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Detect cable stress early on ... better and more accurately than ever before

NEW with optical condition display: The i.Sense CF.D module detects transmission problems early on if bus cables are heavily stressed; for the first time, it determines the distance to the risk area.

Until now, there have often been only two options for servicing and maintaining cables that are subject to high mechanical stress: either these are only replaced reactively when they are already defective or cables that are still functional are replaced at certain intervals as a precaution.
The new smart plastics i.Sense CF.D module provides the first real alternative: Predictive maintenance of data, bus, or Ethernet cables by intelligently monitoring data transmission quality during operation. i.Sense CF.D monitors the performance of heavily stressed, failure-prone Ethernet cables at all times, showing the current status directly on the new multifunction module. In addition, the distance to the identified risk area of the cable is determined for the first time ever, avoiding lengthy, costly troubleshooting. You too can plan your next optimal maintenance and benefit from smart plastics predictive maintenance. 
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Tech up

Tech up

  • Monitoring data transmission quality 
  • Determine the distance to the overstressed area of the cable 
  • Multi-function switch cabinet module with OLED display for key cable parameters
Cost down

Cost down

  • Condition display without additional tools or software costs
  • No time-consuming troubleshooting thanks to the distance meter
  • Indicator for timely cable replacement – prevent unplanned plant shutdowns


  • Ongoing test series in the industry's largest test laboratory  for dynamic cable applications


  • No extra cores needed
  • Condition-based maintenance avoids unnecessary or premature product replacement

The video explains simply how cable monitoring with i.Sense CF.D works:

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 cable condition monitoring in use "The machine works with really high stroke rates, so we needed cables with high flexural strength. We also had to find a predictive warning system to keep this machine, with its high output, from breaking down, which would be costly."

Dipl.-Ing. Oliver Tausch, Head of Electrical Engineering, GHD Georg Hartmann Maschinenbau 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 cable condition monitoring system like i.Sense CF.D?

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 ...

Further smart solutions for cable monitoring

Condition monitoring (i.Sense) with chainflex cables requires no additional module. The system can be integrated and networked without additional software. In these cases, cables provide three options for condition monitoring. 
  • Cable push/pull force measurement (CF.P)
  • Cable electrical property measurement (CF.Q)
  • Transmission quality measurement (CF.D)


  • Condition monitoring
  • measures pull forces acting on cables
  • If there is a fault, the contact closes, and a notification is sent to the machine


  • Condition monitoring 
  • Indicates changes in the electrical properties
  • If there is a fault, notification is with contact and a signal

Integration into your network environment

As part of the smart plastics i.Sense condition monitoring system, the i.Sense CF.D generates data that can be evaluated in the i.Cee switch cabinet module, so the system's entire alarm and escalation management can be controlled digitally. 

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
Download the smart plastics brochure

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The terms "Apiro", "AutoChain", "CFRIP", "chainflex", "chainge", "chains for cranes", "ConProtect", "cradle-chain", "CTD", "drygear", "drylin", "dryspin", "dry-tech", "dryway", "easy chain", "e-chain", "e-chain systems", "e-ketten", "e-kettensysteme", "e-loop", "energy chain", "energy chain systems", "enjoyneering", "e-skin", "e-spool", "fixflex", "flizz", "i.Cee", "ibow", "igear", "iglidur", "igubal", "igumid", "igus", "igus improves what moves", "igus:bike", "igusGO", "igutex", "iguverse", "iguversum", "kineKIT", "kopla", "manus", "motion plastics", "motion polymers", "motionary", "plastics for longer life", "print2mold", "Rawbot", "RBTX", "readycable", "readychain", "ReBeL", "ReCyycle", "reguse", "robolink", "Rohbot", "savfe", "speedigus", "superwise", "take the dryway", "tribofilament", "triflex", "twisterchain", "when it moves, igus improves", "xirodur", "xiros" and "yes" are legally protected trademarks of the igus® GmbH/ Cologne in the Federal Republic of Germany and where applicable in some foreign countries. This is a non-exhaustive list of trademarks (e.g. pending trademark applications or registered trademarks) of igus GmbH or affiliated companies of igus in Germany, the European Union, the USA and/or other countries or jurisdictions.

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, Mitsubishi, NUM,Parker, Bosch Rexroth, SEW, Siemens, Stöber and all other drive manufacturers mention on this website. The products offered by igus® are those of igus® GmbH