Balluff Introduces Ultrasonic Sensor for Workpiece Clamping and Monitoring

In metalworking, efficiency and precision are critical aspects that must be considered, but they are often overlooked is workpiece monitoring during machining processes. Traditional techniques have relied on indirect monitoring solutions that resulted in reliability and cost inefficiency issues, and to cater to these challenges, Balluff has recently upgraded its sensor portfolio with the new BFD ultrasonic position sensor.

The new BFD is specifically suited for direct monitoring of hydraulic short-stroke cylinders, giving it the needed versatility for measuring distance and position, and to detect solid, liquid, or powder media.

 

Swing clamp with the new BFD ultrasonic position sensor. Image used courtesy of Balluff

 

The new BFD Ultrasonic Position Sensor

The new BFD ultrasonic position sensor by Balluff provides a solution that monitors the workpiece clamping process continuously, quickly, and directly through the emission of ultrasound into a hydraulic fluid. This produces accurate information on the status of clamping and enables early detection of deviations like deformed workpieces, casting errors, insertion errors, issues with oils supply, and counter deviations. By identifying the pressure variations in the hydraulic unit and pinpointing any defective seals, or defects in the swivel mechanism, correct action can be taken on time by keeping an eye on the whole clamping operation.

 

BFD Sensor Specifications

When it comes to performance, the BFD ultrasonic position sensor provides a high performance measurement range of 0 to 80 mm with a linearity deviation of ±250 µm and a high repeat accuracy of ±50 µm. The sensor also provides measuring rates of 500 Hz for the IO-Link version and 1000 Hz for analog signals.

 

The three variants of BFD Ultrasonic Positioning Sensor. Image used courtesy of Balluff

 

For durability, the BFD sensor has an IP67 protection rating, a high-pressure resistance of up to 350 bars, and a high operating temperature of up to 85 °C, making the sensor ideal for use in harsh environments.

According to the Product Manager for Product Cluster Process Sensors, Christian Seyfried, relevant additional information can be accessed through IO-Link, in which examples of functions like device temperature, status monitoring, and signal quality can be used to identify the significant alterations present in the hydraulic medium resulting from hydraulic system particles and air.

 

Economic Integration and Scalability

One of the key strengths of Balluff's new BFD sensor lies in its scalability and ease of integration. Designed with standardized system components, interfaces, and a compact design, the BFD sensor can be economically integrated into various setups. The sensor also has configurable interfaces with easy "plug and play" M8 or M12 connectors and continuous automated compensations that offer more flexibility in integration as it allows the sensor to adapt the measurements to the composition and type of the hydraulic fluid.

With the growing need for precision in the field of metalworking, innovative technologies like Balluff's BFD Ultrasonic Position Sensors offer precision clamping and monitoring solutions that ensure efficiency in metalworking processes. With such a solution in the market, the inefficiency challenges from conventional methods of workpiece monitoring will see engineers embracing the new BFD sensor for accurate workpiece monitoring.