Networking, automation, artificial intelligence: Industry 4.0 technology is leading to greater productivity, agility and plant safety worldwide. Igus has therefore been investing in research and development for years in order to develop new types of smart plastics - plain bearings, energy chains and cables that are equipped with sensors and integrated into the Internet of Things. Intelligent predictive maintenance software then calculates optimal maintenance times and alerts technicians in good time via email and text message in the event of critical conditions in order to prevent expensive system failures. The Portuguese company Atronia Tailored Sensing has been a cooperation partner in the development of these smart plastics for around five years. The sensor specialist ensures that the actual condition of Igus products is determined. It teaches them how to feel.

"The aim of the strategic decision is to mass-produce sensor products for the Industry 4.0 era"

"By acquiring Atronia, we can coordinate the processes, systems and teams of both companies even better, which will lead to synergies and efficiency gains in the long term," says Michael Blass, Managing Director of Igus e-kettensysteme. "This will enable us to mass-produce products for the Industry 4.0 era and make them accessible to small and medium-sized companies with limited budgets and little previous experience." Carlos Alexandre Ferreira, Manager at Atronia Tailored Systems, adds: "The acquisition of Atronia by Igus is a promising partnership that will undoubtedly lead to further breakthrough innovations and improved technology integration."

Lifetime sensor for energy chain

Igus and Atronia got to know each other in 2019 as stand neighbors at the Sensor + Test trade fair in Nuremberg. "After initial technical discussions, it quickly became clear that both companies had the same vision of a barrier-free Industry 4.0," says Richard Habering, Head of the smart plastics business unit at Igus. This led to the first joint project. Atronia built the electronics for a sensor called EC.W. Mounted on the opening bars of energy chains, the sensors record the actual condition and the remaining service life of the chain side parts. The sensor was launched on the market for just 259 euros - a fraction of the cost of commercially available predictive maintenance systems. "Customer feedback on the cost-effective and intuitive sensor solution was excellent," says Habering. "We therefore decided to intensify our collaboration with Atronia." The company now manufactures several hundred modules from the i.Cee series from Igus in Portugal. The modules make it possible to evaluate sensor data from anywhere in the world using a web-based dashboard, exploit the maximum service life of products and optimally plan maintenance operations. "We are looking forward to working with the Portuguese sensor experts in the future and are excited about further future-oriented products together."