igus launches new TR.P sensor to prevent costly robot downtime in automotive production

SINGAPORE - Feb. 4, 2026 - PRLog -- Unplanned downtime in automated manufacturing can lead to significant losses—especially in the automotive industry. To address this challenge, igus has introduced the new TR.P sensor, a smart monitoring solution for triflex® energy chain systems used on industrial robots. The technology continuously measures tensile forces on the robot head and reacts instantly when critical thresholds are exceeded, helping prevent damage and increasing operational safety. igus will showcase the innovation at SPS in Nuremberg (Hall 4, Stand 310).

Industrial robots rely on triflex 3D energy chains and chainflex® cables to ensure safe movement under extreme torsion and tension. "A single robot failure can cost an automotive plant €600 per second," says Richard Habering, Head of smart plastics at igus. "With the TR.P sensor, we can detect dangerous loads early and take immediate action—such as alerting operators or stopping the robot."

The TR.P system is especially valuable during robot commissioning. By analysing movement patterns, it helps identify issues such as excessive bending, overextension or jamming before they lead to failures. It complements the existing TR.B breakage detection system, which has been in use globally since 2022. TR.B identifies chain link breakage through rope length changes and sends a direct signal to the plant control system without extra hardware or complex programming.

igus also supports customers through its superwise after‑sales service, which integrates i.Sense condition monitoring with predictive maintenance. By securely linking sensor data to igus systems, the service team can offer proactive recommendations, schedule inspections and streamline replacement orders—helping customers reduce downtime and extend machine life without major investment.

Learn more about the TR.P at https://www.igus.eu/smart-maintenance/condition-monitorin...