This presentation discusses the latest sensor trends from Balluff, including: 1) Their smallest inductive sensors yet, the SuperShorty sensors, which enable new applications due to their miniature size. 2) Alternatives to fiber optic sensors, such as their Ultraframe sensors, which provide more reliable detection for applications like feed systems. 3) New technologies for sensing pneumatic cylinders and loads, including dual sensor systems, lifetime warranties, and direct load monitoring with linear encoders. 4) Methods to improve sensor survivability in harsh environments like welding through products like their Bunker Block housing and high temperature sensors. 5) The new SmartLevel capacitive sensors which can auto-tune for difficult liquid

1. WWW.BALLUFF.COM
Sensing & Feedback Technologies
S i F db k T h l i
The Latest Sensor Trends
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2. PRESENTATION : New Tech
Agenda
• Miniature sensors open up new
applications
• Alternatives to Fiber optics
• Pneumatic cylinder sensing:
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Dual systems, analog and lifetime
warranties are just a start
• Direct load monitoring:
a better way to close the loop
• Sensors survivability:
it’s not by chance
• SmartLevel:
a fusion for capacitive and
conductance technologies
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3. PRESENTATION : New Tech
Miniature Sensors
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4. WWW.BALLUFF.COM
SuperShorty
SuperShorty™ Miniature Inductive Sensors
Imagine the Possibilities...
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5. PRESENTATION : New Tech
SuperShorty™
Imagine the Possibilities...
Main Features:
– The shortest self contained
inductive sensors in the world!
– Cable out models only 6mm & 10mm long
– M8 connectorized models only 18mm long
– Incredibly light weight 6mm long version (0.7g) makes them
ideal for high speed and highly-dynamic applications
– Easy to Integrate - No bulky external amplifier required
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– Easy to install – (2) different threaded mounting brackets
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6. PRESENTATION : New Tech
SuperShorty
SuperShorty™
Application: Pneumatic-motor
Ø6.5 X 6mm
Even in the very space-critical pneumatic-
motor, there is enough room for (3)
SuperShorty sensors.
In this application the sensors have to
verify the “step” position
step position.
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7. PRESENTATION : New Tech
SuperShorty™
p y
Application: Pick-and-place
Ø6.5 x 6mm
Ideal for highly-dynamic
applications
Applications with extremely high
accelerations, e. g. pick-and-place,
are made possible due to its light
d ibl d t it li ht
weight (just 0.7 grams).
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8. PRESENTATION : New Tech
SuperShorty
SuperShorty™
Application: Vertical Linear Slide
Ø6.5 X 6mm
Easy to integrate…
… e g in linear slides for end-of-
e. g.
travel monitoring. Electronics are
fully integrated in the 6 mm
housing. No machine space is
needed f an external amplifier.
for f
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9. PRESENTATION : New Tech
Fiber Optic Alternatives
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10. PRESENTATION : New Tech
Ultraframe Applications
Fiber Optic Upgrade
Absolute #1 solution for feed systems
y
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11. PRESENTATION : New Tech
U t a a e pp cat o s
Ultraframe Applications
Precision Laser “L” Shape
L
– About 10x the
resolution and – Ideal for 2 axis movements
repeatability of – Extremely rugged
standard visible red – Powerful light source
g
– Beam visible in all
conditions
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12. PRESENTATION : New Tech
Distributor Program Reminder
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ULTRAFRAME™
Family of self-contained thru-beam sensors
BGL BOW
Thru-beam reliability in a single-piece package
• Four different shapes to choose from
• Up to f
four application-specific light sources available
f
• IP67 rated housings
• Greatly reduces installation time
BWL
BWL
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13. PRESENTATION : New Tech
Error Proofing Sensors in Tooling
Kohler Case Assembly Press: 30 inspections with Ultraframe
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14. PRESENTATION : New Tech
New Transparent Detection
Ideal for detecting:
- Glass bottles
- PET bottles
- Transparent films
- Glass sheets
- Vials
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15. PRESENTATION : New Tech
Pneumatic Cylinder
P ti C li d
Position Sensors
 Superior Magnetoresistive technology
 Universal and application specific housings
 Lifetime warranty
 Analog versions for cylinders and grippers
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16. PRESENTATION : New Tech
The Solid Solid-State
Solid State
Pneumatic Cylinder Sensor Lifetime Warranty
Magnetically Actuated Sensors
Proven Magnetoresistive
technology offers unmatched reliability
Compatible
Cylinder Profiles
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17. PRESENTATION : New Tech
Technology Comparison
The Upgrade for
pneumatic cylinders
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Giant MagnetoResistive (GMR) Chip manufacturer ad

18. PRESENTATION : New Tech
New Product: V-Twin Series
• Two sensors one connector
• Reduce connection cost and installation time
• Detect multiple positions on grippers and
cylinders
• M8 and M12 versions
• Uses Magneto-resistive technology
• Lifetime warranty
• Multiple versions available for C-Slot, T-Slot, tie
rod, round and dovetail
• Replaces reed and Hall-Effect switches
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19. PRESENTATION : New Tech
Pneumatic Cylinder with Feedback
Linear Feedback for Automated Changeover
– Allows use of low-cost pneumatic cylinders
– Rod locks hold position
– Rod follower or internal magnet tracking
– Absolute position feedback
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20. PRESENTATION : New Tech
DC Motor with Feedback
Linear Feedback for Automated Changeover
– Allows use of low-cost DC Motor
– Use standard Acme screw
– Recipe driven automatic changeover
– Absolute position feedback
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21. PRESENTATION : New Tech
Direct load monitoring
A b tt way t close the loop
better to l th l
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22. PRESENTATION : New Tech
Multiple Feedback Motion Control
• More AC servo drives are appearing with multiple feedback inputs
• Rather than closing just one variable, these newer drive controllers
variable
can close multiple loops
• These new drives are opening up more applications for linear encoders
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23. PRESENTATION : New Tech
Multiple Feedback Motion Control
• Linear encoders augment, rather than
replace, rotary shaft encoders
l h f d
• Torque loop closed by motor current sensor
• Velocity loop closed by motor shaft encoder
– Position loop not closed by shaft encoder
• Position loop closed by linear encoder
– Allows more precise control high-inertia loads
– All
Allows hi h speeds f h
higher d for heavy l d
loads
– Prevents surging, hunting, and position overshoot
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24. PRESENTATION : New Tech
Indirect Position Monitoring
Rotary Encoders
– Report motor shaft position, not actual load position
– Report load position through mechanical drive system:
• Ball screws, rack & pinion, synchronous belt drives
– Mechanical drive tolerances limit practical accuracy
Reported Position: 10.0000
10.0000”
Actual Position: 10.0721”
Load Carriage Rotary Encoder
Ball Screw Follower Rotating Ball Screw Motor
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25. PRESENTATION : New Tech
Indirect Load Monitoring
Rotary encoder itself is accurate
R t d it lf i t
Rotary encoder correctly reports shaft position
BUT…shaft position is only an estimate of actual
BUT h ft iti i l ti t f t l
load position due to mechanical factors such as
backlash
Accuracy decreases as drive wears and backlash
increases
Accuracy li it d by precision of drive
A limited b i i fd i
Using a precision drive to improve rotary encoder
accuracy adds to machine cost
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26. PRESENTATION : New Tech
Direct Position M it i
Di t P iti Monitoring
Linear Encoder Systems
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– Sensor head moves with load
– Sensor head reads actual position of load
Reported Position: 10.0000”
Actual Position: 10.0000
10 0000”
Load Carriage
Sensor head Linear Encoder Scale
Motor
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27. PRESENTATION : New Tech
Direct Position Monitoring
Load position is directly reported
Backlash of actuator drive mechanism is eliminated
as a source of inaccuracy
Constant position accuracy over time regardless of
drive wear and backlash
Accurately reports position regardless of actuator
drive precision or backlash
Allows use of less precise, less expensive actuator
with no sacrifice of position accuracy
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28. WWW.BALLUFF.COM
Sensors survivability
It’s not by chance
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29. PRESENTATION : New Tech
Welding Function
Common Process Issues that Stop Production
Sensor Impact
Improvement
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30. PRESENTATION : New Tech
Welding Function
Common Process Issues that Stop Production
Slag Buildup
Improvement
TM
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31. PRESENTATION : New Tech
Welding Function
Common Process Issues that Stop Production
Cable Damage
Improvement
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32. PRESENTATION : New Tech
Welding Function
Common Process Issues that Stop Production
Improper Mounting
Improvement
TM
Bunker Block
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33. PRESENTATION : New Tech
Welding Function
Common Process Issues that Stop Production
Heat Damage
Improvement
Bunker BlockTM
+
High Temp Sensors
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34. PRESENTATION : New Tech
SMARTLevel Technology
Proximity Sensors that detect more
than just metal
Now with
technology to auto-tune difficult fill
applications
li ti
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35. PRESENTATION : New Tech
The Solution: SMARTLevel Technology
SMARTLevel capacitive sensors incorporate a new patented evaluation
circuit to compensate and adjust automatically for material-build, foaming,
filming and other influences to the sensing field.
field
reliable
SMARTLevel sensors do not require any setup
SMARTL l d t i t
procedure or cleaning maintenance since the
technology allows the sensor to tune out glass or
plastic walls automatically.
Less assembly and maintenance time
SMARTLevel sensors are also available in complete
PTFE (Teflon®) housings to withstand harsh chemical
environments.
Rubustness
R b stness
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36. PRESENTATION : New Tech
Trouble with Standard Capacitive Sensors
C-Wall + C-Ground
Foam / Material Wall
Build-up
Conductive
Target
(e.g. water) SENSOR Standard Capacitive Sensors cannot
distinguish between the true level and
material build-up, foaming or filming.
Result:
- Inconsistent and false triggering
Ground
- Frequent readjustments
- Replacements
- Maintenance cleaning procedures
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37. PRESENTATION : New Tech
Product Family - smartLEVEL
SMARTLevel New technology for liquid level detection.
Solve more applications, because of smartLEVEL technology
-Compensates for humidity, foam and adhering
-Senses through glass or plastic up to 10mm thickness
-Detects aqueous and highly-conductive liquids reliable
Detects highly conductive
Reduce cost
-Free of routine maintenance
-Self-adjusting for most applications
-Reduced material and engineering efforts
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38. PRESENTATION : New Tech
Standard vs SMARTLevel
vs.
Standard Sensor Operation Principle
Amplifier with Oscillator
No Oscillation without
presence of an object
Oscillation
Function of
distance +
coverage +
dielectric factor
Oscillation
Cylindrical Sensor
from top view
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39. PRESENTATION : New Tech
Standard vs SMARTLevel
vs.
Wall
SMARTLevel
oscillator
amplitude
Amplifier
Oscillator
C-FIX
C-COMP
C-FIX
The additionally introduced wall material causes an increase in C-COMP
– which leads to a hi h oscillator amplitude. Th sensor does not active
hi h l d t higher ill t lit d The d t ti
the output at increasing oscillator amplitudes – unlike the standard
capacitive sensors. The result is the ability to compensate and self-adjust.
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40. PRESENTATION : New Tech
Standard vs SMARTLevel
vs.
Conductive Wall
Liquid
SMARTLevel
oscillator
amplitude
Oscillator Amplifier
C-FIX C-FIX
C-COMP
C-GND
The increase of C-GND reduces the output
voltage and pulls the oscillator to 0V – the
trigger condition is reached and the sensor
output will be activated.
t t ill b ti t d
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41. PRESENTATION : New Tech
Standard vs SMARTLevel
vs.
What happens now with material build-up?
Resistor
- A thin film has a low electrical conductivity.
- Extremely high AC frequency (~6.5MHz) causes
additional resistance versus ground.
GND
Sensor doesn’t recognize material build-up anymore as
valid target without this ground reference.
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42. PRESENTATION : New Tech
Agenda
• Miniature sensors open up new
applications
• Alternatives to Fiber optics
• Pneumatic cylinder sensing:
y g
Dual systems, analog and lifetime
warranties are just a start
• Direct load monitoring:
a better way to close the loop
• Sensors survivability:
it’s not by chance
• SmartLevel:
a fusion for capacitive and
conductance technologies
WWW.BALLUFF.COM