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PRECISION FOR HIGH
SYSTEM AVAILABILITY
Plastics,
Rubber and Tires
WE ARE AT HOME IN MANY
INDUSTRIAL SECTORS
2 | Plastics, Rubber and Tires
20
RUBBER AND TIRES
26
SYSTEMS
34
PRODUCTS
PLASTICS
6
	 8	 Material handling
	 10	 Injection molding
	 14	 Blow molding
	 16	 Bonding and joining technology
	 18	 Robotics and automation
	 22	 Tire building machines
	 24	 Heat presses
	 28	 Mold ID
	 ABOUT BALLUFF	 40
	 REFERENCES	42
Plastics, Rubber and Tires | 5
CONTENTS
Plastic is the material of the 21st century. Its application range is
enormous and is becoming ever broader thanks to new compositions,
so the demands on production and machine building continue to grow.
Balluff offers high-performance sensor and system solutions with
high-quality network and connectivity technology. And thereby the ideal
prerequisites for reliably managing the growing variety. The high quality of
our solutions enables sophisticated systems concepts, improves machine
availability and contributes to more efficient utilization, whether in material
handling, injection or blow molding, tire construction and heating presses,
or bonding and joining technology. We also provide solutions for optimal
tool utilization.
Plastic
RELIABLY MANAGING
THE GROWING
VARIETY
Plastics | 7
CONTINUOUSLY KEEP AN EYE ON
THE FILL LEVEL
Our high-resolution ultrasonic sensors
don't miss a thing: they reliably monitor
the level of granulates and powders in
silos. The continuous and contact-free
measurement technology is virtually
immune to dust and dirt. The fill level
can be output as needed by an analog
signal or with two switching signals as
min/max values.
Features
nn Contact-free
nn Detects even the smallest objects
nn Cubic and cylindrical designs
FAST AND RELIABLE CONTROL
IN COUPLING STATIONS
To ensure the correct mixture of addi-
tives, dyes and granulates in the coupling
station Balluff uses autonomous RFID
systems. Each coupling is identified and
only released if it is connected at the
right location. This way, we ensure that
the right component is always used.
Features
nn Rugged
nn Quick and powerful
nn Protection from improper filling
FILL LEVEL INDICATORS FOR
CONTINUOUS MATERIAL FEED
To ensure constant material flow the
min/max level must be detected
continuously in the injection molding
machine. Capacitive sensors can per-
form this task for you: whether in the
hopper in direct contact with the mate-
rials or through the outer wall, the fill
level indicators reliably determine all
the values.
Features
nn For all materials
nn Simple sensor replacement
nn Miniature designs
1
3
2
1
2
HIGH-TEMPERATURE RATED
SENSORS FOR DRYING
Dry granulate is essential for high-quality
plastic parts. Our capacitive stainless
steel sensors, resistant to high tempera-
tures, ensure an even feed of the moist
granulate into the dryer. They are heat
resistant to 250 °C and reliably monitor
all levels.
Features
nn Stainless steel
nn Sensor head made of PTFE
Solutions
for material
handling
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
Plastics | 9
3
Solutions for
injection molding
1
5
Plastics | 11
Precision stands for quality:
resilient, extremely accurate Balluff technology ensures
continuity in injection molding and supports high availability
of your equipment.
2
3
4
12 Plastics |
HIGH-PRECISION DISPLACEMENT
TRANSDUCERS FOR A GENTLE MOLD
CLOSURE
With the help of a high-precision magne-
tostrictive linear position sensor from
Balluff you can precisely monitor the
closing motion of the platen. A gentle
mold closure reduces wear and extends
your mold's useful life.
Features
nn Contact-free and therefore wear-free
nn No homing necessary, immediately
ready
nn Resistant to vibration, moisture
and dust
DETECTING THE INJECTION PROCESS
Our BIW inductive positioning system
ensures that your molds are quickly
filled because the high sampling fre-
quency and repeat accuracy measure
the travel of the injection axis precisely
and reliably. You can exactly calibrate
the injection profile, for example, to
produce high-quality, thin-wall parts.
Features
nn Fast: High measuring frequency
of 32 kHz
nn Non-contact position detection
nn High repeat accuracy
CONTINUOUS MONITORING WITH
INDUCTIVE SENSORS
Inductive distance sensors from Balluff
ensure continuous monitoring of the tie
bar extension in the process. They are
insensitive to contamination and provide
optimal linearity as well as high repeat
accuracy.
Features
nn Distance-proportional, analog
output signal
nn Measuring ranges from 0.5 to 50 mm
nn Measuring speed up to 40 m/s
1
2 3
Plastics | 13
DETECT THE POSITION OF
CORE PULLS
To optimally adjust core pulls our ma-
gnetic field sensors in the mini-format
are ideal. They ensure that the core
pull is at the required end position and
they detect the position directly at the
hydraulic block cylinder. Alternately, you
can use high-temperature rated sensors.
Features
nn Designed for tight mounting locations
nn Can be fully integrated
nn Low weight
nn Wear-free position detection
nn Two teachable switching outputs via
IO-Link for up to eight switchpoints
CONTINUOUS PRESSURE
MONITORING WITH IO-LINK
Perfect closure of the clamping plates
requires the correct pressure. Reliable
pressure monitoring in the hydraulic
cylinder is handled by a rugged pressure
sensor in a stainless steel housing.
Equipped with IO-Link, the pressure
sensors relay their values directly to the
controller and thus let it readjust with
precision.
Features
nn Extended temperature range up to
125 °C
nn Up to 600 bar
nn Process-oriented installation
MEASURING MOLD FILLING IN RTM
(RESIN TRANSFER MOLDING)
Our high-pressure and high temperature
rated capacitive sensors reliably check
whether the cavity is fully filled and the
RTM is completed. They offer great
mechanical stability, e.g., for lightweight
construction and can be integrated
directly in the tool. Their specially
polished surface prevents plastics and
composites from sticking.
Features
nn Pressure rated to 150 bar
nn Temperature-resistant up to 180 °C
nn Flush-mounted
4
5
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
Solutions for
blow molding
A MODULE FOR MORE
TRANSPARENCY
The Balluff EtherCAT module with
IO-Link interface collects all the signals
from the various standard sensors
and relays them to the controller.
This solution simplifies the entire network
structure and creates transparency
down to the last meter.
Features
nn 8 independent IO-Link ports
nn Integrated display
nn Automatic address assignment
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
14 Plastics |
1
1
ALL MOVEMENTS FIRMLY UNDER
CONTROL
Travel movements at the blow station
are under control with Balluff BTL
magnetostrictive linear position sensors
even if there are vibrations. The high-
precision measurement systems have
an EtherCAT interface. Because of their
contact-free and wear-free measuring
principle, they contribute to long ma-
chine running times.
Features
nn EtherCAT interface
nn No homing necessary, immediately
ready
FAST MOLD CHANGING AND RELIABLE
PROTECTION AGAINST COUNTERFEITS
Balluff Industrial RFID enables fast and
reliable mold replacement with the
unambiguous association of mold halves
through unique IDs. You also benefit
from secure counterfeit protection. This
solution allows for rapid size changes
and facilitates a continuous process.
Features
nn Flexible, non-contact data communi-
cation
nn Fast and sturdy
nn Counterfeit protection
FILL BEVERAGES ON SITE
The beverage industry uses stretch blow
molding machines to produce bottles.
If the bottles are filled immediately
afterward, our high-precision SF fill level
sensor controls the fill level during the
process. On-site filling can save you
transport distances and thereby mini-
mize costs.
Features
nn Ecolab, 3A-approval, IP69K
nn For aseptic processes
nn Safe for sterilization (SIP) and cleaning
(CIP)
2
2
3
3
FAST AND PRECISE ALIGNMENT OF
THE WELDING HEAD
Our fast and high-precision magnetic
encoders give you precise position feed-
back. They position the welding head
exactly at the right place. Because the
absolute measurement is made directly
on the load, tolerance shifts and inac-
curacies are prevented.
Features
nn Accurate position feedback
nn Compact housing
nn Ideal for short strokes
VISUAL QUALITY CONTROL
The SmartCamera checks all the parts
including their production stages:
Are they complete and defect-free?
Are the size, distance and position
correct?
And are they correctly aligned?
The best part: all the steps can be easily
taught.
Features
nn Flexible use of analysis tools
nn Simple to operate with user-guided
teach-in
nn Optimized display of the results
Solutions for bonding and
joining technology
16 Plastics |
1
2
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
1
2
Solutions for
robotics and
automation
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
2
Plastics | 19
SIMPLE GRIPPER CHANGES USING
INDUCTIVE COUPLERS
With the help of Balluff inductive coup-
lers, the need for manual insertion of
mechanical connectors is eliminated.
The couplers send signals and power
without contact, are easy to use and
offer maximum flexibility. The quick-
disconnect units can be changed in the
gripper in just moments.
Features
nn Long service life, no mechanical wear
nn Plug-and-play
nn Weight savings
COST REDUCTION THANKS TO
SIMPLE RECORDING OF SIGNALS
Our IO-Link sensor hubs made of plastic
or metal collect the signals from the sen-
sors embedded in the gripper and pass
them along in bundled form to the con-
troller. The controller can be connected
to a 16-port IO-Link master, which re-
cords the signals of up to 272 sensors.
This reduces your wiring effort, saves
weight and reduces cost.
Features
nn Easy to install
nn Central parameter setting
nn Continuous diagnostics
1
2
1
To address production of different batch sizes with minimal changeover
times Balluff offers advanced and rugged technology for the tire building
machine and heat press. Our high-quality sensors detect end positions
of the pneumatic cylinders, position the sliders for the correct tire build,
monitor for liner sag, and ensure the same pressure for each press cycle.
They remain unaffected by heat, steam and aggressive media.
Use our machine concepts and profit from high equipment availability
to further increase the productivity of your manufacturing process.
Rubber and tires
PRECISION AND
QUALITY FOR HARSH
CONDITIONS
Rubber and tires | 21
CONTROLLED MOVEMENT OF THE
TIRE BUILDING MACHINE
Our magnetic field sensors reliably de-
tect the end position of the piston in
pneumatic cylinders and ensure proper
motion of the tire building machine. The
sensors, which are resistant to tempera-
tures up to 105 °C, replace wear-prone
magnetic reed switches and have a long
service life.
Features
nn Precise switching point
nn Also for short stroke cylinders
nn Wear-free
MAXIMUM PRECISION DURING
WINDING
High fitting accuracy means each tire
layer must be precisely fed, wound and
cut. Our BTL magnetostrictive linear
position sensors position the slide with
precision, even in rough conditions.
This ensures that the tire build precisely
complies with the specifications.
Features
nn Highly precise and wear-free
nn Impervious to vibration
CONTINUOUS MONITORING WITH
PHOTOELECTRIC DISTANCE SENSORS
Our photoelectric distance sensors con-
tinuously check the roll diameter in order
to continuously provide the winding roll
with tread strips for the green tire. The
robust sensors also perform sag control.
The difficult-to-detect black layers have
no effect on the result.
Features
nn Absolute, distance-proportional
analog signal
nn Compact, solid and reliable
nn Also available with IO-Link
1
2
1
2
3
4
3
PRECISE MONITORING OF TILT
MOVEMENTS
Balluff inclination sensors reliably moni-
tor the tilt movements of the conveyor
belt. This allows the belt to be accurately
guided when it is moved for the subse-
quent work steps. The inclination sen-
sors guarantee a high accuracy of 0.1°
and very low temperature drift.
Features
nn Precise position monitoring
nn Extended temperature range
–40 to 85 °C
Solutions for
tire building
machines
Rubber and tires | 23
4
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
RELIABLE CLOSING STROKE, EVEN
UNDER EXTREME CONDITIONS
When the green tire is pressed into the
hot mold under high pressure with hot
water, the heating press must be tightly
closed. A reliable closing stroke is en-
sured by Balluff BTL magnetostrictive
linear position sensors, even under high
temperatures and strong vibrations.
Features
nn Profile housing for easy installation
nn Temperature rated
RELIABLE PRESSURE TRANSMITTER
FOR HIGH TEMPERATURES
Balluff pressure transmitters ensure
that the pressure in the heat press is
reliably monitored. They are distinguished
by a broad temperature range of –40
to 125 °C and reliable measurement
technology. The rugged transmitters
are flexible to use: you can select from
eleven different pressure ranges, voltage
or current output, as well as various
process connections.
Features
nn Extended temperature range
nn Stainless steel housing
nn Great product variety
Solutions for
heat presses
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
1
2
REDUCE COSTS WITH IO-LINK
All the pneumatic lines come together
in the control cabinet. With our IO-Link
valve terminal connectors you use a
simple industry standard cable to con-
nect with the controller. This makes it
easy to control the reliable movement of
the pneumatic cylinders. This reduces
cost: with IO-Link, you can reduce the
wiring effort and require less cable and
hose material.
Features
nn Compact adapter housing
nn Pin compatible with a wide range of
valve terminals
nn Controls up to 24 solenoids
OPTIMUM SUPPORT FOR ALL
PROCESSES
Our high-quality and high-temperature
resistant sensors support all processing
steps of the heat press and reliably
ensure an optimum process. Optical
sensors reliably detect black rubber.
Pressure sensors reliably monitor
process media such as hydraulic fluids.
Inductive sensors monitor end positions
at little cost.
Features
nn Resistant to lubricants
nn Durable seals
Rubber and tires | 25
1
4
3
4
2
3
26 | Systems
The autonomous Balluff Mold-ID system guarantees condition-based maintenance
of the molds without time-consuming and error-prone mold logs because all relevant
data, such as drawing number, number of shots, last maintenance or service life,
is automatically saved on the mold and can be retrieved at any time. The optimum
capacity utilization of the injection molds is thus guaranteed. You can retrofit all
machines individually regardless of location or manufacturer.
Systems
Mold-ID – automatic
data acquisition
28 | Systems
1
More information about our solutions for the plastics, rubber and tire industry
can be found here: www.balluff.com
Solutions with
Mold-ID
OPTIMAL UTILIZATION OF MOLDS
With automatic documenting of the mold
utilization via RFID you can reduce un-
planned downtimes. A separate shot
counter records all production cycles.
All the data is available on a data carrier
either directly on the mold or on the
multi-coupling. In this way you can see
the mold condition directly on the ma-
chine and always keep an eye on the
life cycle of the current mold.
Features
nn Immediate information about the mold
condition
nn Mobile readout of the data using a
smart phone or RFID handheld reader
1
30 | Systems
Why Mold-ID?
Mold-ID ensures condition-based maintenance of all your
molds without having to maintain error-prone mold logs
because all the relevant information is automatically recorded
and documented. You are always informed, since the data
can be recalled at any time. In this way you can accurately
track the use of your injection molds and ensure their optimal
utilization.
Transparent mold utilization with Mold-ID allows you to monitor
maintenance and repair and provides you with basic informa-
tion for optimizing your processes.
The best part: all machines can be upgraded individually,
without the manufacturer and regardless of the location
because Mold-ID is an autonomous system.
All the molds at a glance
What Mold-ID provides
nn Fewer unplanned downtimes as the result of
− continuous counting of the shots
− automatic documentation on the mold
− visualizing the mold status
−notice for the operator about the next scheduled
maintenance
nn Transparency through the level of use of identically
designed molds
nn Overview of all molds currently running on the machines,
through access to the systems over the company network
via TCP/IP
nn Mobile reading out of the documented mold data via
smart phone or RFID handheld, for example, during an audit
or when selecting the correct mold
Mobile end devices
nn Read data
nn Initialize data carriers
nn Set limit values
nn Protect password
Mold-ID unit
nn Compact process unit
nn Webserver
nn Gateway to the company
network
nn Visualization with the
SmartLight signal light
RFID unit
nn For communication with
the data carrier
Shot counter
nn For recording
production cycles
Data carriers
nn For each mold
nn Variant depends
on the ambient conditions
Components of the Mold-ID system
Systems | 31
How Mold-ID works
The functions of Mold-ID can be divided into different phases.
You can see examples of these phases here.
How you integrate tools and asset tracking across different plants
Many companies use their tools both at the main plant and
in other production locations or at suppliers who are not con-
nected to MES. In many cases you have only incomplete
information about the location and condition of the tools,
thereby preventing an overall view.
OEM (Original Equipment Manufacturer)
MES (Manufacturing Execution System)
nn Adding data carrier
nn Specifying limit values
nn Defining names
nn Writing to data carrier
nn Reading out data
nn Defining new limit value
nn Write data to data
carrier
Initialization Resetting
One-time
nn Shot counter detects
motion
nn Feedback to system
nn RFID
nn Data from the system
nn Writing to the data
carrier on the mold
nn System
nn Comparing data
nn Updating the status
nn SmartLight stack light
triggered
Counting Write Comparing
Cyclical Maintenance
Supplier 1
Mold ID n+
IP address
Mold ID n+
IP address
Mold ID 1
IP address
MES
Tool Manager
OEM
Mold ID 1
IP address
Supplier 2
Industrial
Cloud
With Mold-ID you get detailed information about the
entire stock of tools from plant to plant. And you achieve
horizontal integration as defined by Industry 4.0.
More information about our solutions for the
plastics, rubber and tire industry can be found here:
www.balluff.com/local/gb/industry-area/industry/
32 | Plastics, Rubber and Tires
INNOVATIVE SOLUTIONS FOR
ALL REQUIREMENTS
32 | Plastics, Rubber and Tires
34 | Plastics, Rubber and Tires
Application Product group Example Functions, interfaces and properties
MATERIAL HANDLING
Detecting levels in silos BUS ultrasonic distance sensors BUS000E 80×80 mm, analog output 0...10 V,
operating range 600...6000 mm
Detecting limits (min/max)
in hoppers
BCS capacitive sensors BCS00NH M30 × 1.5, preferred types (worldwide availability
and applicability, good price/performance ratio),
level detection, M12 connection
Identify couplings at the
coupling station
Industrial RFID systems BIS BIS00YL Data carrier, Ø 7.9 mm, memory capacity 112 bytes
BIS013Z Read/write head, Ø 14.5 mm, for connecting to
BIS-V processor units
BIS00U9 BIS V processor unit, EtherCAT, connect up to four
read/write heads, with IO-Link interface, other field-
bus versions available
Detecting levels in granulate
dryers
High-temperature rated
capacitive sensors BCS
BCS00A1 M18 × 1, unshielded, high-temperature rated to
+250 °C, please order sensor amplifier separately
Sensor amplifier for BCS capa-
citive sensors without internal
amplifier
BAE00L9 Standard version, narrow design, mountable on DIN
rail, M12 connection
INJECTION MOLDING
Measuring close movement BTL magnetostrictive linear
position sensors
BTL7-V50E-...* Profile, with EtherCAT interface, measures up to
16 positions, stroke lengths up to 7620 mm
Detect movement of the
injection axis
BIW inductive positioning systems BIW1-A310-...* Profile style, analog output 0...10 V, sampling rate
typ. 32 kHz, stroke lengths up to 750 mm
Measuring clamping force on
tie bars
BAW inductive distance sensors BAW001P M12 × 1, analog output 0...10 V,
measuring range up to 2 mm, IP67
Monitor position of core pulls BMF magnetic field sensors in
mini-style
BMF00JJ Up to 8 switchpoints configurable via IO-Link
BHS high-pressure rated inductive
sensors
BHS0058 M8 × 1, switching distance 1.5 mm,
pressure rated to 500 bar, 2 m PUR cable
Product overview
* Please contact our Sales department to
configure your product.
Plastics, Rubber and Tires | 35
Application Product group Example Functions, interfaces and properties
Monitoring pressures on
hydraulic power units
BSP pressure sensors BSP008Z 0...40 bar, analog output 0...10 V with one
programmable switching point, IO-Link interface
Detecting plastic in the mold BCS high-temperature and
high-pressure rated capacitive
sensors
BCS00TC M12 × 1, length 38.5 mm, high-temperature rated
to +250 °C, high-pressure rated to 150 bar, please
order sensor amplifier separately
Sensor amplifier for capacitive sen-
sors BCS without internal amplifier
BAE00KH Standard version, narrow design, mountable on
DIN rail, 2 m PUR cable
BLOW MOLDING
Collecting signals from
standard sensors
IO-Link modules BNI BNI0077 EtherCAT IO-Link master, 8× IO-Link 1.1, 16× I/O,
IP67, additional fieldbus types available
Measuring closing and travel
movements
BTL magnetostrictive linear
position sensors
BTL7-V50E-...* Profile, with EtherCAT interface, measures up to
16 positions, stroke lengths up to 7620 mm
Counterfeit protection,
monitoring mold halves
Industrial RFID systems BIS BIS004A Data carrier, Ø 10 mm, memory capacity 2000 bytes
BIS013H Read/write head, M12 x 1, for connecting to
BIS-V processor units
BIS00U9 BIS V processor unit, EtherCAT, connect up to
four read/write heads, with IO-Link interface,
other fieldbus versions available
Monitoring level BTL magnetostrictive linear
position sensors, SF level sensor
BTL5-E17-...-SF-...* FDA- and Ecolab-certified, IP69K, analog output
IP69K, analog output 4...20 mA, temperatures up
to 130 °C (1 hr)
BONDING AND JOINING TECHNOLOGY
Precise welding head
positioning
BML magnetic encoders BML-S2B0-...* Incremental measuring principle, resolution to
50 µm, output RS422, absolute versions available
Visual quality control SmartCamera Color BVS002F Image resolution 1280 × 1024 pixels, IP67 (with
protective tube), storage capacity 4 GB, process
interface Profinet, Ethernet/IP, TCP, UDP, digital
interface 8× input/output
36 | Plastics, Rubber and Tires
Application Product group Example Functions, interfaces and properties
ROBOTICS AND AUTOMATION
Simple tool changing BIC inductive couplers BIC0070,
BIC0071
40 x 40 mm, bi-directional version,
working range 1...5 mm, with IO-Link interface
Collecting sensor signals IO-Link modules BNI BNI0077 EtherCat IO-Link master, 8× IO-Link 1.1, 16× I/O,
IP67, other fieldbus versions available
TIRE BUILDING MACHINES
Detecting end positions on
pneumatic cylinders
BMF magnetic field sensors for
cylinders, standard version
BMF006U PNP normally open, for T-slots, compact design,
with LED, 2 m PUR cable
BMF magnetic field sensors for
cylinders, reed version
BMF008P Normally open AC/DC, reed switch with LED, for
T-slots, compact design, 3 m PVC cable
Controlling centric winding BTL magnetostrictive linear
position sensors, flat profile series
BTL6-U110-...* Flat profile, with IO-Link interface 1.1,
programmable measuring length, strokes up
to 4572 mm
Monitoring roll diameter BOD photoelectric
distance sensors
BOD001E Laser red light, PNP/NPN, normally open/normally
closed, range 150...2000 mm, measuring range
1850 mm adjustable, analog output 1...10 V
Checking tilt movements on
material feed equipment
BSI inclination sensors BSI0002 Measuring range ±45°, resolution ±0.01°, analog
output 4...20 mA, metal housing, M8 connector
HEAT PRESSES
Monitoring the closing
movement of the press
BTL magnetostrictive linear
position sensors
BTL7-E500-...* Rod style, analog output 4...20 mA, programmable
measuring range, strokes up to 7620 mm
BTL7-E501-...* Profile style, analog output 4...20 mA, measuring
range programmable,
stroke lengths up to 7620 mm
Monitoring pressure in the
heating press
BSP pressure transmitter BSP...-DV004-...* Pressure ranges selectable from –1 to 600, analog
output 0...10 V DC, process connection G¼“
Sending bundled signals from
valve terminals
Valve terminal plug BNI BNI001K Actuators, valve terminal and pneumatics can be
turned off individually, 24 outputs, compact size,
LED indicator
* Please contact our Sales department to
configure your product.
Plastics, Rubber and Tires | 37
Application Product group Example Functions, interfaces and properties
Heat press processing steps BES inductive sensors BES01C8 M12 × 1, PNP normally open, with LED, switching
distance 2 mm, IP68, M12 connector
BES04CK M12 × 1, PNP normally open, switching distance
2 mm, temperature range –25...+160 °C, IP69K,
2 m FEP cable
BOS photoelectric sensors BOS013H Series BOS 18M, PNP N.O./N.C., with LED,
detection range 0...350 mm, M12 connector
BOS01CL Series BOS 50K, retro-reflective, red light, detection
range 0.1...18 m, connection M12 connector
BCS capacitive sensors BCS001F Disc Ø 22 × 4 mm, shielded, perfect for detecting
rubber, please order sensor amplifier separately
Sensor amplifier for capacitive sen-
sors BCS without internal amplifier
BAE00L9 Standard version, narrow design, mountable on
DIN rail, M12 connection
BMF magnetic field sensors for
cylinders
BMF00C9 For T-slots, V-Twin (two sensor heads), IP67,
0.3 m cable with M12 connector
BLA light arrays BLA0001 Light-band width 50 mm, max. distance 2 m, laser,
2× analog output 0...10 V or 4...20 mA switchable
MOLD ID
Optimal utilization of molds Industrial RFID systems BIS BIS00YE
BIS0180
Data carrier, PPS plastic, IO-Link
BIS00EJ
BIS018E
Read/write head with integrated processor unit,
M18 × 1.5, IP67, working temperature up to +70 °C
Mold-ID unit BNI00CE Compact process unit, webserver, gateway to
company network, visualization with SmartLight
stack light, rugged housing, IP67
Handhelds BIS M-87_-...* Mobile reading and writing of BIS data carriers,
with display and touch screen, WLAN optional
Balluff is one of the leading suppliers of high-quality sensor, identification and network solutions
and of software for your automation requirements. Family-owned for more than 90 years,
around 3600 employees worldwide in 37 wholly-owned subsidiaries for sales, production and
development are dedicated to the highest quality.
We give our all to provide top services for innovative solutions that increase your competitive
edge. Through years of experience we bring the competence of a manufacturer and high
personal engagement.
We follow our motto „Innovating Automation“ as pacemakers of automation, refiners and new
developers, and technological trailblazers. In open exchange with associations, universities
and research institutes as well as in close contact with our customers we create new industrial
sector solutions for automation. With innovative Balluff solutions you are well equipped for a
successful future.
You can always count on us, our products and our scheduling and delivery reliability.
In the spirit of a good partnership.
Balluff
WE OPEN UP NEW
PERSPECTIVES
Balluff | 39
Global Project Management
WE ARE EVERYWHERE
FOR YOU
40 | Balluff
Always where you need us
Wherever you are doing business, we will support you locally. We work
closely with machine and systems builders, systems integrators, planning
offices and maintenance engineers. Balluff has constructed a global network
for you consisting of technical consulting, sales and after-sales services.
Project manuals and approval lists
We provide you with custom tailored product data for smooth running
of your projects. You receive project-specific manuals and approval lists.
And personal contacts from Balluff are at your side throughout the entire
project.
Individual services
If our services need to be even more personalized, we make this possible
as well: with individual e-catalogs, application-specific product modifications,
integrated software and system solutions, and comprehensive logistics
concepts.
Questions? Contact us. We are happy to help.
Photo credit:
Reproduced with
the kind permission
of Hennecke GmbH
The demands in the plastics, rubber and tire are high and getting higher.
Our commitment is to the success of our customers. Future-looking technologies,
market-oriented solutions and the expertise of an experienced manufacturer are what
we draw on to increase your competitiveness. This is why companies worldwide trust
in Balluff solutions for plastics, rubber and tire solutions.
We work together with such companies as
REFERENCES
Plastics, Rubber and Tires | 43
Doc.-No.922252/Mat.-No.2464421EN·K17;subjecttochanges.ReplacesE15.
www.balluff.com
Headquarters
Balluff GmbH
Schurwaldstrasse 9
73765 Neuhausen a. d. F.
Germany
Phone +49 7158 173-0
Fax +49 7158 5010
balluff@balluff.de
CONTACT
OUR
WORLDWIDE
SUBSIDIARIES

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PRECISION FOR HIGH SYSTEM AVAILABILITY IN PLASTICS AND RUBBER

  • 1. PRECISION FOR HIGH SYSTEM AVAILABILITY Plastics, Rubber and Tires
  • 2. WE ARE AT HOME IN MANY INDUSTRIAL SECTORS 2 | Plastics, Rubber and Tires
  • 3.
  • 4.
  • 5. 20 RUBBER AND TIRES 26 SYSTEMS 34 PRODUCTS PLASTICS 6 8 Material handling 10 Injection molding 14 Blow molding 16 Bonding and joining technology 18 Robotics and automation 22 Tire building machines 24 Heat presses 28 Mold ID ABOUT BALLUFF 40 REFERENCES 42 Plastics, Rubber and Tires | 5 CONTENTS
  • 6. Plastic is the material of the 21st century. Its application range is enormous and is becoming ever broader thanks to new compositions, so the demands on production and machine building continue to grow. Balluff offers high-performance sensor and system solutions with high-quality network and connectivity technology. And thereby the ideal prerequisites for reliably managing the growing variety. The high quality of our solutions enables sophisticated systems concepts, improves machine availability and contributes to more efficient utilization, whether in material handling, injection or blow molding, tire construction and heating presses, or bonding and joining technology. We also provide solutions for optimal tool utilization. Plastic RELIABLY MANAGING THE GROWING VARIETY
  • 8. CONTINUOUSLY KEEP AN EYE ON THE FILL LEVEL Our high-resolution ultrasonic sensors don't miss a thing: they reliably monitor the level of granulates and powders in silos. The continuous and contact-free measurement technology is virtually immune to dust and dirt. The fill level can be output as needed by an analog signal or with two switching signals as min/max values. Features nn Contact-free nn Detects even the smallest objects nn Cubic and cylindrical designs FAST AND RELIABLE CONTROL IN COUPLING STATIONS To ensure the correct mixture of addi- tives, dyes and granulates in the coupling station Balluff uses autonomous RFID systems. Each coupling is identified and only released if it is connected at the right location. This way, we ensure that the right component is always used. Features nn Rugged nn Quick and powerful nn Protection from improper filling FILL LEVEL INDICATORS FOR CONTINUOUS MATERIAL FEED To ensure constant material flow the min/max level must be detected continuously in the injection molding machine. Capacitive sensors can per- form this task for you: whether in the hopper in direct contact with the mate- rials or through the outer wall, the fill level indicators reliably determine all the values. Features nn For all materials nn Simple sensor replacement nn Miniature designs 1 3 2 1 2
  • 9. HIGH-TEMPERATURE RATED SENSORS FOR DRYING Dry granulate is essential for high-quality plastic parts. Our capacitive stainless steel sensors, resistant to high tempera- tures, ensure an even feed of the moist granulate into the dryer. They are heat resistant to 250 °C and reliably monitor all levels. Features nn Stainless steel nn Sensor head made of PTFE Solutions for material handling More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/ Plastics | 9 3
  • 11. Plastics | 11 Precision stands for quality: resilient, extremely accurate Balluff technology ensures continuity in injection molding and supports high availability of your equipment. 2 3 4
  • 12. 12 Plastics | HIGH-PRECISION DISPLACEMENT TRANSDUCERS FOR A GENTLE MOLD CLOSURE With the help of a high-precision magne- tostrictive linear position sensor from Balluff you can precisely monitor the closing motion of the platen. A gentle mold closure reduces wear and extends your mold's useful life. Features nn Contact-free and therefore wear-free nn No homing necessary, immediately ready nn Resistant to vibration, moisture and dust DETECTING THE INJECTION PROCESS Our BIW inductive positioning system ensures that your molds are quickly filled because the high sampling fre- quency and repeat accuracy measure the travel of the injection axis precisely and reliably. You can exactly calibrate the injection profile, for example, to produce high-quality, thin-wall parts. Features nn Fast: High measuring frequency of 32 kHz nn Non-contact position detection nn High repeat accuracy CONTINUOUS MONITORING WITH INDUCTIVE SENSORS Inductive distance sensors from Balluff ensure continuous monitoring of the tie bar extension in the process. They are insensitive to contamination and provide optimal linearity as well as high repeat accuracy. Features nn Distance-proportional, analog output signal nn Measuring ranges from 0.5 to 50 mm nn Measuring speed up to 40 m/s 1 2 3
  • 13. Plastics | 13 DETECT THE POSITION OF CORE PULLS To optimally adjust core pulls our ma- gnetic field sensors in the mini-format are ideal. They ensure that the core pull is at the required end position and they detect the position directly at the hydraulic block cylinder. Alternately, you can use high-temperature rated sensors. Features nn Designed for tight mounting locations nn Can be fully integrated nn Low weight nn Wear-free position detection nn Two teachable switching outputs via IO-Link for up to eight switchpoints CONTINUOUS PRESSURE MONITORING WITH IO-LINK Perfect closure of the clamping plates requires the correct pressure. Reliable pressure monitoring in the hydraulic cylinder is handled by a rugged pressure sensor in a stainless steel housing. Equipped with IO-Link, the pressure sensors relay their values directly to the controller and thus let it readjust with precision. Features nn Extended temperature range up to 125 °C nn Up to 600 bar nn Process-oriented installation MEASURING MOLD FILLING IN RTM (RESIN TRANSFER MOLDING) Our high-pressure and high temperature rated capacitive sensors reliably check whether the cavity is fully filled and the RTM is completed. They offer great mechanical stability, e.g., for lightweight construction and can be integrated directly in the tool. Their specially polished surface prevents plastics and composites from sticking. Features nn Pressure rated to 150 bar nn Temperature-resistant up to 180 °C nn Flush-mounted 4 5 More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/
  • 14. Solutions for blow molding A MODULE FOR MORE TRANSPARENCY The Balluff EtherCAT module with IO-Link interface collects all the signals from the various standard sensors and relays them to the controller. This solution simplifies the entire network structure and creates transparency down to the last meter. Features nn 8 independent IO-Link ports nn Integrated display nn Automatic address assignment More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/ 14 Plastics | 1 1
  • 15. ALL MOVEMENTS FIRMLY UNDER CONTROL Travel movements at the blow station are under control with Balluff BTL magnetostrictive linear position sensors even if there are vibrations. The high- precision measurement systems have an EtherCAT interface. Because of their contact-free and wear-free measuring principle, they contribute to long ma- chine running times. Features nn EtherCAT interface nn No homing necessary, immediately ready FAST MOLD CHANGING AND RELIABLE PROTECTION AGAINST COUNTERFEITS Balluff Industrial RFID enables fast and reliable mold replacement with the unambiguous association of mold halves through unique IDs. You also benefit from secure counterfeit protection. This solution allows for rapid size changes and facilitates a continuous process. Features nn Flexible, non-contact data communi- cation nn Fast and sturdy nn Counterfeit protection FILL BEVERAGES ON SITE The beverage industry uses stretch blow molding machines to produce bottles. If the bottles are filled immediately afterward, our high-precision SF fill level sensor controls the fill level during the process. On-site filling can save you transport distances and thereby mini- mize costs. Features nn Ecolab, 3A-approval, IP69K nn For aseptic processes nn Safe for sterilization (SIP) and cleaning (CIP) 2 2 3 3
  • 16. FAST AND PRECISE ALIGNMENT OF THE WELDING HEAD Our fast and high-precision magnetic encoders give you precise position feed- back. They position the welding head exactly at the right place. Because the absolute measurement is made directly on the load, tolerance shifts and inac- curacies are prevented. Features nn Accurate position feedback nn Compact housing nn Ideal for short strokes VISUAL QUALITY CONTROL The SmartCamera checks all the parts including their production stages: Are they complete and defect-free? Are the size, distance and position correct? And are they correctly aligned? The best part: all the steps can be easily taught. Features nn Flexible use of analysis tools nn Simple to operate with user-guided teach-in nn Optimized display of the results Solutions for bonding and joining technology 16 Plastics | 1 2 More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/
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  • 18. Solutions for robotics and automation More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/ 2
  • 19. Plastics | 19 SIMPLE GRIPPER CHANGES USING INDUCTIVE COUPLERS With the help of Balluff inductive coup- lers, the need for manual insertion of mechanical connectors is eliminated. The couplers send signals and power without contact, are easy to use and offer maximum flexibility. The quick- disconnect units can be changed in the gripper in just moments. Features nn Long service life, no mechanical wear nn Plug-and-play nn Weight savings COST REDUCTION THANKS TO SIMPLE RECORDING OF SIGNALS Our IO-Link sensor hubs made of plastic or metal collect the signals from the sen- sors embedded in the gripper and pass them along in bundled form to the con- troller. The controller can be connected to a 16-port IO-Link master, which re- cords the signals of up to 272 sensors. This reduces your wiring effort, saves weight and reduces cost. Features nn Easy to install nn Central parameter setting nn Continuous diagnostics 1 2 1
  • 20. To address production of different batch sizes with minimal changeover times Balluff offers advanced and rugged technology for the tire building machine and heat press. Our high-quality sensors detect end positions of the pneumatic cylinders, position the sliders for the correct tire build, monitor for liner sag, and ensure the same pressure for each press cycle. They remain unaffected by heat, steam and aggressive media. Use our machine concepts and profit from high equipment availability to further increase the productivity of your manufacturing process. Rubber and tires PRECISION AND QUALITY FOR HARSH CONDITIONS
  • 22. CONTROLLED MOVEMENT OF THE TIRE BUILDING MACHINE Our magnetic field sensors reliably de- tect the end position of the piston in pneumatic cylinders and ensure proper motion of the tire building machine. The sensors, which are resistant to tempera- tures up to 105 °C, replace wear-prone magnetic reed switches and have a long service life. Features nn Precise switching point nn Also for short stroke cylinders nn Wear-free MAXIMUM PRECISION DURING WINDING High fitting accuracy means each tire layer must be precisely fed, wound and cut. Our BTL magnetostrictive linear position sensors position the slide with precision, even in rough conditions. This ensures that the tire build precisely complies with the specifications. Features nn Highly precise and wear-free nn Impervious to vibration CONTINUOUS MONITORING WITH PHOTOELECTRIC DISTANCE SENSORS Our photoelectric distance sensors con- tinuously check the roll diameter in order to continuously provide the winding roll with tread strips for the green tire. The robust sensors also perform sag control. The difficult-to-detect black layers have no effect on the result. Features nn Absolute, distance-proportional analog signal nn Compact, solid and reliable nn Also available with IO-Link 1 2 1 2 3 4 3
  • 23. PRECISE MONITORING OF TILT MOVEMENTS Balluff inclination sensors reliably moni- tor the tilt movements of the conveyor belt. This allows the belt to be accurately guided when it is moved for the subse- quent work steps. The inclination sen- sors guarantee a high accuracy of 0.1° and very low temperature drift. Features nn Precise position monitoring nn Extended temperature range –40 to 85 °C Solutions for tire building machines Rubber and tires | 23 4 More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/
  • 24. RELIABLE CLOSING STROKE, EVEN UNDER EXTREME CONDITIONS When the green tire is pressed into the hot mold under high pressure with hot water, the heating press must be tightly closed. A reliable closing stroke is en- sured by Balluff BTL magnetostrictive linear position sensors, even under high temperatures and strong vibrations. Features nn Profile housing for easy installation nn Temperature rated RELIABLE PRESSURE TRANSMITTER FOR HIGH TEMPERATURES Balluff pressure transmitters ensure that the pressure in the heat press is reliably monitored. They are distinguished by a broad temperature range of –40 to 125 °C and reliable measurement technology. The rugged transmitters are flexible to use: you can select from eleven different pressure ranges, voltage or current output, as well as various process connections. Features nn Extended temperature range nn Stainless steel housing nn Great product variety Solutions for heat presses More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/ 1 2
  • 25. REDUCE COSTS WITH IO-LINK All the pneumatic lines come together in the control cabinet. With our IO-Link valve terminal connectors you use a simple industry standard cable to con- nect with the controller. This makes it easy to control the reliable movement of the pneumatic cylinders. This reduces cost: with IO-Link, you can reduce the wiring effort and require less cable and hose material. Features nn Compact adapter housing nn Pin compatible with a wide range of valve terminals nn Controls up to 24 solenoids OPTIMUM SUPPORT FOR ALL PROCESSES Our high-quality and high-temperature resistant sensors support all processing steps of the heat press and reliably ensure an optimum process. Optical sensors reliably detect black rubber. Pressure sensors reliably monitor process media such as hydraulic fluids. Inductive sensors monitor end positions at little cost. Features nn Resistant to lubricants nn Durable seals Rubber and tires | 25 1 4 3 4 2 3
  • 26. 26 | Systems The autonomous Balluff Mold-ID system guarantees condition-based maintenance of the molds without time-consuming and error-prone mold logs because all relevant data, such as drawing number, number of shots, last maintenance or service life, is automatically saved on the mold and can be retrieved at any time. The optimum capacity utilization of the injection molds is thus guaranteed. You can retrofit all machines individually regardless of location or manufacturer. Systems Mold-ID – automatic data acquisition
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  • 29. More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com Solutions with Mold-ID OPTIMAL UTILIZATION OF MOLDS With automatic documenting of the mold utilization via RFID you can reduce un- planned downtimes. A separate shot counter records all production cycles. All the data is available on a data carrier either directly on the mold or on the multi-coupling. In this way you can see the mold condition directly on the ma- chine and always keep an eye on the life cycle of the current mold. Features nn Immediate information about the mold condition nn Mobile readout of the data using a smart phone or RFID handheld reader 1
  • 30. 30 | Systems Why Mold-ID? Mold-ID ensures condition-based maintenance of all your molds without having to maintain error-prone mold logs because all the relevant information is automatically recorded and documented. You are always informed, since the data can be recalled at any time. In this way you can accurately track the use of your injection molds and ensure their optimal utilization. Transparent mold utilization with Mold-ID allows you to monitor maintenance and repair and provides you with basic informa- tion for optimizing your processes. The best part: all machines can be upgraded individually, without the manufacturer and regardless of the location because Mold-ID is an autonomous system. All the molds at a glance What Mold-ID provides nn Fewer unplanned downtimes as the result of − continuous counting of the shots − automatic documentation on the mold − visualizing the mold status −notice for the operator about the next scheduled maintenance nn Transparency through the level of use of identically designed molds nn Overview of all molds currently running on the machines, through access to the systems over the company network via TCP/IP nn Mobile reading out of the documented mold data via smart phone or RFID handheld, for example, during an audit or when selecting the correct mold Mobile end devices nn Read data nn Initialize data carriers nn Set limit values nn Protect password Mold-ID unit nn Compact process unit nn Webserver nn Gateway to the company network nn Visualization with the SmartLight signal light RFID unit nn For communication with the data carrier Shot counter nn For recording production cycles Data carriers nn For each mold nn Variant depends on the ambient conditions Components of the Mold-ID system
  • 31. Systems | 31 How Mold-ID works The functions of Mold-ID can be divided into different phases. You can see examples of these phases here. How you integrate tools and asset tracking across different plants Many companies use their tools both at the main plant and in other production locations or at suppliers who are not con- nected to MES. In many cases you have only incomplete information about the location and condition of the tools, thereby preventing an overall view. OEM (Original Equipment Manufacturer) MES (Manufacturing Execution System) nn Adding data carrier nn Specifying limit values nn Defining names nn Writing to data carrier nn Reading out data nn Defining new limit value nn Write data to data carrier Initialization Resetting One-time nn Shot counter detects motion nn Feedback to system nn RFID nn Data from the system nn Writing to the data carrier on the mold nn System nn Comparing data nn Updating the status nn SmartLight stack light triggered Counting Write Comparing Cyclical Maintenance Supplier 1 Mold ID n+ IP address Mold ID n+ IP address Mold ID 1 IP address MES Tool Manager OEM Mold ID 1 IP address Supplier 2 Industrial Cloud With Mold-ID you get detailed information about the entire stock of tools from plant to plant. And you achieve horizontal integration as defined by Industry 4.0. More information about our solutions for the plastics, rubber and tire industry can be found here: www.balluff.com/local/gb/industry-area/industry/
  • 32. 32 | Plastics, Rubber and Tires INNOVATIVE SOLUTIONS FOR ALL REQUIREMENTS 32 | Plastics, Rubber and Tires
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  • 34. 34 | Plastics, Rubber and Tires Application Product group Example Functions, interfaces and properties MATERIAL HANDLING Detecting levels in silos BUS ultrasonic distance sensors BUS000E 80×80 mm, analog output 0...10 V, operating range 600...6000 mm Detecting limits (min/max) in hoppers BCS capacitive sensors BCS00NH M30 × 1.5, preferred types (worldwide availability and applicability, good price/performance ratio), level detection, M12 connection Identify couplings at the coupling station Industrial RFID systems BIS BIS00YL Data carrier, Ø 7.9 mm, memory capacity 112 bytes BIS013Z Read/write head, Ø 14.5 mm, for connecting to BIS-V processor units BIS00U9 BIS V processor unit, EtherCAT, connect up to four read/write heads, with IO-Link interface, other field- bus versions available Detecting levels in granulate dryers High-temperature rated capacitive sensors BCS BCS00A1 M18 × 1, unshielded, high-temperature rated to +250 °C, please order sensor amplifier separately Sensor amplifier for BCS capa- citive sensors without internal amplifier BAE00L9 Standard version, narrow design, mountable on DIN rail, M12 connection INJECTION MOLDING Measuring close movement BTL magnetostrictive linear position sensors BTL7-V50E-...* Profile, with EtherCAT interface, measures up to 16 positions, stroke lengths up to 7620 mm Detect movement of the injection axis BIW inductive positioning systems BIW1-A310-...* Profile style, analog output 0...10 V, sampling rate typ. 32 kHz, stroke lengths up to 750 mm Measuring clamping force on tie bars BAW inductive distance sensors BAW001P M12 × 1, analog output 0...10 V, measuring range up to 2 mm, IP67 Monitor position of core pulls BMF magnetic field sensors in mini-style BMF00JJ Up to 8 switchpoints configurable via IO-Link BHS high-pressure rated inductive sensors BHS0058 M8 × 1, switching distance 1.5 mm, pressure rated to 500 bar, 2 m PUR cable Product overview * Please contact our Sales department to configure your product.
  • 35. Plastics, Rubber and Tires | 35 Application Product group Example Functions, interfaces and properties Monitoring pressures on hydraulic power units BSP pressure sensors BSP008Z 0...40 bar, analog output 0...10 V with one programmable switching point, IO-Link interface Detecting plastic in the mold BCS high-temperature and high-pressure rated capacitive sensors BCS00TC M12 × 1, length 38.5 mm, high-temperature rated to +250 °C, high-pressure rated to 150 bar, please order sensor amplifier separately Sensor amplifier for capacitive sen- sors BCS without internal amplifier BAE00KH Standard version, narrow design, mountable on DIN rail, 2 m PUR cable BLOW MOLDING Collecting signals from standard sensors IO-Link modules BNI BNI0077 EtherCAT IO-Link master, 8× IO-Link 1.1, 16× I/O, IP67, additional fieldbus types available Measuring closing and travel movements BTL magnetostrictive linear position sensors BTL7-V50E-...* Profile, with EtherCAT interface, measures up to 16 positions, stroke lengths up to 7620 mm Counterfeit protection, monitoring mold halves Industrial RFID systems BIS BIS004A Data carrier, Ø 10 mm, memory capacity 2000 bytes BIS013H Read/write head, M12 x 1, for connecting to BIS-V processor units BIS00U9 BIS V processor unit, EtherCAT, connect up to four read/write heads, with IO-Link interface, other fieldbus versions available Monitoring level BTL magnetostrictive linear position sensors, SF level sensor BTL5-E17-...-SF-...* FDA- and Ecolab-certified, IP69K, analog output IP69K, analog output 4...20 mA, temperatures up to 130 °C (1 hr) BONDING AND JOINING TECHNOLOGY Precise welding head positioning BML magnetic encoders BML-S2B0-...* Incremental measuring principle, resolution to 50 µm, output RS422, absolute versions available Visual quality control SmartCamera Color BVS002F Image resolution 1280 × 1024 pixels, IP67 (with protective tube), storage capacity 4 GB, process interface Profinet, Ethernet/IP, TCP, UDP, digital interface 8× input/output
  • 36. 36 | Plastics, Rubber and Tires Application Product group Example Functions, interfaces and properties ROBOTICS AND AUTOMATION Simple tool changing BIC inductive couplers BIC0070, BIC0071 40 x 40 mm, bi-directional version, working range 1...5 mm, with IO-Link interface Collecting sensor signals IO-Link modules BNI BNI0077 EtherCat IO-Link master, 8× IO-Link 1.1, 16× I/O, IP67, other fieldbus versions available TIRE BUILDING MACHINES Detecting end positions on pneumatic cylinders BMF magnetic field sensors for cylinders, standard version BMF006U PNP normally open, for T-slots, compact design, with LED, 2 m PUR cable BMF magnetic field sensors for cylinders, reed version BMF008P Normally open AC/DC, reed switch with LED, for T-slots, compact design, 3 m PVC cable Controlling centric winding BTL magnetostrictive linear position sensors, flat profile series BTL6-U110-...* Flat profile, with IO-Link interface 1.1, programmable measuring length, strokes up to 4572 mm Monitoring roll diameter BOD photoelectric distance sensors BOD001E Laser red light, PNP/NPN, normally open/normally closed, range 150...2000 mm, measuring range 1850 mm adjustable, analog output 1...10 V Checking tilt movements on material feed equipment BSI inclination sensors BSI0002 Measuring range ±45°, resolution ±0.01°, analog output 4...20 mA, metal housing, M8 connector HEAT PRESSES Monitoring the closing movement of the press BTL magnetostrictive linear position sensors BTL7-E500-...* Rod style, analog output 4...20 mA, programmable measuring range, strokes up to 7620 mm BTL7-E501-...* Profile style, analog output 4...20 mA, measuring range programmable, stroke lengths up to 7620 mm Monitoring pressure in the heating press BSP pressure transmitter BSP...-DV004-...* Pressure ranges selectable from –1 to 600, analog output 0...10 V DC, process connection G¼“ Sending bundled signals from valve terminals Valve terminal plug BNI BNI001K Actuators, valve terminal and pneumatics can be turned off individually, 24 outputs, compact size, LED indicator * Please contact our Sales department to configure your product.
  • 37. Plastics, Rubber and Tires | 37 Application Product group Example Functions, interfaces and properties Heat press processing steps BES inductive sensors BES01C8 M12 × 1, PNP normally open, with LED, switching distance 2 mm, IP68, M12 connector BES04CK M12 × 1, PNP normally open, switching distance 2 mm, temperature range –25...+160 °C, IP69K, 2 m FEP cable BOS photoelectric sensors BOS013H Series BOS 18M, PNP N.O./N.C., with LED, detection range 0...350 mm, M12 connector BOS01CL Series BOS 50K, retro-reflective, red light, detection range 0.1...18 m, connection M12 connector BCS capacitive sensors BCS001F Disc Ø 22 × 4 mm, shielded, perfect for detecting rubber, please order sensor amplifier separately Sensor amplifier for capacitive sen- sors BCS without internal amplifier BAE00L9 Standard version, narrow design, mountable on DIN rail, M12 connection BMF magnetic field sensors for cylinders BMF00C9 For T-slots, V-Twin (two sensor heads), IP67, 0.3 m cable with M12 connector BLA light arrays BLA0001 Light-band width 50 mm, max. distance 2 m, laser, 2× analog output 0...10 V or 4...20 mA switchable MOLD ID Optimal utilization of molds Industrial RFID systems BIS BIS00YE BIS0180 Data carrier, PPS plastic, IO-Link BIS00EJ BIS018E Read/write head with integrated processor unit, M18 × 1.5, IP67, working temperature up to +70 °C Mold-ID unit BNI00CE Compact process unit, webserver, gateway to company network, visualization with SmartLight stack light, rugged housing, IP67 Handhelds BIS M-87_-...* Mobile reading and writing of BIS data carriers, with display and touch screen, WLAN optional
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  • 39. Balluff is one of the leading suppliers of high-quality sensor, identification and network solutions and of software for your automation requirements. Family-owned for more than 90 years, around 3600 employees worldwide in 37 wholly-owned subsidiaries for sales, production and development are dedicated to the highest quality. We give our all to provide top services for innovative solutions that increase your competitive edge. Through years of experience we bring the competence of a manufacturer and high personal engagement. We follow our motto „Innovating Automation“ as pacemakers of automation, refiners and new developers, and technological trailblazers. In open exchange with associations, universities and research institutes as well as in close contact with our customers we create new industrial sector solutions for automation. With innovative Balluff solutions you are well equipped for a successful future. You can always count on us, our products and our scheduling and delivery reliability. In the spirit of a good partnership. Balluff WE OPEN UP NEW PERSPECTIVES Balluff | 39
  • 40. Global Project Management WE ARE EVERYWHERE FOR YOU 40 | Balluff Always where you need us Wherever you are doing business, we will support you locally. We work closely with machine and systems builders, systems integrators, planning offices and maintenance engineers. Balluff has constructed a global network for you consisting of technical consulting, sales and after-sales services. Project manuals and approval lists We provide you with custom tailored product data for smooth running of your projects. You receive project-specific manuals and approval lists. And personal contacts from Balluff are at your side throughout the entire project. Individual services If our services need to be even more personalized, we make this possible as well: with individual e-catalogs, application-specific product modifications, integrated software and system solutions, and comprehensive logistics concepts. Questions? Contact us. We are happy to help.
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  • 42. Photo credit: Reproduced with the kind permission of Hennecke GmbH
  • 43. The demands in the plastics, rubber and tire are high and getting higher. Our commitment is to the success of our customers. Future-looking technologies, market-oriented solutions and the expertise of an experienced manufacturer are what we draw on to increase your competitiveness. This is why companies worldwide trust in Balluff solutions for plastics, rubber and tire solutions. We work together with such companies as REFERENCES Plastics, Rubber and Tires | 43
  • 44. Doc.-No.922252/Mat.-No.2464421EN·K17;subjecttochanges.ReplacesE15. www.balluff.com Headquarters Balluff GmbH Schurwaldstrasse 9 73765 Neuhausen a. d. F. Germany Phone +49 7158 173-0 Fax +49 7158 5010 balluff@balluff.de CONTACT OUR WORLDWIDE SUBSIDIARIES