Balluff Product News - Spring 2012

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Benefit from our comprehensive system competence, let us make you aware of new high-performance products that constant progress brings.

Benefit from our comprehensive system competence, let us make you aware of new high-performance products that constant progress brings.

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  • 1. sensors worldwideProducts +NewsSuperior quality for efficient automation
  • 2. object detection sensors worldwidemechanical multiple position switchesinductive sensorsphotoelectric sensorssensors for pneumatic cylinderscapacitive sensorsultrasonic sensors
  • 3. Ultra-high temperature-resistant sensors worldwide single and multiple position switches BNSStays cool, even if things are getting too hotThe ultra-high temperature-proof single and multiple position switches can be used fortemperatures up to 180 C, require little space and feature a robust die casting housing.They are the perfect solution for harsh environments in die construction, plastic and steelindustry.+23…356 F -5…+180 C High Temperature
  • 4. Ultra-high temperature-resistant sensors worldwidesingle and multiple position switches BNS
  • 5. Inductive Sensors BES 8x8 mm Shorties sensors worldwide The sensors with the miniature dimensions Thanks to miniature frame size, position sensing is now possible where there was never space for a sensor before Assemblies can be smaller, since the sensors require less space Ideal price/performance ratio Robust through high-quality metal enclosure High functional reserve through increased switching distance Common application examples  Linear units  Robotics and automation  Vibrating conveyor
  • 6. Inductive Sensors BES 8x8 mm Shorties sensors worldwideThe sensors with the miniature dimensions
  • 7. Pressure-resistant Inductive Mini Sensors sensors worldwidePowerful M5 sensors up to 100 bar Pressure-resistant inductive Mini Sensors  Mini design M5  For pressure-resistant applications up to 100 bar  Ideal price/performance ratio Application Areas  Coolant/lubricant sector  Laboratories  Low-pressure hydraulic systems  Valves  Pneumatic systems  Industrial cleaning  Special machine construction
  • 8. Pressure-resistant Inductive Mini Sensors sensors worldwidePowerful M5 sensors up to 100 bar
  • 9. Weld Immune Factor 1+ Sensors sensors worldwideA plus for your application A plus for your application  Greater switching distances for increase performance  Saves time during installation because adjustments are minimized  Greater reliability, even if the detected objects vibrate  Housing and sensor identification optimized to meet requirements in the automobile industry  Ideal for applications with variable detection objects (steel, AL, CuZn, and Cu) Application Areas  Welding lines  Lightweight construction  Automobile suppliers  Material handling technology  Electric motors and electric brakes  Special machine construction
  • 10. Weld Immune Factor 1+ Sensors sensors worldwideA plus for your application
  • 11. For applications up to +160 F sensors worldwide Ultra-high temperature-resistant inductive sensorsThe ultra-high temperature-resistant inductive sensors can be used in temperatureranges up to +160 C. These sensors are ideally suited to harsh environments in thesteel industry, in plastic injection molding machines and in forging and foundry processes.  Reduction in maintenance costs  Increase in process quality
  • 12. For applications up to +160 F sensors worldwideUltra-high temperature-resistant inductive sensors
  • 13. Sensors for the Food Industry sensors worldwide New inductive Proxinox sensors Designed for wet and washdown conditions Resistant to aggressive cleaning agents Ecolab and FDA compliant Extended temperature ranges Steam jet tested!
  • 14. Sensors for the Food Industry sensors worldwideNew inductive Proxinox sensors
  • 15. Inductive Q40 Block Sensors with Corner LEDs sensors worldwideOptimized for material handling technology applications Compact sensor designs with long switching distances are required in material handling technology. In addition, the switching and operating state of the sensor can be identified from far away. Housing optimized for material handling technology  Highly visible corner LEDs  Sensor head can be mounted in five positions  Connector outlet set to position within a 270 range Factor 1 sensors are the first choice for welding applications because they have a Teflon-coated sensing face and are immune to magnetic fields.
  • 16. Inductive Q40 Block Sensors with Corner LEDs sensors worldwideOptimized for material handling technology applications
  • 17. Inductive Ring Sensors BES IKVS sensors worldwide Optimal for automated sensing Easy installation (since they can be mounted side-by-side and universally installed, stacked with a spacing of > 20 mm) Very reliable (due to inductive sensor principle) Optimal for the detection of small parts (with integrated pulse extension, permanently set)Applications Detection of nails, screws, welded studs, rivets or similar Ejection monitoring Part counting Wire-breakage monitoring Nail machines for pallet manufacturing Infeed monitoring in assembly technology Jam detection in feed tubes
  • 18. Inductive Ring Sensors BES IKVS sensors worldwideOptimal for automated sensing
  • 19. Inductive Tube Sensors BES Z06K sensors worldwideFast and easy to install Inductive tube sensors complement the line of ring sensors. Optimized for tube infeeds in automated assembly, they detect small parts easily and reliably.  Simple attachment to infeed tube  Pulse extension of 150 ms results in a reliable detection of fast-moving parts  Object speed max. 20 m/z
  • 20. Inductive Tube Sensors BES Z06K sensors worldwideFast and easy to install
  • 21. Reliable Transparency Detection sensors worldwide BGL Laser Fork Sensors Reliable detection of transparent objects Rigid one-piece construction – always in alignment, easy to install, eliminates the hassles associated with setting up thru-beam sensors Maximum reliability – simple installation Balluff BGL laser fork sensors ensure completely reliable detection of transparent objects. These sensors also provide the unsurpassed advantages offered by all of Balluff’s fork sensors: the transmitter and receiver do not need to be aligned. The rugged metal housings contain both the emitter and receiver with pre-aligned optics. This aids in installation, reduces mechanical setups, and ends misalignment nuisances.
  • 22. Reliable Transparency Detection sensors worldwideBGL Laser Fork Sensors
  • 23. Fork Sensors for Fluid Detection sensors worldwide Reliable level detection through transparent container walls  Detect fluids with a water content > 15%  Detection independent of color  Sensor can be taught to ignore thin film fluid buildup on container wallsBalluff has widened its scope ofexpertise in through-beam forksensors by offering sensors forfluid detection. Detect the levelof clear, colored, or opaque fluidswith a water content > 15%through transparent containerwalls.
  • 24. Fork Sensors for Fluid Detection sensors worldwideReliable level detection through transparent container walls
  • 25. Reliable Web Edge Control sensors worldwide BGL fork sensors: analog array edge postion monitoringIn-process monitoringAbsolute position detection based on how faran object enters/blocks the sensor’s detectionbeam. For applications that require exactposition measurement with either the 30 mm or50 mm sensing window and the 54 mmmeasuring area thick or thin objects or materialin continuous webs can be detected to aresolution of 0.08 mm.Technical highlights Excellent resolution and repeatability Configurable digital and analog outputs Up to 4 selectable switch pointsDetection and compensation of contaminationIntegrated air nozzle designed to prevent dust anddebris from accumulating on optical elements.
  • 26. Reliable Web Edge Control sensors worldwideBGL fork sensors: analog array edge postion monitoring
  • 27. BOS 08E Photoelectric Sensors sensors worldwide Background suppression in a minature formatThe proven BOS 08M family now has a new member. forthe first time, background suppression with adjustablesensing range is available in this very compact design.Thanks to the innovative PinPoint technology, it provides avery sharp and homogeneous red light spot which can beused for reliable detection of the smallest parts up to asize of 0.5 mm. If you do not require an adjustment to thesensor, background suppression permanently calibratedto a sensing range of 20 mm is also available.Technical highlights Background suppression (BGS) permits versatile use Precise, almost color-independent object detection up to 30 mm Bright, sharply contoured light spot aids alignment Simple and fast setting with potentiometer Extra short housing for simple and space-saving assembly New: Housing made of 1.4404 (316L) stainless steel for extended application areas
  • 28. BOS 08E Photoelectric Sensors sensors worldwideBackground suppression in a minature format Accessories  Clamping block BES 08,0-KB-3, plastic (ordering code: BAM00A5)  Clamping block BES 08,0-KB-7, aluminum (ordering code: BAM00AA)  Mounting clamp BES 08,0-BS-1, plastic (ordering code: BAM00A2)  Retaining bracket BES 08-HW-1, for surface assembly 90 , aluminum (ordering code: BAM009U)  Sensor holder BMS CS-P-D12-AD08-00, for Balluff mounting system, 90 angle, plastic (ordering code: BAM002K)  Sensor holder BMS CS-M-D12-ID08-01, for Balluff mounting system, 90 angle, stainless steel (ordering code: BAM0036)  Connector BCC M313-0000-10-001-PX0334-020, M8 straight, 3-pin, 2 m PUR cable (ordering code: BCC02M8) Further accessories upon request.
  • 29. Red Light and Laser Thru-beam Sensors BOS Q08M sensors worldwide Extreme accuracy in a compact, high-performance designReliably detect the smallest partsBalluff thru-beam sensors BOS Q08M are innovative, compact products that reach a high level ofperformance. The BOS Q08M sensors offer right angle thru-beam sensing. Nothing else producescomparable results under similar conditions. These compact and rugged sensors are designed to beinstalled and operated in tight spaces. Compact design for limited space Rugged metal housing Reliable detection of small parts up to 0.4 mm (PinPoint red light) or 0.28 mm (laser) Patented mounting concept for Bosch profiles that allows quick, precise positioning
  • 30. Red Light and Laser Thru-beam Sensors BOS Q08M sensors worldwideExtreme accuracy in a compact, high-performance design
  • 31. BOS Q08M Diffuse Sensor with Fixed Background Suppression sensors worldwideQuick Installation Rapid application - high reliability Only Balluff offers the powerful combination of fixed background suppression and homogeneous red light through innovative PinPoint technology. All of this is integrated into a compact design, enabling simple installation in even the most confined spaces.
  • 32. BOS Q08M Diffuse Sensor with Fixed Background Suppression sensors worldwideQuick Installation A new, patented mounting bracket also ensures flush installation in aluminum profiles. For Bosch profile: BES Q08-KH-3
  • 33. Photoelectric Sensors M18 sensors worldwide BOS 18M background suppression expertiseBalluff M18 laser diffuse sensors with background suppression are Technical highlightsavailable with different light types, allowing you to simply select a  Exact, almost color-independent object detectionsensor according to your requirements. The perfectly focused light  For every application the correct light type – laser or red lightbeam is able to detect the smallest of parts, grooves or holes with  Precise setting with 10-turn potentiometermaximum precision and reliability. The large light spot of the red light  Robust M18 metal housing with same design for all typesvariant with 300 mm is ideal for detecting objects with notches, holes  universal fastening and alignment thanks to wide range ofor openings. installation accessoriesHigh-precision distinction between foreground and background atextremely short distances – the 150 mm red light version is ideal inthis case.
  • 34. Photoelectric Sensors M18 sensors worldwideBOS 18M background suppression expertise Accessories  Clamping block BOS 18,0-KB-1 with ball joint, plastic (ordering code: BAM00T3)  Sensor holder BMS CS-P-D12-AD18-00 for Balluff mounting system, 90 angle, plastic (ordering code: BAM002P)  Sensor holder BMS CS-M-D12-ID18-01, for Balluff mounting system, 90 angle, stainless steel (ordering code: BAM0032)  Adjusting unit BMS AD-M-002-D12/D18 for Balluff mounting system, for fine adjustment (ordering code: BAM0038)  Connector BCC M415-0000-1A-003-PX0434-020, M12 straight, 2 m PUR cable (ordering code: BCC032F) Further accessories upon request.
  • 35. Photoelectric Sensors M18 BOS 18M GlobalEye – reliable and cost-effective sensors worldwideWe often come across systems in which a sensor adjustment is not Technical highlightsrequired, not possible or is undesirable. Our BOS 18M diffuse  Reliable performance and object detectionsensors and light barriers from the GlobalEye family are the correct  Ideal for standard applications, e.g. in automationchoice for these applications. All of these sensors have a fixed  Cost-effective alternative for all types of lightsetting. This shortens the time required for system commissioning  Plug and play: All sensors with fixed settingand protects against manipulation. Equipped with a wide range of  Easy installation thanks to wide range of accessoriesfunctions, these sensors also have the best possibleprice/performance ratio.
  • 36. Photoelectric Sensors M18BOS 18M GlobalEye – reliable and cost-effective sensors worldwide Accessories  Reflector BOS R-1, round, dia. 84 mm (ordering code: BAM00UK)  Reflector BOS R-9, 50x50 mm (ordering code: BAM00WL)  Clamping block BOS 18,0-KB-1, with ball joint, plastic (ordering code: BAM00T3)  Mounting clamp BES 18,0-BS-1, plastic  (ordering code: BAM00F2)  Retaining bracket BES 18-HW-1, angle for surface assembly 90 , aluminum (ordering code: BAM00EY)  Sensor holder BMS CS-P-D12-AD18-00, for Balluff mounting system, 90 angle, plastic (ordering code: BAM002P)  Sensor holder BMS CS-M-D12-ID18-01, for Balluff mounting system, 90 angle, stainless steel (ordering code: BAM0032)  Connector BCC M415-0000-1A-003-PX0434-020, M12 straight, 2 m PUR cable (ordering code: BCC032F) Further accessories upon request.
  • 37. Photoelectric Red Light Sensors M18 sensors worldwideFor maximum precision Precise switching response – excellent repeat accuracy Cutting-edge LED technology and the latest Fresnel lenses are combined in this unit to form an innovative and powerful photoelectric sensor. In practice this means reliable background suppression, improved repeat accuracy and a precise switching response even at large distances. Technical highlights  Large operating range  Rugged M18 metal housing  State-of-the-art LED technology with sharply contoured light spot
  • 38. Photoelectric Red Light Sensors M18 sensors worldwideFor maximum precision
  • 39. Photoelectric Sensors M18 sensors worldwide BOS 18M infrared – invisible powerThe successful BOS 18M series now includes invisible infrared  Reliable object detection even in a contaminated environmentlight. This type of light demonstrates its advantages particularly  Invisible light – does not irritate personnelin heavily contaminated production environments: objects are  Simple and fast setup with potentiometerreliably detected regardless of dust or dirt. With its range of 100  Through-beam sensor with test input for function controlmeters, the high-power version of the through-beam sensor  Wide range of assembly accessoriesexcels in this area. The standardized design of all BOS 18Mspermits a simple change between the different types of light –without changing brackets.
  • 40. Photoelectric Sensors M18 sensors worldwideBOS 18M infrared – invisible power Accessories  Reflector BOS R-1, circular, dia. 84 mm (ordering code: BAM00UK)  Reflector BOS R-9, 50x50 mm (ordering code: BAM00WL)  Clamping block BOS 18,0-KB-1, with ball joint, plastic (ordering code: BAM00T3)  Mounting clamp BES 18,0-BS-1, plastic (ordering code: BAM00F2)  Retaining bracket BES 18-HW-1, angle for surface assembly 90 , aluminum (ordering code: BAM00EY)  Sensor holder BMS CS-P-D12-AD18-00, for Balluff mounting system, 90 angle, plastic (ordering code: BAM002P)  Sensor holder BMS CS-M-D12-ID18-01, for Balluff mounting system, 90 angle, stainless steel (ordering code: BAM0032)  Connector BCC M415-0000-1A-003- PX0434-020, M12 straight, 2 m PUR cable (ordering code: BCC032F) Further accessories upon request.
  • 41. Photoelectric Sensor with Additional Diagnostics sensors worldwideBOS 18M Teach-in For users who prefer the teach-in procedure for sensor setting, Balluff now offers its successful red light series BOS 18M, with long ranges, precise switching behavior and very high levels of repeat accuracy. the top sensor in its class is quickly set at the push of a button. Further advantage: The BOS 18M teach-in reports "difficulties" immediately by means of our patented diagnostic system "Dynamic Sensor Control", which is available as an option. The DSC allows you to react immediately to contamination or malfunctions. Even users without DSC can make use of the contamination detection as the sensors are also optionally available with a separate alarm output.  Continuous sensor monitoring of contamination and malfunctions  Switchable output  Simple teach-in procedure  Standardized BOS-18M design for fast sensor change
  • 42. Photoelectric Sensor with Additional Diagnostics sensors worldwideBOS 18M Teach-in Accessories  Reflector BOS R-1, circular, dia. 84 mm (ordering code: BAM00UK)  Reflector BOS R-9, 50x50 mm (ordering code: BAM00WL)  Clamping block BOS 18,0-KB-1, with ball joint, plastic (ordering code: BAM00T3)  Mounting clamp BES 18,0-BS-1, plastic (ordering code: BAM00F2)  Retaining bracket BES 18-HW-1, angle for surface assembly 90 , aluminum (ordering code: BAM00EY)  Sensor holder BMS CS-P-D12-AD18-00, for Balluff mounting system, 90 angle, plastic (ordering code: BAM002P)  Sensor holder BMS CS-M-D12-ID18-01, for Balluff mounting system, 90 angle, stainless steel (ordering code: BAM0032)  Connector BCC M415-0000-1A-003-PX0434-020, M12 straight, 2 m PUR cable (ordering code: BCC032F) Further accessories upon request.
  • 43. New Photoelectric Sensors BOS 23K sensors worldwide Red light and laser provide a competitive edge Accurate switching characteristics for precision positioning tasks High ranges and compact design for greater freedom of system design Highly visible red light/laser light for precision alignment LEDs visible from all sides Varied mounting options Laser variants ideal for small part detection Outstanding price/performance ratio
  • 44. New Photoelectric Sensors BOS 23K sensors worldwideRed light and laser provide a competitive edge
  • 45. New Photoelectric Sensors BOS 50K sensors worldwide Even longer ranges with red lightThe new sensors in the BOS 50K series combine topperformance and compact dimensions. Thanks to their longrange, these sensors are suitable for use in numerousindustries: from the automobile industry to the woodworkingindustry.  Reliable object detection even at long distances  Real background suppression up to 2m sensing range even on dark objects  Simple alignment with to bright, clearly visible beam spot  Simple and fast setting with potentiometer  Through-beam sensor with test input for function control  Varied and timesaving assembly options
  • 46. New Photoelectric Sensors BOS 50K sensors worldwideEven longer ranges with red light Accessories  Reflector BOS R-1, circular, dia. 84 mm (ordering code: BAM00UK)  Mounting bracket BMS CS-M-D12-BX07-06, for Balluff mounting system, 90 angle (ordering code: BAM01AY)  Assembly plate BMS CS-M-D12-BX05-02, for Balluff mounting system, straight (ordering code: BAM003C)  Mounting bracket BAM MB-XO-005-B04-4, angle for surface assembly 90 , adjustable sensor inclination (ordering code: BAM01E8)  Clamp holder BOS 21-KH-2, for fastening to dovetail (ordering code: BAM00TH)  Connector BCC M415-0000-1A-003- PX0434-020 M12 straight, 2 m PUR cable (ordering code: BCC032F) Further accessories upon request
  • 47. True-color Sensor BFS 33M sensors worldwide Distinguishes between different color shades Distinguishes between different color shades Large sensing range of 400 mm High degree of flexibility through fiber adaptation Simple configuration and visualization using software Robust metal housing Balluff has raised the bar in photoelectrics with the True-color Sensor BFS 33. The sensor succeeds where existing RGB sensors reach their limits by using the lab color space. The sensor can detect minute differences in color on injection molded parts and opens up a wealth of new possibilities in color detection. The sensor uses three digital outputs and a serial interface to perform evaluations. The lab color space values are transmitted directly via this interface.
  • 48. True-color Sensor BFS 33M sensors worldwideDistinguishes between different color shades
  • 49. Cylindrical magnetic Field Sensors for Long Operating Ranges sensors worldwide Miniature design, long switching distancesCylindrical magnetic field sensors are characterized by their  Non-contact position requests up to a distance ofsmall, extremely compact design. The new magnets with 90 mmcylindrical magnetic field sensors for position applications are  Object detection through non-metallic materialsideal for extremely long switching distances, which means that  Compact sensors and small magnets provide theyou can query positions up to 90 mm away using one sensor with perfect basis for installationa diameter of 6.5 mm without making contact. These sensors areindustrial grade and resistant to soiling. Positions can also beretrieved through containers or pipes because magnetic fields canpenetrate many non-metallic materials. The detection of codesusing magnets is also possible.
  • 50. Cylindrical magnetic Field Sensors for Long Operating Ranges sensors worldwideMiniature design, long switching distances
  • 51. Sensors for Pneumatic Cylinders sensors worldwide BMF 235Can be installed fromabove, easy to install withhexagon socket or slotscrewdriver
  • 52. Sensors for Pneumatic Cylinders sensors worldwide BMF 235 For other pneumatic cylinder sensors, please request a copy of our brochure"BMF magnetic field sensor product overview".
  • 53. Cylindrical Magnetic Field Sensors with Mounting System sensors worldwideNow even more flexible due to new mounting elements Increase of overall system effectiveness Remedy Autonomous Scheduled Training Preventative of key maintenance maintenance and training maintenance problems courses Total Productive Maintenance (TPM) Removal of key problems No unreliable switching, even under highest stress, due to highly precise GMR sensor elements and robust metal clamps. Autonomous maintenance Faster and safer sensor replacement using one sensor type for all grooves with retaining switching point. Scheduled maintenance program The wear-free, fully electronic sensors protect against creeping failure, even after several million switching cycles, thereby increasing your process reliability. Training and training courses Easy handling and reduced training effort due to one sensor type for all grooves with uniform operating principle of all mounting brackets. Maintenance prevention The costs for maintenance are already reduced to a minimum during the design with the consistent use of Balluff magnetic field sensors with mounting bracket concept.
  • 54. Cylindrical Magnetic Field Sensors with Mounting System sensors worldwideNow even more flexible due to new mounting elements
  • 55. Capacitive Mini Sensors BCS sensors worldwide Object detection in the smallest of spacesmini.s
  • 56. Capacitive Mini Sensors BCS sensors worldwide Object detection in the smallest of spacesmini.s
  • 57. Steelface Ultrasonic Sensors sensors worldwide For the most extreme applications in harsh environmentsBalluff has expanded its range of ultrasonic sensors to include a sensor in an enclosed stainless steelhousing in designs M30 1.5 and Ø 30 mm. The ultrasonic converter is protected by the metal wall toguarantee degree of protection IP 68/IP 69K for the first time and opens up a wealth of new possibilitieseven under the harshest ambient conditions. The robust stainless steel sensing surface protects thesensor against aggressive cleaning products such as those used in the packaging and food industry. Extremely rugged and reliable Large range up to 1.5 m High degree of protection IP 68/IP 69K
  • 58. New: Steelface Ultrasonic Sensors sensors worldwideFor the most extreme applications in harsh environments
  • 59. linear sensors worldwideposition sensing inductive positioning system magnetic linear encoder systems micropulse transducers
  • 60. High-pressure Inductive Sensors sensors worldwide Switching or analog up to 500 bar One design – two output models Applications areas Switching for extended and retracted position  Control of valves Analog for control of valves or immediate stop  Final position of installation supports Measurements of valves and cylinders possible  Service measurements of valves Ceramic coated sensing face – robust  Position monitoring in hydraulic systems Pressure rated up to 500 bar 500 bar
  • 61. High-pressure Inductive Sensors sensors worldwideSwitching or analog up to 500 bar
  • 62. Inductive Positioning System BIP sensors worldwide Linear position detection – reliable and accurate Absolute measuring principle, several measuring ranges, teachable High level of repeat accuracy and precision Optimal linearity and low temperature drift Optimized housing design for clamping distance monitoring The optimal sensor for Distance-proportional IO-Link output signal clamping distance monitoring Standard output 0...10 V, 4...20 mA Position sensor BIP in use at a drive spindle for tools.The inductive positioning system BIP is the accurate measuring system forthe position detection of metallic objects.ApplicationsThe main application area of the BIP is the linear position monitoringof drive spindles and clamping devices for tools and workpieces.
  • 63. Inductive Positioning System BIP sensors worldwideLinear position detection – reliable and accurate
  • 64. Inductive Positioning System BIP sensors worldwide Optimized effective length Absolute measuring principle, several measuring ranges, teachable High level of repeat accuracy and precision Wide working temperature range and low temperature drift Optimized housing design, degree of protection IP 67 Standard output 0…10 V, 4…20 mAThe inductive positioning system BIP is theaccurate measuring system for the positiondetection of metallic objectsApplicationsThese BIP positioning systems are ideal forintegrated production monitoring becausetheir unmatched effective length ratio makesinstallation in the tightest of applicationspossible
  • 65. Inductive Positioning System BIP sensors worldwideOptimized effective length
  • 66. Magnetic Linear Encoder System BML, guided sensors worldwide The solution for many applications Easy integration, even in existing systems Minimum space requirements Robust and lubricant-free design Standard connection via control arm Random side-by-side mountingApplicationsThe guided BML can be usedwherever long paths have to bemeasured, but without any preciseguidance by the machine.Examples: sheet metal presses,elevators, cutting installations,material handling technology.
  • 67. Magnetic Linear Encoder System BML, guided sensors worldwideThe solution for many applications
  • 68. Micropulse Transducers BTL5-CD sensors worldwide High-pressure transducers resistant to 1000 bar make it easy for the heavy-duty cylindersPositioning extremely heavy bridge sections accurateto the millimeterBridge sections are usually assembled on land to minimize the obstruction of shippingtraffic on rivers. After assembly, the sections are lowered horizontally onto floatingpontoons in the river, moved into place, raised to the future road level and secured inposition. Special heavy-duty hydraulic cylinders with integrated micropulsedisplacement systems guide the horizontal feed and vertical lifting movements. Theintegrated micropulse displacement systems ensure that the heavy bridge sections arepositioned synchronously and accurate to the millimeter. Applications Structural design and calculations  Active support of walls  Bridge positioning and lifting technology  Leveling structures  Off-shore sector  Tunnel construction Industry applications  Pumps and compressors  Lift and lifting technology  Forging presses  High-pressure hydraulics Features  For pressures up to 1000 bar  Measuring lengths 25...2000 mm  Resolution down to 1 μm  Degree of protection IP67/68  Temperature range –40...+85 C  Plug or cable variants  Multi-magnet technology
  • 69. Micropulse Transducers BTL5-CD sensors worldwideHigh-pressure transducers resistant to 1000 bar make it easy for the heavy-duty cylinders
  • 70. Micropulse Transducers BTL ProCompact sensors worldwide The cylinder feedback system for extreme environmentsMicropulse ProCompact with cable protection systemExtreme ambient conditions, in which high reliability together with accuracy is required, aretypical application areas for Micropulse ProCompact transducers.The non-contact operating principle ensures a complete absence of wear and nearly endlessservice life. The high-precision output signal serves as an absolute signal for the controller in awide range of interfaces. Areas of application  Locks and floodgates  Run-of-river plants  Large hydraulically powered valves  Monitoring reflection channels on thermosolar power stations  Sand dredgers  Track systems  Logging machines  Hydroelectric power plants  Construction equipment  Combines
  • 71. Micropulse Transducers BTL ProCompact sensors worldwideThe cylinder feedback system for extreme environments
  • 72. Micropulse Transducers BTL 7 Compact sensors worldwide Compact in stainless steel for precise measurement of piston positionFeatures BTL Compact – the standard in power plant and process engineering Non-contact detection of piston position As early as 1995 at the Hanover trade fair Balluff presented the BTL Compact with a length of only Insensitive to contamination, up to IP 68 34 mm as a trade fair innovation. The target applications were hydraulically actuated valve drives in Shock and vibration resistant 150 g/20 g power plant and process engineering. In the meantime, thousands of BTL Compacts all over the Absolute output signal world reliably measure the current position of valves and guarantee safe, dependable and perfect Measurement lengths 25 to 7620 mm in control. Balluff is once again setting standards with the new generation, the Micropulse BTL7 mm increments Compact. The distance measuring system, which is 100% backward compatible with the existing Flexibly adjustable measuring range BTL5 generation, impresses with its improvement in many types of performance data and large through key programming number of extensions to the application and function. High measure value rate up to 4 KHz Temperature range -40 to +85 C Its stainless steel housing, with a length of only 34 mm, and fastening with the special stainless screws included in the delivery, usually makes additional mechanical protection unnecessary.
  • 73. Micropulse Transducers BTL 7 Compact sensors worldwideCompact in stainless steel for precise measurement of piston position
  • 74. Micropulse Transducers BTL 7 sensors worldwide Rod-style with Rapid Replacement ModuleThe Rapid Replacement Module (RRM) option allows quick field replacementwithout removing the pressure tube from the hydraulic cylinder, making field-level maintenance fast and easy.With the RRM option, the transducer electronics and sensing element can bereplaced as a single unit, while the hydraulic seal remains intact. No hydraulic oil spillage, and no need for environmental containment No danger of hot oil spillage No need to bleed air from the hydraulic system after replacement No danger of hydraulic system contamination 100% exchange of sensor package eliminates troubleshooting guesswork Dimensionally identical to standard Balluff rod-style transducers Replacement cartridges can be installed into existing standard pressure tubes (consult Balluff Technical Support for guidance) Available for all BTL7 output types Available for all BTL7 connector types
  • 75. Micropulse Transducers BTL 7 sensors worldwideRod-style with Rapid Replacement Module
  • 76. Micropulse Transducers BTL 7 sensors worldwideSSI interface – Super linear and synchronized
  • 77. Micropulse Transducers BTL 7 sensors worldwideSSI interface – Super linear and synchronized
  • 78. Micropulse Transducers BTL AR ZA0 sensors worldwideZA0-M12 integrated connector system, fast and simple installation Clever – the new integrated connector system ZA0 from Balluff Ideal for hydraulic cylinders with rod eyes, where the Micropulse BTL AR is totally integrated in the cylinder and the hollow-bored piston rod. With the Standard 4-pin M12 connector, the screen connection is via a flange and union nut. An 8-pin M12 version will be available shortly. Features  Simple and fast installation that reduces costs  Small design and integrative to save installation space  Standard solution for Standard M12 connector  Degree of protection IP 67  Prefabricated complete solutions available
  • 79. Micropulse Transducers BTL AR ZA0 sensors worldwideZA0-M12 integrated connector system, fast and simple installation
  • 80. fluid sensors sensors worldwide capacitive sensors for level detection micropulse filling level sensor
  • 81. Standard Pressure Sensors BSP sensors worldwide For a wide variety of applications in factory automationStandard Balluff Pressuresensors offer impressiveperformance and are suitablefor a wide variety of applicationsin factory automation. A largedisplay and simple operatingconcept, according to VDMA,saves time when configuringparameters. These Balluffpressure sensors are versatileand space-saving. The displayand electrical output can berotated independently of theflange. Other features of thesesensors include: A compact housing design Local pressure display Digital switching outputs Analog output signals
  • 82. High-End Pressure Sensors BSP sensors worldwide For demanding applications involving extended temperature rangesBalluff Pressure sensors withstainless steel housings weredesigned for demandingrequirements and extendedtemperature ranges and harshenvironments. The compacthousing is manufacturedentirely from hard-wearingstainless steel. Parameters areconfigured quickly and easily inline with VDMA standards.High-end applications include: Wind turbines Off-shore Refrigeration and air-conditioning systems
  • 83. Capacitive Sensor SMARTLEVEL 500+ sensors worldwide Progress in smart level technology Detecting high-conductive acids, such as sulfuric or hydrochloric acid, through plastic or glass containers that are up to 20 mm thick Reliable detection of fill levels in food items, such as ketchup or mustard, despite heavy buildup Detecting concentrated cleaning agents in plastic containers
  • 84. Capacitive Sensor SMARTLEVEL 500+ sensors worldwideProgress in smart level technology
  • 85. Micropulse BTL-SF Filling Level Sensor sensors worldwide Maximum precision for foodstuffs and hygiene Continuously precise measurement in μ range delivers excellent filling results 100 % stainless steel ensures top hygiene standards and long service life International certificate guarantees maximum qualityMaximum precision for food hygiene –internationally certifiedThe BTL-SF filling level sensor ensures continuously precise measurementin applications that demand extreme hygiene. Made from corrosion-freestainless steel with excellent surface quality and rounded edges, thesensor meets the highest international hygiene standards and fulfills allstrict requirements of the food industry. Take advantage of the best qualitydirectly from the manufacturer.Other benefits Neutral for all liquids Compensates for foam to deliver reliable filling level values Adjustment-free installation Easy to clean in installed state (CIP – Clean in Place) For process temperatures up to 130 C (SIP – Sterilization in Place) Standardized interfaces ensure flexible installation Internationally certified quality guarantees global marketing and sales of your system Rising and falling signal available
  • 86. Micropulse BTL-SF Filling Level Sensor sensors worldwideMaximum precision for foodstuffs and hygiene
  • 87. industrial identification sensors worldwide vision sensors industrial RFID systems
  • 88. Sharpshooter BVS-E Identification sensors worldwide Detecting and identifying varied codesCheck the marking on your products. Regardless of whether you label themwith 1D codes (barcodes) or 2D codes (Data Matrix codes), the Sharpshooterreads all common codes on the market. Text and sequences of numberssuch as code plain text can be verified using OCV. The result: “Inspection OK”or “Inspection not OK”.If you need to view the read code data to find out which partsare being processed, you can output it via the RS232 or Ethernetinterface. Simple operation Read several codes in an inspection simultaneously Output code data via RS232 or Ethernet interface Verify character strings Change between inspections via PLC 360 position detection Extensive range of accessories Function module for PLC availableReadable barcodes Interleaved 2-of-5 Code 39 Code 128 Pharmacode Codabar EAN 8 EAN 13 UPC-E Postnet IMB ECC 200Readable Data Matrix codes ECC 200
  • 89. Sharpshooter BVS-E Identification sensors worldwideDetecting and identifying varied codes
  • 90. Vision Sensor Monitor BVS-E sensors worldwideSee what the sensor sees Do you want to see what the sensor sees? Do you wish to increase your inspection quality with the use of statistical values? And to simply adapt your inspection to changes in components? We have a simple solution: the Vision Sensor Monitor. It visualizes the sensor images and inspection results and displays the process statistics in a simple overview graphic. The detection of unwanted deviations thus becomes really simple. If an inspection feature changes, such as a sell-by date, authorized users can then adapt the inspection criteria even without a PC. Lengthy setting work is therefore no longer necessary. the monitor allows simple switching between two inspections. The easy-to-use, intuitive user interface of the monitor can be controlled by operating buttons and is available in multiple languages.  Simple, self explanatory operation  Can be retrofitted on all existing sensors  Clearly arranged presentation of process statistics and sensor results  Access for operators, setters and administrators can be controlled by passwords  Memory for 20 inspections  Connection to sensor via direct link or network (TCP/IP)
  • 91. Vision Sensor Monitor BVS-E sensors worldwideSee what the sensor sees Available accessories:  2 m connecting cable BCC M415-0000-1A-004-PX0334-020 Ordering code: BCC030A  5 m connecting cable BCC M415-0000-1A-004-PX0334-050 Ordering code: BCC030C  2 m connecting cable, monitor/sensor BCC M415-M415-5D-687-ES64N8-020 Ordering code: BCC0ANA  5 m connecting cable, monitor/sensor BCC M415-M415-5D-687-ES64N8-050 Ordering code: BCC0ANC  5 m Ethernet cable, monitor/RJ45 BKS-AD-05-RJ45/GS180-05 Ordering code: BCC02H1  10 m Ethernet cable, monitor/RJ45 BKS-AD-05-RJ45/GS180-10 Ordering code: BCC02H2  Monitor protective housing BAM PC-AE-002-1 Ordering code: BAM01A8
  • 92. Degree of Protection IP 67+, Inexpensive Retrofit sensors worldwideOptional housing for Vision Sensors BVS Balluff now provides an optional housing for splash water areas and other problematic environments for all sensors in the vision Sensor family. With its IP 67+ protection, it also provides safe protection during long-term use in harsh environments. With a few simple hand movements, the sensor is easily integrated in the robust housing and then mounted on a machine or system. all functions are then available as usual without any loss.  Rugged housing  Degree of protection IP 67+  Flexible handling  Simple assembly and mounting  Full range of sensor functions  Inexpensive acquisition
  • 93. Degree of Protection IP 67+, Inexpensive Retrofit sensors worldwideOptional housing for Vision Sensors BVS
  • 94. Spotlight with IP 67 Protection sensors worldwide For universal useIf the application environment is very harsh, particularly highdemands are placed on the equipment. Red light spotlights in thehousing with IP 67 protection, as offered by Balluff as a world first,are the right lights for the job. the extremely robust versions in thespace-saving sizes M18 and M30 are also characterized not only bytheir low power consumption but also by their powerful and evenlydistributed light spot. Degree of protection IP 67 Flexible handling For universal use Energy-saving LED technology Space-saving M18 and M30 designs Precision illumination even from far distances
  • 95. Spotlight with IP 67 Protection sensors worldwideFor universal use
  • 96. Extremely Flat Infrared Background Lights sensors worldwide Including trigger and function displayBackground lights are suitable for the through-beam method or for diffuse object illumination.Infrared light is invisible to the human eye –machine operators are no longer dazzled by theselights and your image processing solution stillworks perfectly. Balluff has extended itsbackground light range by an infrared version.They have high-quality, high luminous LEDs, whichguarantee an intensive and evenly distributedillumination field. the required operational safety isguaranteed by an LED status display and a trigger.Special Properties Powerful LEDs Status display on/off 24 V DC operating voltage, trigger Extremely flat design, low space requirements Easy assembly
  • 97. Extremely Flat Infrared Background Lights sensors worldwideIncluding trigger and function display Light field 100 100 mm  No interference by extraneous light  Sharp image of object contours  Easy registration of dimensions  Object surface with no influence on inspection result
  • 98. Why RFID from Balluff? sensors worldwide Comprehensive system expertise – many years of experienceMore than 25 years of experience with Industrial RFID We are complete providers –make use of our knowledge and expertise. Industrial RFID is just one of our many product ranges.Extensive product portfolio: LF-HF-UHF More than just components –the right solution for every application. trained integrators create solutions for you.No experiments –benefit from our application experience.Project support from A…Z –your solution from a single source.Service whenever you need it –you can rely on us.Global presence – short channels –ensure rapid availability on a global scale.Functional and operational reliability –certified products safeguard your investment.Flexible: solution competence –your ideas are our motivation.High degree of acceptance on the market –trust the market leader in tool identification.
  • 99. Protecting Products and Know-how sensors worldwide Balluff is thereProduct piracy is a significant threat to the innovation force Applicationsand competitiveness of the capital goods industry. Accordingto the VDMA survey from 2008, product piracy already affects The use of RFID allows storing data directly at the object. Thistwo-thirds of the more than 3000 member companies. Today, allows not only the identification of pirated copies, but alsoaggregates, modules and even complete machines are being automating setup routines and increasing machine availability. Bycopied. This is reason enough for Balluff to actively identifying security and quality-relevant parts, RFID supports you inparticipate in the "product and know-how protection" working securing your quality and ensuring security within the process. Wegroup of the VDMA. will gladly show you the options that are relevant to you – contact us!For companies, the product piracy leads to a violation of patent and n technicalsupport@balluff.combrand rights and to the loss of their good image. This is frequentlyaccompanied by an enormous price pressure on the original. Atthe end of the day, it not only costs companies a lot of money, but italso threatens jobs.Only a holistic approach that includes the areas technology,product, information, process and rights, can lead to a solution.Especially with respect to technologies and products, industrialRFID components from Balluff can be an important tool inidentifying the original and tracking its further path.
  • 100. A Powerful High-Frequency Package ensures Maximum Reliability sensors worldwideHF antenna BIS M-340 and BIS M-350 One of the challenges of intralogistics is the transportation of constantly changing materials. However, smooth operation and transparent processes are still required in spite of the wide variety of different products. A requirement that is not always easy for RFID systems because metallic surfaces, fluids and dirt really put these systems to the test. Not the HF antenna BIS M-350, however. The antenna is fitted with optimized data carriers that help overcome difficulties of this kind with ease while reliably ensuring maximum transparency. All data can be traced at any time.  Distances up to 130 mm offer greater flexibility, regardless of the background surface  FRAM data carriers ensure virtually unlimited read/write cycles.  Conformity applicable worldwide as per ISO 15693.  Status indicators mounted directly on the antenna housing are a valuable feature.  The robust housing guarantees reliable operation in harsh environments.  100% RFID quality means greater reliability. Application areas The advantages of the HF antenna BIS M-350 become immediately obvious in all applications where the data carrier is mounted directly on metal or the material in the immediate vicinity cannot be predetermined accurately, for example when products are transported in a crate. BIS M sensors simply ignore the different materials, which means that water, oil, dust and metal have absolutely no effect on the high-performance data carriers.
  • 101. A Powerful High-Frequency Package ensures Maximum Reliability sensors worldwideHF antenna BIS M-340 and BIS M-350
  • 102. Industrial RFID in Transfer Systems sensors worldwide High data reliability and extremely simple assemblyThe Balluff BIS-M System combines advantages such as the fullyflush installation of data carriers in steel and absolute data reliabilitywith important properties such as: Large reading/writing distances of up to 130 mm Fast data communication from data carrier via processor to controller Seamless integration in intralogistics applications through global standard ISO 15693/14443 Smallest possible antenna design sizesThe components are specifically designed and manufactured foruse with transfer systems from Bosch-Rexroth (TS1 and TS2). Thedesign not only takes RFID communication into consideration butalso simple assembly.Can be installed from the kit, depending on the application. Thanksto the robust systems and 20 years of experience with RFID, thedescribed solution is a must for every automation task.
  • 103. Industrial RFID in Transfer Systems sensors worldwideHigh data reliability and extremely simple assembly
  • 104. Processor with CC-Link for 13.56 MHz sensors worldwideSuitable for every environment  Flexible use due to a wide range of different combinations of data carriers and antennas  Up to two antennas per processor  Tested quality with CC-Link certificate  Make use of timesaving features: Connector- based cabling, robust housing that is easy to install, preassembled function modules and diagnostics function that enable easy commissioning The CC-Link field bus protocol ensures quick, robust communication between different stations. The new BIS M-699 processor can now be used directly in the field. Conformity with standards ISO 15693 and 14443 as well as globally approved frequency of 13.56 MHz allow worldwide use of this CC-Link processor.
  • 105. Processor with CC-Link for 13.56 MHz sensors worldwideSuitable for every environment
  • 106. Processor for Mitsubishi Controller sensors worldwide Identification without diversions Easy startup with function modules at no extra cost Direct integration into the controller eliminates the need for decentralized wiring Function indicator directly on the terminals Degree of protection IP 40The HF processor BIS M-688-001 with 13.56 MHZwas developed specifically for integration in theMELSEC-Q series from Mitsubishi. All read/write The MELSEC-Q series enables the user to select the best combination of CPU modules as well as communication, special or I/O modules for configuration of tailored systems.heads from the BIS M series can be connected to the The use of RFID ensures the best possible individual solutions. And in all areas where2-channel card. A wide range of variations provides the highest possible level of flexibility is required. RFID makes processes even morethe right configuration for every application. transparent and effective.
  • 107. Processor for Mitsubishi Controller sensors worldwideIdentification without diversions
  • 108. RF Databolt BIS M sensors worldwideIndustrially hardened – maximum reusability It is not always possible to use a workpiece carrier in the production process. If the information should still be coupled directly to the object, it is essential to install the data carrier at the object without any difficulties and to quickly remove it again after it has fulfilled its task. The design of a screw is perfectly suited for this purpose. The new data carrier in accordance with ISO 15693 with a storage capacity of 2000 bytes is perfectly suited, for example, for parts tracking in manufacturing processes and for closedloop applications in which it is always being used recurrently. Varied application options also open up for the identification of manufacturing equipment, such as pressing tools. Thanks to large reading distances, the data screw with degree of protection IP68/x9K offers many degrees of freedom during the installation. Long range data bolts  High degree of protection – where it is needed  Data carrier in screw form – simplest form of installation  Large distances – for more flexibility in your application  ISO 15693 – applicable worldwide
  • 109. RF Databolt BIS M sensors worldwideIndustrially hardened – maximum reusability
  • 110. industrial networking sensors worldwideand connectivityEthernet/IPCC-linkDistributed Modular I/O Utilizing IO-LinkSpecialty CablesNon-contact ConnectorsIP67 Power Supplies
  • 111. Industrial Networking and Connectivity sensors worldwideSystem Technology networked with intelligence
  • 112. Industrial Networking and Connectivity sensors worldwide System Technology networked with intelligenceHardwired Centralized I/O Network I/O BlocksAdvantages Advantages Low component cost  Diagnostics Basic electrical knowledge needed  Faster troubleshooting controls cabinet Low MRO costs  One cable back to the  Lower maintenance costDisadvantages  Shorterup time cables sensor No diagnostics  Higher Hard to troubleshoot High maintenance cost routed to controls Disadvantages Large number of cables  Higher component costs cabinet  Network knowledge needed Long sensor cables Long downtime IO-Link Modular Network I/O AdvantagesHardwired I/O with Junction Blocks  DiagnosticsAdvantages  Faster troubleshooting controls cabinet Low componentknowledge needed cost  One cable back to the Basic electrical  Lower maintenance cost Low MRO costs  Shorterup time cables sensor Fewer multi-conductor cables back to controls  Higher cabinet  Scalable Shorter sensor cables  Parameterization DisadvantagesDisadvantages No diagnostics  Higher component costs Hard maintenance cost to troubleshoot  Network knowledge needed High Long downtime
  • 113. EtherNet/IP sensors worldwide Network Block I/O with embedded switchEthernet/IP with IO-Link functionalityIO-Link not only communicates with Profibus, Profinet and CC-Link now. At Balluff,IO-Link now communicates with Ethernet/IP so that all the benefits of IO-Link areavailable right down to the second lowest level.IO-Link not only ensures freedom of installation, but also guarantees simplifiedwiring, integrated diagnostics and central configuration. System failures can bereliably prevented and systems started up again quickly if the worst comes to theworst.Ethernet/IP with IO-Link guarantees efficient operation, saves time, reduces costsand incorporates intelligent connection technology to improve process quality.The Ethernet/IP module with IO-Link includes four IO-Link master ports that canbe configured and used fully independently of one another. You get four additional,freely configurable standard I/O ports that provide a further eight inputs/outputs forstandard sensors and actuators.
  • 114. EtherNet/IP sensors worldwideNetwork Block I/O with embedded switch IO-Link
  • 115. CC-Link sensors worldwide Powerful products from a single sourceCC-Link is the principle fieldbus technology used in Asia. The open network issupported by the global CC-Link partner association CLPA, which comprises morethan 1000 companies. CC-Link is a standardized fieldbus designed to integratedifferent automation components from a wide range of providers. CC-Link is aneffective integral system that will fulfill 100 % of your application requirements.Utilize the extensive, high-quality CC-Link portfolio from Balluff to implement yourown powerful control topologies using products from a single source.The CC-Link module with IO-Link includes four IO-Link master ports that can beconfigured and used fully independently of one another. You get four additional,freely configurable standard I/O ports that provide a further eight inputs/outputsfor standard sensors and actuators. Clearly visible status LEDs Addressable display Powerful and safe outputs Innovative housing design
  • 116. CC-Link sensors worldwide Powerful products from a single sourceGet Rid of Remote I/O Cabinets Once and For AllEvery equipment designer goes through a phase of their design process where they need to decide howtheir I/O gets from their sensors and their valves to their controller. Some people use I/O cards on theirPLC, or networks with IP20 solutions inside remote I/O cabinets.Remote I/O cabinets are costing you money in three ways:1. Initial Equipment Costs You have to purchase a remote NEMA Box, bulkhead pass through connectors or gaskets, the remote I/O network connection as well as the required input and output cards for the application.2. Installation Time The box needs to be mechanically mounted in its designated space and installed with all of the wires and connectors run to it. an electrician then needs to come in and wire everything to the I/O ports. If you are using PNP or NPN sensor, there are three terminations per sensor that the electrician needs to connect.3. Setup Time If for some reason the machine needs to be town down and shipped someplace else (which many machines do), many hours can be spent disconnecting the I/O only to be reassembled in the final destination.These costs in time and money can be reduced by looking at industrial network I/O mounted right on themachine. IP67 I/O gives quick industrial connection for the network communication and power cables. Mostof the sensor and actuator cables can stay with the block because the I/O block is mounted right on themachine where the I/O is needed. Look at the labor and money you are putting into your remote I/O boxesand consider machine mount I/O the next time you are working on designing cost out of your machine.
  • 117. CC-Link sensors worldwidePowerful products from a single sourceIO-Link NPN PNP
  • 118. Distributed Modular I/O sensors worldwideIO-Link Think of a remote “slice” I/O solution. In a typical application, the communication head and the power supply sit on the left hand side and are followed along the backplane by the individual I/O devices, such as discrete 24V input cards or 0-10V analog cards. Usually there are a limited number of slots available in the backplane and individual slices of control components can be inserted. In a similar fashion, a Distributed Modular I/O system has a communications head that talks over the desired industrial network on one side and acts as a data collector on the right hand side. In lieu of a backplane, each device is connected to an industry standard M12 port utilizing a basic 3-wire sensor cable for communication. With the ability to be installed within a 20 meter radius from the data collector devices can be easily distributed across the machine.
  • 119. Distributed Modular I/O sensors worldwideIO-Link
  • 120. IO-Link sensors worldwide Metal M12 sensor/actuator hubs, single-channel monitoringSimple handling – lower costs –universal useIO-Link sensor hubs with ID fromBalluff are a market innovation. Theuser can write and read his own,userdefined identification data.They are, therefore, particularlyeconomical when it is necessary toencode tools. In addition, they areeasy to use.As an interface forinterchangeable tools, they offerclearly calculable benefits: Quick, reliable format changes Quick, economical installation Speedy setupAdditional advantages IP 67 sensor hubs are extremely versatile. Single-channel monitoring provide detailed diagnostic data relating to overloads, short circuits and cable breaks.ID sensor hubs from Balluffrepresent more than just lowercosts, less work and reduceddowntimes. Sensor hubs withID from Balluff also stand forgreater efficiency.
  • 121. IO-Link sensors worldwide Tool ID and I/O in one Application: Die Identification and I/O on a Press In a metalforming and stamping facility, there is usually the need to change out dies and tooling in the press on a regular basis. Tracking the die ID is becoming an important piece of information in every press shop. Many die ID programs implement a simple input-based system that has a code of sorts built into a high density pin connector. This 24-pin connector also collects a small set of I/O data on the press. This solution has a high initial cost due to the 24- wire cable and the special wiring configurations that need to be made. Then once implemented the pin connectors inside get damaged or bent causing downtime to repair the connectors. Damage to these connectors from die change or from daily use can cause significant downtime. Balluff offers a rugged solution for quick die changes that collect I/O data as well as provide die identification information all in one simple-to-implement package. Basic Solution: An I/O hub for identification can easily be integrated into the existing industrial network on the press or straight into the controller using an IO-Link expansion module. IO-Link is an open standard that is adopted by many major controller manufacturers and allows for smart devices to communicate with the controller and collects more information about the process than just I/O. IO-Link expansion modules can work with EtherNet/IP, ProfiNet and Profibus and can communicate with up to 4 IO- Link devices simultaneously. The I/O hubs are available with diagnostics and 2 bytes of ID data, as well as 16 inputs or can drive up to 16 outputs. This allows for greater flexibility right on the die for any die protection program in effect in the facility.Benefits: Decreases wiring time and Enhanced Solution: In addition to replacing high density connectors and mistakes by using standard wiring cables, there can be issues with operators forgetting to disconnect the wired for all dies connectors. This requires costly die repair due to cable damage of the die Eliminates pin damage by using a protection sensors and devices. To alleviate this problem, a non-contact non-contact connector connector solution can be implemented that will power the sensors in use on Eliminated die rework due to the die as well as collect the I/O and ID data. The non-contact connector operator forgetting to unplug transmits power and data across a small air gap and communicates back to connector the IO-Link expansion module. This removes any need for the operator to Increases data reliability using remember to disconnect the homerun cable when changing out a die. See Industrial RFID for die page 160 for non-contact connectors. identification
  • 122. IO-Link sensors worldwide Isolated output control Robust housing Powerful outputs Two isolated zones of output controlIf you wish to depict standard I/Os or safety I/Os in a fieldbustopology, the issue of safety becomes increasingly important fornetwork/system integration.Type BNI IOL-252/256 IO-Link actuator hubs fulfill requirementsrelating to the safe deactivation of outputs in accordance withMachinery Directive 2006/42/EC, EN 954-1 category 3, EN13849-1, EN 62061 SIL2.The I/O block is divided into two galvanically isolated segmentsin order that two separately switching circuits can beimplemented using one module. The functions of the IO-Linksystem concept are extended considerably as a result. The IO-Link fulfills the requirements for a holistic approach andsimultaneously reduces the number of components andguarantees simpler installation.
  • 123. IO-Link sensors worldwideMetal M12 actuator hubs, Isolated output control
  • 124. IO-Link sensors worldwide Sensor hubs/actuator hubs, IP 20Easy installation with IO-Link underIP 20 conditionsThe maximum number of 16 channelsof the IP 20 IO-Link sensor/actuatorhub are user configurable(input/output) and meet therequirements for an inexpensiveflexible wiring. The connection on theIO-Link side is carried out using a four-pole standard sensor cable, theconnection from/to the I/O devices iscarried out using detachable screw-type terminal blocks.IO-Link up to the control panelThe compact size enables the simpleand straightforward installation incontrol cabinets, control boxes andcontrol panel housings. Simply snapthe plastic housing onto a mountingrail according to EN 60175 – done.IO-Link for integration in devicesand device modulesCircuit board variants are available forthe integration in spatially limited andcomplex functional units which can beintegrated via spacing bolts.
  • 125. IO-Link sensors worldwideCompatible valve manifolds
  • 126. Inductive Couplers sensors worldwide IO-Link unidirectional in 40x40 mm Unicompact housingIO-Link unidirectional in 40 40 mm Unicompact housingThe IO-Link interface guarantees simple installation because theIO-Link is quickly wired. The new housing concept also reducesinterfering variables.Inductive couplers make mechanical plug-in contactsunnecessary because the signals can be reliably transmittedwithout contact via an air gap. This ensures not only resistanceto wear but also a fast size change and high flexibility. For theRobotic coupling, IO-Link unidirectional in the compact 40 40housing is therefore ideal. No mechanical wear Maintenance-free Increased system availability Shorter times when replacing changeover tools Simplification of system design Simple wiring of replaceable tools
  • 127. Inductive Couplers sensors worldwideIO-Link unidirectional in 40x40 mm Unicompact housing
  • 128. Intelligent Sensors sensors worldwide Advantages of intelligent sensorsAs manufacturing becomes even more Intelligent sensors are part of this solution. By providing Constant Condition Monitoring, Preventativecompetitive and the demand for Diagnostics and Automatic Configuration over common industrial networks, intelligent sensors provideflexibility rises, we begin to ask tough the flexibility and detailed data required in a modern manufacturing facility.questions to ourselves, our machinebuilders and our component suppliers: How do I increase my production throughput and maintain quality? How can I predict sensor or machine failure? What can I do to decrease my unplanned downtime? Where and how often are most failures occurring? How do I get more detailed information out of the system?The ideal solution to these questions isa system that can easily provide statusinformation from the health of a PLCand industrial network down to theindividual sensor location at one workstation. The system could predictimpending issues and automaticallydirect action to solve the issue before itcauses production to stop. In additionthe system should be able to be flexibleand adjust to multiple configurations,sizes, colors, etc.
  • 129. Intelligent Sensors sensors worldwide Types of intelligent sensorsUsing distributed modular I/Otechnology and talking over thesame backplane from slave tomaster device, multiple intelligentsensors can be connected to oneIP address on an industrialnetwork. Depending on thecomplexity of the information thesensor provides or requires, anycombination of 1 to 32 intelligentsensors can be connected. Utilizingthe open standard IO-Link, it is alsopossible to mix and match with anydistributed modular I/O productsavailable such as: discrete I/O,analog I/O, valve manifold control,RFID and third party intelligentsensors and devices.
  • 130. Intelligent Sensors sensors worldwide ApplicationsPrinting and Paper ExampleReliable diagnostics are extremely important for highly dynamic machines. You can identifyquality issues linked to the manufacturing process in real-time and take appropriatemeasures immediately. In the printing and paper machine industry, for example, the machine Intelligent sensor hubmust react to faults within milliseconds.Color Sensor ExampleWhile running project A, the color sensor is configured to detect the difference between fivedifferent colors as parts are loaded into a fixture.After the required parts are run off, a new project is begun with a different color set. In thepast, a second color sensor would be required, or the operator would have to reprogram thecurrent sensor for each new color. By using device parameterization, the controller tells thesensor its configuration for project B and quickly, without hassle, the sensor has its newcolors.
  • 131. Intelligent Sensors sensors worldwideLevel 1 intelligent sensors
  • 132. Intelligent Sensors sensors worldwideLevel 2 intelligent sensors
  • 133. Intelligent Sensors sensors worldwideLevel 2 intelligent sensors
  • 134. Intelligent Sensors sensors worldwideLevel 3 IO-Link intelligent sensors
  • 135. Intelligent Sensors sensors worldwideLevel 3 IO-Link intelligent sensors
  • 136. Connectivity Solutions sensors worldwideM8 & M12 specialty cablesIP67k, ECOLAB, stainless, high temperature
  • 137. Connectivity Solutions sensors worldwide Weld Resistant PURNew welding PUR lineStandard PUR lines have numerous advantages.They are resilient, wear-resistant, impact-resistantand resistant against solvents. Balluff now also hasweld spatter-resistant versions according to ISO14001 in its product range. This permits thereplacement of irradiation-crosslinked lines, whichrequire costly disposal as hazardous waste at the endof their service life. Possible field of applicationsinclude automobile manufacturing, in particular,bodyshell work. Resistant to sparks and weld spatter Degree of protection IP 67 and IP 68 Conforms with ISO 14001 – not hazardous waste Replacement for irradiation-crosslinked lines Jacket color: Orange
  • 138. Connectivity Solutions sensors worldwide Weld Resistant PURJacket Materials: Available Lengths:Yellow PVC = VX45T2 003 = 0.3 mBlack PUR = PX0534 006 = 0.6 mYellow TPE = EX45T2 010 = 1.0 m 015 = 1.5 m 050 = 5.0 m 100 = 10.0 m
  • 139. Connectivity Solutions sensors worldwideM8 and M12 Splitters
  • 140. Industrial Networking and Connectivity sensors worldwideBulk cable Sometimes in automation applications it is necessary to wire individual connectors and cables by hand, using bulk cable. It is available for sensors, auxiliary power, and industrial networks. Lengths Available: 100m coils or spools depending on cable size.
  • 141. Industrial Networking and Connectivity sensors worldwide Passive splitter box BPI, 5-pinIdeal areas of application for passive splitterboxes by Balluff include local installations inassembly and handling machines, packagingtechnology, special machine construction, etc.Balluff Passive Interface BPI – A multi-talent, even under demanding conditions Outstanding design Fully enclosed housing High shock and vibration ratings Flexible mounting options High visibility of LEDs Large terminal compartment Modular design Quick to mount/detach for transportation
  • 142. Non-contact connectors sensors worldwide Simple connection, rapid commissioning Wear-free Robot gripper The sensor determines whether Robust, even in harsh environments the gripper has collected the workpiece. The switching state of the sensors is transmittedRetrofitting is simple: BIC is plug-and-play. without contact.Your maintenance costs are reduced to aminimum because cable breaks andmechanical wear are a thing of the past.
  • 143. Non-contact connectors sensors worldwidePower-only
  • 144. Non-contact connectors sensors worldwide8-input and IO-Link
  • 145. Intelligent Power Supplies sensors worldwideIntelligent power supplies from BalluffThe autonomous installation of power supplies without switchcabinets with IP 67 protection is becoming more and more popular inindustrial automation. Autonomous power supplies are already widelyavailable but are generally difficult to access once they are installed andto further complicate matters, monitoring the operating status ispractically impossible. As a result, operators rely on preventivemaintenance concepts to guarantee maximum possible availability.These concepts are reliable but also expensive because devices are General key information about the IP-20 and IP-67frequently replaced during the maintenance cycle well before the end of power suppliestheir service life as there is no alternative system available. High degree of efficiency > 93 % Minimal heat loss and generationFor the first time, intelligent, energy-saving power supplies from Balluff Increased efficiency of the turbinepromise to remedy this situation. Their condition is visualized by means 3-stage status indicationof optical indicators. Power boost (150 % for 4 sec.) Extremely compactThis novel concept allows detection of the condition of the device at a More efficient utilization of the power suppliesglance. The device follows dynamic loads and can therefore be operated Planned reserves are not wastedat a high level of capacity utilization. Usual reserves of Prevention of unexpected failures caused by permanent overload30 to 50 % are therefore superfluous. Scheduled maintenance and repairs no longer necessary Higher productivityThis intelligence forms the basis of a new intelligent generation of power PSU only replaced at the end of its service lifesupplies that can be permanently utilized at full capacity and provides Lifetime of 15 years (at 80 % load and 40 C),visual information about the internal status via the: MTBF > 800,000 h Load level Enclosed housing guarantees high degree of resistance to Stress level vibration and shock loads Lifetime.Visualization should allow the operator to view the status in the Ideal areas of application for these intelligent power supplies include localsimplest way possible. installations in the automobile industry, machine construction, wind turbines, etc.
  • 146. Intelligent Power Supplies sensors worldwideIntelligent power supplies LEDs indicate the load level and stress level so theFor outstanding system availability operator knows immediately when the unit isIf you want to operate your systems and machines with maximum efficiency, the power supply you operating at maximum performance. The service lifeuse must be reliable. Intelligent power supplies from Balluff guarantee a high degree of reliability. of the devices is also displayed, making maintenanceWherever you install the power supply unit, you will obtain a complete picture of your environment and operation extremely easy. The operator can alsowhich you can then monitor continually. see exactly when a device need replacing, which increases the overall availability of systems.LEDs for easy monitoring Load level The benefits to you Stress level  Continuous monitoring of machines and systems Lifetime  Reliable power supplies guarantee efficient operation  Optimized use of devices and a longer service life  Assists with maintenance planning  Devices only replaced when necessary Versions Intelligent power supplies from Balluff are available in two versions IP 20 (with screw terminal)  With wide input voltage range from 380 to 690 V AC  Designed for versatile use in industrial automation  Also satisfies all wind turbine requirements IP 67 (with connector)  Suitable for direct use in harsh environments  Fully enclosed housing  High shock and vibration ratings
  • 147. Intelligent Power Supplies sensors worldwide HEARTBEAT Load level Stress Level Lifetime Reversible in short term Reversible in medium term Irreversible in long term Load level indicates the current Stress level indicates the Lifetime indicates the remaining load on the device. the display physical and thermal loads. A useful life of the device and is indicates the load without delay. change in the load status delays based on the combination of all the "pulse" of the device slightly. loads.All indicators multi-coloredin green, yellow or red andshow the status of thedevice
  • 148. Power Supply sensors worldwideIntelligent power supplies – Inside the cabinet IP20
  • 149. IP67 Power Supplies sensors worldwideReliable power for demanding industrial automation
  • 150. mechanical accessories sensors worldwideprotection capmounting systemclamp holderscushion mountstube switch
  • 151. Balluff Protection Cap sensors worldwide For ultrasonic sensors in harsh ambient conditions Suitable for ultrasonic sensors M18 series Protects the sensing surface from mechanical load and hot weld splatter With a special coating and grid technology, the cooled splatter does not reach the sensing surface and drops out through an outletWhether position detection, distancemeasurement or the detection of solid, powderor liquid media independent of color,transparency and surface finish: ultrasonicsensors are precision solutions. Particularly Ultrasonic sensors in welding lineswhen large operating ranges and high In a welding line, ultrasonic sensors BUS detectaccuracies are called for, the BUS ultrasonic workpieces in the various steps and positions.sensors show what theyre capable of. In With the use of a protection cap, the ultrasonicdusty, humid and misty working conditions, converter is protected from hot weld splatter.they are often the only alternative. Very large operating range For difficult environmental conditions Insensitive to dirt Object-independent distance measurement High resolution Reliable detection of the smallest objects Detection of sound-absorbing materials
  • 152. Balluff Protection Cap sensors worldwide For ultrasonic sensors in harsh ambient conditionsInstallation noteThe sensor is pushed through a bore hole andsecured in the protected area using a locknut.With this type of installation, only the protectioncap is exposed to the harsh ambient conditions.
  • 153. Clamp Overview sensors worldwide 65 clamp variants17x Standard 3x Stainless steel10x PTFE-coated, weld-immune12x Standard with latch 6x Standard with latch PTFE-coated, weld-immune 6x Stainless steel with latch 6x Stainless steel with latch PTFE-coated, weld-immune 5x for installation in containers65 clamp variants!Balluff has revolutionized methods for attaching sensors with the newlatch clamping principle. The sensor is inserted into the clamps andsecured in position by folding over the latch. The latch can secure anysensor in all areas of the automation sector without the use of tools.
  • 154. Cushion Mounts and Tube Switch sensors worldwide Reliable protection for your sensors and processesCushion mountsThe cushion mount absorbs any contact with the sensor whilepreventing damage, max. stroke 15 mm. The object runs upagainst an attached protective cap and pushes the sensor back,preventing damage to the sensor or the coil as a result. Thecushion mount reduces impact related failures and retains thesensor’s mounting position. For all areas in the automation and material handling industry Protects your sensors Increases system reliability
  • 155. Cushion Mounts and Tube Switch sensors worldwide Reliable protection for your sensors and processesTube SwitchThe tube switch combines the advantages offered by mechanicalposition switches and inductive sensors. Manufactured fromstainless steel, it is extremely robust, very reliable even underdifficult conditions and can be used immediately in any applicationin combination with the relevant inductive sensor