Extremely light, but always monitoring ... now also for fixed flange bearings with i.Sense igubal®

The intelligent fixed flange bearing from smart plastics constantly monitors the condition of the bearing point and immediately reports the first signs of wear in order to avoid serious bearing damage.

i.Sense igubal® sensor The i.Sense igubal® sensor in practical use in the gearbox of Luxembourg's largest train washing station.
The CFL train washing station uses igus® energy chains and igubal® fixed flange bearings in the washing trolleys. Previously used metal bearings have been replaced with plastic bearings to reduce maintenance requirements. A "smart" bearing that monitors condition is being tested to prevent unforeseen damage. The aim is to receive an immediate notification if the bearing properties deteriorate. This is intended to prevent expensive disruptions and failures.

The CFL's maintenance manager, Mike Feinen, emphasises the importance of avoiding downtime, as this is costly and the contracts call for regular cleaning of the trains. Failure to comply will result in penalties. In collaboration with igus®, a solution was found to ensure optimal performance of the system. After initial adjustment problems, the system now runs smoothly and the smart fixed flange bearing has saved a lot of maintenance time.
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Tech up

Tech up

  • Continuous condition monitoring of heavy-duty two- and four-hole fixed flange bearings 
  • Early anomaly detection
  • Comprehensive connectivity for optional integration into the predictive maintenance concept with i.Cee
Cost down

Cost down

  • Identical design can replace metallic counterparts 1:1
  • Avoidance of unplanned downtime thanks to condition-based alarm messages


  • First successful pilot application on site at customer CFL in Luxembourg 
  • Ongoing test series in the industry's largest test laboratory  for high-performance polymers


  • Minimal material requirements for the integrated sensor
  • Use-based product replacement reduces unnecessary material costs

Feinen, Habering Mike Feinen and Richard Habering

Intelligent condition monitoring implemented successfully

i.Sense from smart plastics 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, the capability of guiding all different cables and hoses in a single system, intelligent i.Sense condition monitoring … I would definitely choose the intelligent igus energy chains again!"

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

Customer applications worldwide

Overview of i.Sense examples Whether in international automotive production, the global crane industry or regional wastewater plants: i.Sense systems are successfully used and maintenance costs are saved and machine downtime prevented.

To the application overview

When do I need a smart condition sensor like the i.Sense igubal?

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 ...

Live condition monitoring in every bearing

i.Sense BRG for everyone

A defective bearing point can ruin the day, not only for farmers, but for any machine operator. Machine failures and downtimes are among the biggest cost drivers in industry. It is therefore important for maintenance personnel to act in good time to prevent unplanned stoppages.

igus smart bearing products are great for especially sensitive or hard-to-reach spots on a machine, since they allow the bearing's condition to be assessed at any time. The sensor can be used to monitor each machine wear part remotely – and this could benefit many other motion plastics applications in the future.
There are no limits to the application possibilities for the new mini-sensor.

Integration into your network environment

Since the new i.Sense BRG mini-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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