XX.BETA 
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Tech up

Tech up

  • Cable-based condition monitoring for gliding e-chain® applications
  • Direct connection via potential-free contacts to the plant control system (PLC)
  • Suitable for harsh, dark, or dirty environments
  • In many cases, no additional cable routing in the e-chain® is necessary
  • Comprehensive connectivity for integration into predictive maintenance concept with i.Cee
Cost down

Cost down

  • 80% cost reduction with a direct connection to the plant control system
  • Maintenance cost reduction thanks to predictive maintenance recommendations
  • Avoidance of unplanned downtime thanks to condition-based alarm messages


  • If there is a direct connection to the PLC customer control system, the switch cabinet module can be eliminated
  • Ongoing test series in the industry's largest test laboratory  for dynamic power transmission systems


  • Minimal material requirements for the integrated sensor
  • Condition-based maintenance avoids unnecessary or premature chain replacement

With the optional use of the i.Cee module, the new i.Sense EC.W service life sensor can also be connected to a wide range of IoT systems or online dashboards.

Predictive maintenance implemented successfully

Industry 4.0: i.Cee in practice

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


Avoid downtimes, extend service life

i.Cee in a train washing station i.Cee gives CFL a system service life estimate, taking into account condition monitoring data such as temperature, travel speed, and distance travelled and provides maintenance and inspection instructions.

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:

When do I need a smart service life sensor like the i.Sense EC.W?

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 ...

Lifelong condition monitoring

EC.W LoRa Solar separator with solar power supply

No more battery changes. The sliding feeder's abrasion condition is communicated with the LoRa radio transmission standard to i.Cee:box or i.Cee:plus.
Energy is supplied from the solar panel.  Graduated percentage service life information is provided across four sensor layers.
More about the EC.W LoRa solar sensor
In open environments, the EC.W solar sensor is a good choice.

Integration into your network environment

Since the new EC.W sensor is part of the smart plastics i.Sense condition monitoring system, all of its data can also be evaluated in the i.Cee control cabinet module. These data can then be used to digitally control the system's alarm and escalation management. 

The i.Cee module can be integrated into predictive maintenance concepts in a number of ways, from preventive service management, which schedules regular maintenance depending on use, to location-independent fault management, which immediately reports any unforeseen change via various mobile channels. All information is collated in a modern dashboard, online or offline in the local network, depending on the customer's requirements.

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

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The terms "igus", "Apiro", "chainflex", "CFRIP", "conprotect", "CTD", "drylin", "dry-tech", "dryspin", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-skin", "e-spool", "flizz", "ibow", "igear", "iglidur", "igubal", "kineKIT", "manus", "motion plastics", "pikchain", "plastics for longer life", "readychain", "readycable", "ReBeL", "speedigus", "triflex", "robolink", "xirodur", and "xiros" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries.

igus® GmbH points out that it does not sell any products of the companies Allen Bradley, B&R, Baumüller, Beckhoff, Lahr, Control Techniques, Danaher Motion, ELAU, FAGOR, FANUC, Festo, Heidenhain, Jetter, Lenze, LinMot, LTi DRiVES, Mitsibushi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention in this website. The products offered by igus® are those of igus® GmbH

igus inc headquarters is located at 257 Ferris Ave, Rumford, RI 02916. igus enjoyneering center is located at 2055 Franklin Rd, Bloomfield Twp, MI 48302