Small but mighty ... the easiest entry into the world of sensors

smart plastics DIY tools: With the new low-cost sensor technology, you can now independently measure moving applications and drive data-supported product or process improvements - Tech up. Cost down.

smart plastics DIY tools Travel measuring sensor, rotary sensor, climate sensor ... the world of low-cost sensor technology from igus is large.
In modern industry, sensors have become indispensable as data sources. With smart plastics, we have been consistently going in this direction for almost 10 years and develop new, intelligent monitoring systems for energy supply systems, cables and linear guides every year. Now we want to give even more users access to this and are entering the world of low-cost sensor technology with our smart plastics DIY tools. These combine numerous different types of sensors for measuring moving applications under one roof and enable the user to optimise their application with the help of data. These include, a.o. various travel measuring systems, rotary sensors and matching microcontrollers for direct data evaluation on site. 
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Tech up

Tech up

  • Data-based product and process quality improvement
  • Direct connection via potential-free contacts to plant control system (PLC)
Cost down

Cost down

  • Cost-effective and easy entry into the sensors world; also suitable for DIY applications
  • Avoidance of unplanned downtimes through condition-based data streams




  • Low-cost sensors save expensive product development effort
  • Condition-based maintenance avoids unnecessary or premature product replacement

Current overview of DIY tools:

SMA DIY Tools rotary sensor

Rotation sensor

  • Application: Measurement of the extension length
  • Part No.: IS.DY.T.9U.01.BETA
  • Sensitivity: 9 revolutions
  • Output signal: 4-20mA
SMA DIY Tools travel measuring system

Linear sensor

  • Application: Position detection / path measuring system on 10mm perforated rail
  • Part No.: IS.DY.L.D.01.BETA
  • Output signal: TTL 5V
  • Voltage: 5V DC
SMA DIY Tools microprocessor

Communication module

  • Application: Data distribution
  • Part No.: IS.DY.ESP.08.01.0.BETA
  • Hardware: ESP 32 microprocessor
  • Output signal: TTL 5V
  • Connectivity: WiFi, NBlot, USB, M8
SMA DIY tools

Rotation sensor

  • Application: Measurement of rotary movements
  • Part No.: IS.DY.T.29PP.01.BETA
  • Sensitivity: 29 increments
  • Output signal: TTL 5V
SMA DIY tools

Linear sensor

  • Application: Position measuring system for linear guides
  • Part No.: IS.DY.L.D.01.BETA
  • Output signal: TTL 5V
SMA DIY tools

Industrial PC

  • Application: Data evaluation and processing
  • Part No.: IS.PLUS.01.50.0.BETA
  • Hardware: Rasperry 4
  • Software: Raspian
  • Connectivity: WiFi, LAN, USB, M8

IoT expert Richard Habering explains the use and benefits of the new low-cost sensor technology using a mini wear sensor.

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

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
Download the smart plastics brochure

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