Connectivity, automation, artificial intelligence: Industry 4.0 technologies are driving productivity, flexibility, and device security around the world. That’s why igus has been investing in R&D and innovation for years in “smart plastics” – plain bearings, tow chains and cables equipped with sensors and integrated into the Internet of Things.

Intelligent predictive maintenance software calculates the optimal maintenance time and alerts technicians in time via email and text messages in the event of a critical situation to avoid costly system failures. Portuguese company Atronia Tailored Sensing has been working on these smart plastics as a partner for about five years. The company’s sensor technology can monitor the current state of igus products, that is, teach them the ability to sense.

1756-OB16IS Scale production of sensor products for Industry 4.0

In March 2024, igus acquired a majority stake in Portugal’s Atronia Tailored Sensing company.

“By acquiring Atronia, we can better align the processes, systems and teams of both companies, which will lead to long-term synergies and efficiencies.” “This allows us to start mass production of our Industry 4.0 products and make them available to small and medium sized businesses with limited budgets and less experience,” said Michael Blass, CEO of igus Tow Chain Systems.

Carlos Alexandre Ferreira, head of Atronia Tailored Systems, added: “The acquisition of Atronia by igus is a promising collaboration that will undoubtedly lead to more breakthrough innovations and a higher level of technology integration.”

First joint product: towing chain service life sensor

igus and Atronia met in proximity to each other at the Sensors & Test & Measurement Exhibition 2019 in Nuremberg, Germany.

“After initial technical exchanges, it quickly became clear that the two companies’ vision for accessible Industry 4.0 was aligned.” Richard Habering, head of igus’ smart Plastics business unit.

1756-OB16IS Thus came the first joint project between the two companies: a sensor called EC.W (the electronics of the sensor were developed in part by Atronia), which can be installed on the cross bar of the tow chain to monitor the operating status and remaining service life of the sliding surface of the side plate of the tow chain. At just €259, this sensor is significantly lower than other predictive maintenance products on the market (prices vary by country).

“Customers have been very positive about this cost-effective and intuitive sensor.” “So we decided to go further with Atronia,” Habering said. Currently, the company has produced hundreds of I.EE series modules for igus in Portugal.

With these modules, users can analyze sensor data from anywhere in the world via connected panels, maximizing product life and better planning maintenance. “We look forward to continuing to work with sensor specialist Atronia to deliver more ground-breaking innovations in the future.”