Automation in Metalworking

Automation in MetalworkingApplications and solutions

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As a leading sensor specialist and system provider with a compa-ny tradition of over 90 years, Balluff GmbH has been a recognized partner for factory automation and industrial hydraulics for decades. The global player has a strong presence with 61 sales branches and representative offices as well as nine production sites on all conti-nents. The corporate headquarters in Neuhausen a.d.F. is located near Stuttgart.

Balluff offers a wide array of products with varied operating princi-ples: high-quality sensors and systems for position measurement and identification, as well as sensors to detect objects and measure fluids. The full-range assortment includes optimal network and connection technology and a comprehensive line of accessories.

We offer innovative, first-class products tested in our own accredited laboratory and maintain certified quality management in accordance with DIN EN ISO 9001:2015. Our technology speaks for itself in international applications. since it also meets regional standards.

Balluff stands for application-specific customer solutions, com-prehensive services, individual consultation and prompt service. Our staff of more than 3000 employees is committed to providing outstanding service worldwide.

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Balluff Sets Benchmarks for the Standards of TomorrowOn the pulse of customers and key industries

Applications for metalworkingTurning 4Milling 6Stamping 8

Applications in assembliesSpindles, chucks, rotary and swivel tables 10Handling, transport and process monitoring 12

Tool IDTool identification 14

ProductsThe Heartbeat of Industry 4.0 16Controlling, regardless of frequency and environment 18IO-Link simplifies assemblies and machine tools 20Intelligent connectivity with IO-Link devices 22Machine safety 24Product selector 26

Machine tools are the backbone of modern manufacturing. They have always stood for precision and high efficiency, because without them high-volume produced, high-quality products are impossible. Balluff began as early as the 1950's to lend value to the world of machine tool building – from the classic manually operated machine to the complex, automated multi-axis machining center of today.

Our solution portfolio has developed out of long years of partnership with the innovation drivers of metalworking. We work with machine and systems builders as well as the aircraft and automobile indus-tries and their suppliers. Whether it is the production of transmis-sions, engines and drivetrains or the bodywork, we drive innovations ahead and secure a technological lead.

Balluff was one of the pioneers in the development of inductive sen-sors. Over 30 years ago we were the very first to turn this technology into RFID for tool identification. RFID enabled CIM (Computer Inte-grated Manufacturing) as the precursor to Industry 4.0 on the factory level. The path for Industry 4.0 was cleared through digitizing with fieldbus links, system solutions, process sensing and monitoring.

Our full offering reflects this evolution: classic position limit switches for end-of-travel sensing, all types of machine motion detection as well as sophisticated technology for measuring, managing and identifying parts and tools. And with IO-Link data transmission and communication down to the last meter becomes a reality. What will the future bring? Just keep challenging us!

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TurningProduce reliably and with precision – from single parts to high volume

You deal with them every day – fittings, valves, fastening elements as well as motor and transmission parts in automobile engines, industrial machines and household appliances. But how do you manufacture such high-volume metal components economically? By clamping them in a lathe and constructing them rotation-symmetri-cal. This is especially true of parts which are produced in a clamping process where they are automatically fed and removed. Sensors play a decisive role in monitoring these processes with a short cycle and a high level of automation.

You will find such products on page 26

Tailstock positioningBTL magnetostrictive position sensors enable reliable and cost-effective tailstock positioning, such as with a hydraulic or a simple motor-driven axis. A second measuring system can be installed for the fine-positioning.

Steady rest alignmentSteady rests assist the machining process for long or heavy turning parts. Here a rod-style BTL magnetostrictive position sensor monitors the piston position. For both compact and precise steady rest positioning the actuator and sensor are integrated.

Bar loader monitoringFeeding of the bar material is monitored by BES inductive sensors at multiple locations. Good for achieving a seamless production process with optimal machine utilization as well as the ability to implement unmanned shifts.

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Checking workpiece clampingOnly if a workpiece is securely chucked, it can be machined correctly – with consis-tent quality. In addition to sensors with a switching output, BIP inductive positioning systems are increasingly taking over this task. Our wide range of measuring systems – from just a few millimeters long up to 130 mm – ensures the greatest precision for varying dimensions.

Detecting the turret positionDetecting whether the tool turret has reached its correct index position after a rotational move is accomplished using BES inductive sensors. They detect not only the turret position but also the locking.

Monitoring drive beltsMachine tools often use drive belts for trans-ferring rotary motion. Depending on the drive belt design, either BCS capacitive sensors or BES inductive sensors monitor its presence and function. They initiate stopping of the drive in cases of a fault or error.

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MillingBroad range of solutions for individual and high-dynamic applications

Thanks to their flexibility, milling machines and machining centers are among the most commonly found machine tools. They range from simple 3-axis systems to complex multi-axis machining centers to hybrid machines which combine for example milling and laser machining. The main prerequisite for machining block-shaped workpieces: correct positioning and exact tool guidance at high speed. These requirements present a challenge for the controlling of measuring systems. Because the degree of automation is continually increasing – especially when linked machines are used more and more for the production of high-volume parts.


Monitoring tool clampingBIP inductive positioning systems provide information about the correct clamping of the tool: unclamped, clamped with tool, and clamped without tool. Combined with BSP pressure sensors, a second channel can also check the plausibility of the sensor signals in hydraulic clamping systems.

Decentralizing installation technologyCompared with traditional wiring topologies, fieldbus blocks make startup of the machine control much simpler and more cost-effec-tive. Designed for all commonly used fieldbus systems, they enable the use of many con-troller types using the same connector topol-ogy. And with IO-Link they are also enabled for the exchange of process, parameter and diagnostic data for Industry 4.0.

Monitoring end positionsIf you need to monitor the travel path of machine axes, there are two options: tradi-tionally using BNS mechanical position limit switches with series-wired NC switches, or using non-contact BES inductive sensors. With the BML magnetic encoders in many cases the sensor signals are also used for the homing move.

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Detecting the rotation angle on the C-axisTo determine the rotation along the Z-axis, rotary axis angles (A-, B-, C-) are increasingly used in addition to the main axes (X-,Y-,Z-). The BML magnetic encoder is used for high-precision detection of the rotary angle. Its measuring principle enables generous leeway in the center of the axis, so that there is more room there for media such as coolants as well as the power supply and signal lines.

Identifying tools in the magazineIndustrial RFID systems BIS C operating at LF (Low frequency) or BIS M at HF (High Frequency) ensure that the CNC controller in milling machines and machin-ing centers always have the correct tool data available (number, diameter, length, number of cuts, etc.). Reliably identified and trans mitted, these parameters also form the basis for high-quality tool asset management including service life monitoring.

Matching and tracking workpiecesPallet systems with automated external loading and unloading reduce internal setup times to virtually zero, so that the machine can continue to produce without interrup-tion. The BIS M 13.56 MHz HF system has established itself as the standard for reliable matching and tracking. It can read and write two-side coded corner tags or databolt attached directly to the pallet or workpiece.


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StampingEnsuring system up-time and continually protecting investments

Mechanical presses are indispensable tools for metal forming. The tools used, which are of particularly high quality and precision, are most often designed for high production quantities. And no one can afford long downtimes. Every minute is valuable and any lengthy production delay costs a lot of money, especially when damage to the expensive assets makes their replacement or repair necessary. To detect the exact position during operation cycles, sensor solutions are used in many locations. These allow malfunctions to be immediately detected and consequential damage prevented, since a press so equipped can be shut off safety.


Shut height monitoringHydraulic presses achieve their rated force over the entire stroke travel. BTL magne-tostrictive position sensors handle position monitoring. The magnetic position marker is attached to the slide or ram, and the profile style housing fixed to a location on the press along the axis. Insensitive to mechanical shock, the high measurement precision and update rate enables optimal machine utilization.

Switching eccentric pressesFor presses with short strokes and high stroke counts the BSW rotary cam switches. Available in mechanical and inductive switching versions, have proven themselves for decades. Mechanically adjustable cams allow them to determine multiple on- and off-points for the controller, depending on the rotational angle of the eccentric cam shaft. Depending on the press type and require-ments, rotary cam switches are offered with our without safety regulations.

Changing die setsTo protect expensive press tools sensors often need to be attached to the tool itself. The BIC inductive couplers can power for die protection sensors as well as transmit the data they receive between the tool and the press controller. Thus the non-con-tacting system permits quick changing of tools without the need for mechanical plug connections.

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Monitoring press forcesBSP pressure sensors allow press forces to be simply determined using the hydraulic pressure which is in effect. This provides users of hydraulic presses a high-value tool for dynamic monitoring of the press forces.

Monitoring sheet metal thicknessesBAW inductive distance sensors prevent improper loading of sheet material. They can be used to detect whether sheets have been double fed and the thickness of the sheet. This is indicated by a continuous analog signal (e.g. 0...10 V) or IO-Link interface. Depending on the application, accuracy re-quirements and holding method for the sheet metal, one or two sensors may be used.

Checking metal strip sagBUS ultrasonic distance sensors with a continuous output signal assist in automated feeding of metal strips, whereby the speed is matched to the cycle rate of the press. The distance between the sheet metal and the sensor is provided as a signal for con-trolling the feed motor speed.


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For applications with a rotational component, traditional applications become more difficult. Confined spaces and access to the axis of rotation make size, weight and form-factory very important aspects to consider. Monitoring on spindles and chucks can be used to en-sure proper clamping or even measurement of the fixed component. Rotary and swivel tables with continuous turning can cause trouble for cables and connectivity. Solutions to connect the automation to the controller across the axis of rotation are innovating automation across the industry.


Monitoring clamping distances with binary sensorsTools are typically clamped using tapered geometries. Using three inductive sensors from the BES family three conditions can be checked non-contact and wear-free: unclamped, clamped without a tool, and clamped with a tool. Since the sensors are installed at a defined distance from each other, this type of clamping distance monitoring is especially useful for larger strokes.

Monitoring clamping distances with positioning systemUsing linear position measurement clamping distance monitoring can be implemented even when the clamping mechanism rotates. The BIP inductive positioning system detects the position of a metal cam which passes by the sensor from the side. Measuring systems for various travel distances are available depending on the requirements.

Monitoring clamping distances with a distance sensorIf there is a tapered geometry on the tool holder, movement transverse to the sensor axis can also be detected using a BAW inductive distance sensor. Such an arrange-ment is considered the classic solution for continuously monitoring measured clamping distance.

Spindles, Chucks, Rotary and Swivel TablesInnovating automation in 360 degrees

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Determining travel on rotary tablesThe BML magnetic encoder is ideal for pre-cise rotary angle detection. It meets require-ments for compactness and thanks to its compatibility with all standard encoder inputs is simple to integrate into the application.

Sending signals and data on swivel tablesIf sensors and actuators need to be attached to the swivel table, BIC inductive couplers can provide connectorless transmission of power and signals. As hermetically sealed "non-contact slip ring transmitters", they work very reliably and are especially rugged.

Detecting piston position in clamping cylindersTo monitor the clamping position of the hydraulic piston on swing clamps, high- pressure-rated inductive sensors are used. These rugged versions, with a large variety of models, use their inductive measuring principle to reliably detect the position in block cylinders.


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Linked production systems consist of standard machines which are connected to each other by means of intralogistic fixtures and continuous conveyors. An especially economical concept, with low costs and few modifications to the system, both high-volume parts and lower volume part variants can be produced. At the same time the so-called "small process technology" needs to be state-of-the-art in order to reliably monitor loaders, ensure coolant and lubricant provision and keep an eye on levels in the hydraulic units. And the ever shorter product development times and associated layout changes need to be easily accommodated.


Controlling positioning of the linear drivesFreely selectable target positions increase the flexibility of linear drives with integrated displacement measurement. The BML magnetic encoder is all that is needed to upgrade positioning drives including the position-controlled axis.

Monitoring grippers on gantry loadersPneumatically actuated grippers are often equipped with pistons and magnets for position detection of the gripper jaws. When this is the case, the gripping actions can be simply monitored using BMF magnetic cylinder sensors. Here's how it works: Insert sensors into the mounting slot. Slide to set the desired switching point. Screw in place. Done.

Detecting end positions on gantry loadersBES inductive sensors are used to detect end positions on overhead loading systems. All that is needed is to attach a metal target at the desired position. This is detected by the sensors without contact to provide the controller with the correct switching signal.

Handling, Transport and Process MonitoringFlexibly meet changing requirements

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Checking levels on the hydraulic power unitDetecting the level of hydraulic fluid can be done with magnetostrictive level sensors and floats. They are fully encapsulated for ruggedness, precise and designed for high sampling rates. Both analog signals (0...10 V or 4...20 mA) and IO-Link can be used as interfaces.

Detect process fluids and levels continuously or switchingDepending on the version BUS ultrasonic level sensors can be used for 2-point switching or for continuous level control.

Leak detectionInstalling BCS capacitive sensors on a spacer attached to the catch tank floor is the most elegant solution to leak detection. These will register even the slightest fluid losses with absolute reliability.


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Tool presettingThe tool presetter with built-in RFID read/write head uses the tool number to automat-ically know which tool has been inserted. It then writes the measured actual tool parameters to the RFID tag embedded in the tool holder.

Documenting tool dataHaving the unique documentation of all the parameters on the RFID tag in the tool holder is of great value. In this way the tool can remain in storage for any length of time without its data getting lost. And when need-ed, it is immediately ready to use.

Communicating with the CNC controllerBefore or when the tool is introduced into the spindle, the actual tool parameters on the tag are read out. Alternately the data can be read when tools are placed in the tool store, chain or magazine. In both cases the CNC controller gets all the current tool data in real time.

Tool IdentificationThe right tool at the right time at the right place

Industrial RFID for automated tool identification brings numerous advantages. Transmitting the tool parameters (tool number, tool diameter, tool length, number of cuts, ...) to the CNC controller ensures optimal tool utilization and high machine up-time. By adding tool life monitoring and asset management concepts, unproductive idle time, mismatches and missing or unsharpened tools become a thing of the past. Tool ID solutions read the current data directly from the tool, docu-ment all the data and thus provide predictive information for future use. Highly beneficial for users, since this not only increases the quality and efficiency of the production process, but also reduces costs and improves profitability. Many companies take advantage of the opportunity to retrofit and upgrade. Or they decide on the purchase of new equipment and solicit bids from those machine builders who have already integrated such technologies. Making them well-positioned for Industry 4.0.

Do you have more questions? Contact us at [email protected] for immediate and comprehensive assistance.

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Organizing data mappingThe advantage of decentralized data retention on the RFID tag is that tool parameters are available continuously and independent of the central server. The user can define to what extent this data is stored entirely according to his specific requirements. Also import-ant: so-called data mapping, i.e. organization of memory addresses coordinated between the presetter, inventory management and machine tool.

Different ways of mapping are available depending on the manufac-turer. If needed you can also use the Balluff mapping system. Would you like to learn more? Contact us at: [email protected].

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The Heartbeat of Industry 4.0In metalworking and throughout the entire workflow

The basis of Industry 4.0 is the availability of all relevant data in real-time as well as the ability to create the optimal value creation flow from this data at any point in time. Combined with our networ-king and connectivity technology, Balluff sensors and identification systems provide all the prerequisites. Data are acquired, transported and provided as basic information for interpretation and sending to higher level systems such as controllers or the cloud. This is our core competency as a pacesetter for Industry 4.0 solutions.

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Controlling, Regardless of Frequency and EnvironmentHow tool identification, material flow and handling tasks are quickly and easily combined

(1) IRT-capable by looping through the signals from other slaves(2) BIS C only possible using BCC0FCK adapter

Application for BIS M (13.56 MHz) n n

BIS L (125 kHz) n n

BIS C (70/455 kHz) n

Profibus BIS00T3 BIS012EEtherCAT BIS00U9 BIS0147CC-Link BIS010P BIS014EEthernet/IP Power, 5-pin BIS012F BIS014C

Power, 4-pin BIS0122 BIS0146Profinet (1) BIS013U BIS013WRead/write head ports 4 × BIS VM and BIS VL 4 × BIS C (2) (BIS VM and BIS VL can also be

connected)Power supply 24 V DC ±10% LPS Class 2 24 V DC ±10% LPS Class 2Power supply ≤ 2 A ≤ 2 AOperating/storage temperature 0...+60 °C 0...+60 °CDegree of protection per IEC 60529 IP65 IP 65IO-Link master Version 1.1, max. 0.5 A Version 1.1, max. 0.5 AMax. cable length (read/write heads) 50 m 10 m for BIS C, 50 m for BIS M/BIS L

Read/write heads BIS M (13.56 MHz)

BIS

013H

BIS

0140

BIS

0132

BIS

0131

BIS

012Z

BIS M tagsBIS004A 7 5.5BIS00PT 7.5 22BIS0043 28BIS00NZ 25 57BIS00P3 60 100Read/write distances in mm

Read/write heads BIS C (70/455 kHz)

BIS

005Z

BIS

006F

BIS

00P

H

BIS

0067

BIS C tagsBIS0011 2.5 2.5 2.5BIS0009 3.5 3.5 5BIS0019 8 3.5BIS002P 3.5 3.5 10

Read/write heads BIS L (125 kHz)

BIS

00U

L

BIS

00U

6

BIS

00U

F

BIS

00U

H

BIS L tagsBIS00KJ 17 13 13BIS00KK 21 18 16BIS003E 32 18 22BIS0036 40 55 25 65BIS0039 55 70 30 85

The following combinations of tags and read/write heads are possible (examples):

RFID systems with different frequency ranges – often mixed – are being increasingly used in modern production and assembly systems. Whereas low-frequency (LF) systems prove to be especially rugged and reliable particularly in metal surroundings. High-frequency (HF) systems score high with their high speed and greater read/write distance.

The BIS V processor unit is the first to permit frequency-indepen-dent use of a controller. It allows up to four HF (13.56 MHz) and LF (70...455 kHz) read/write heads per processor unit to be operated at the same time. So that now just one version is needed to automati-cally track and control the entire material flow without interruption.

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IO-Link Simplifies Assemblies and Machine ToolsIdeal for process parameterization and control

Pressure monitoring directly where the action isWithout secure holding of the workpiece and tool on a lathe, high-quality results cannot be guaranteed. Pressure sensors for clamping force monitoring verify secure holding and are also ideal for monitoring process media such as coolants, lubricants, hydraulic fluids and pneumatic components.

The special feature of IO-Link pressure sensors: they continuously relay their measured values and data to the controller, let it provide precise readjustment when necessary, and ensure the greatest possible machine up-time. Sensor replacement is just a matter of plug-and-play. Because the current data are automatically loaded by the IO-Link master.

BSP pressure sensors with IO-Link

Pressure sensors –1...2 bar BSP00AM BSP00JE0...10 bar BSP00AT BSP00JK0...250 bar BSP00AZ BSP00JP0...400 bar BSP00C0 BSP00JR0...600 bar BSP00C1 BSP00JT

Output signals PNP, one programmable switching point and analog output 0...10 V DC

PNP, analog output 0...10 V DC

Ambient/media temperature –40…+85 °C/–40...+125 °C –40…+85 °C/–40...+125 °CConnection Plug connector M12 connector, 4-pin M12 connector, 4-pin

Process connection Internal thread G1/4" per DIN EN 3852 * G1/4"

with display

* Please order adapter for G1/4" process fitting separately using order code BAM01KP

no display

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Clamping distance monitoring in a machining centerThe BIP inductive positioning system with IO-Link was designed especially for position monitoring and fits easily into tight mounting spaces. It features an optimum ratio of useful to physical length as well as a calibrated measuring range, which makes it ideal for series production applications.

BIP inductive positioning systems with IO-Link

This compact performer uses an absolute measuring principle and uses an additional Out-of-Range bit to tell the controller if the target has left the measuring range. A welcome side-effect: its digital IO-Link signal is guaranteed to be noise immune even with unshielded cable. And an analog input card can also be eliminated.

Inductive positioning systems BIP0007 BIP0004Measuring range 1...14 mm 1...40 mmLinearity ±250 µm ±400 µmRepeat accuracy ±80 µm ±100 µmDistance to tape, position encoder, target 0.5...2 mm 1...3 mmTarget/position encoder metal n n

IO-Link interface n n

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Intelligent Connectivity with IO-Link DevicesMaximum flexibility in handling with minimal installation effort

Technologies that think along and aheadIO-Link solutions are implemented using traditional cabling. Balluff IO-Link blocks make any controller ready for Industry 4.0: from Profibus and Profinet to CC-Link and Devicenet all the way to Ethernet/IP and EtherCAT. And that's not all. We make many tech-nologies IO-Link capable.

Now even the most complex challenges can be met simply and with the greatest possible handling flexibility. For instance, the universal IO-Link interface integrates intelligent devices, such as the BVS vision sensor, into the controller. And any standard analog sensor can be integrated there with equal ease using the IO-Link analog converter.

A Balluff IO-Link sensor hub can bundle the signals from up to 16 sensors or actuators. If these hubs are connected to our 8 × IO-Link module, then a it can transmit up to 136 inputs/outputs. Even actuators like valve terminals can be controlled via Balluff IO-Link by the master. Full functionality requires only connecting the valve terminal to the IO-Link module using a standard cable with valve terminal plug.

IO-Link module

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IO-Link blocks BNI003K BNI003P BNI007M BNI005H BNI0092 BNI006C BNI007JFieldbus Profibus ProfinetNo. of ports/IO-Link ports 8/4 4/4 16/16 8/8 4/4 8/4 8/8Inputs/outputs max. 16/16 4/4 32/32 16/16 8/8 16/16 16/16Configurable inputs/outputs 16 32 16 8/8 16IO-Link version 1.1 1.1 1.1 1.1 1.1 1.1 1.1

IO-Link blocks BNI006A BNI004A BNI005A BNI0001 BNI0040 BNI0049 BNI0077Fieldbus Ethernet/IP Devicenet CC-Link EtherCATNo. of ports/IO-Link ports 8/8 8/4 8/4 8/– 8/4 8/8 8/8Inputs/outputs max. 16/16 16/16 16/16 16/16 16/16 16/16 16/16Configurable inputs/outputs 16 16 16IO-Link version 1.1 1.1 1.1 1.1 1.1 1.1

IO-Link devices BNI0035 BNI005U BNI0021 BNI0072 BNI0083 BNI0042 BNI004CSeries Sensor hub SmartLight Analog converterSpecial properties M12, metal M12, plastic M8, plastic without sound with sound Voltage variantNo. of ports 8 8 8Inputs/outputs max. 16/16 16/16 16/–Configurable inputs/outputs 16 16Analog in-/output 1/– –/1IO-Link version 1.0 1.1 1.0 1.1 1.1 1.0 1.0

IO-Link devices BNI004W BNI005M BNI006N BNI000F BNI0067 BNI0073 BNI00AMSeries Valve terminal

interfaceUniversal interface

Valve terminal plug

Unmanaged Switch

USB master Memory module

Special properties IP67 IP30No. of ports 9 8IO-Link version 1.1 1.1 1.1 1.1 1.1

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Functional safety for machine toolsMultiple position limit switches with forced opening contacts have proven themselves for years in end-of-travel monitoring on machine tools. Rotary cam switches with a BG certificate are classics for monitoring presses and stamping machines.

E-stop, light curtains and door switches ensure the safety of machine tools. These are the economical way to meet current specifications.

Machine SafetyIn metalworking

Photoelectric light grid

Subject to modification. Please refer to data sheets.

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Safety switch BID0005 BID0004 BID0002 BID0003 BID0001Guard locking mechanical (closed-

circuit current)mechanical (closed- circuit current)

electrical (open- circuit current)

electrical (open- circuit current)

Escape release Yes YesDoor contacts 2 × positive

opening contacts and 1 × NO

1 × NO 1 × NO 1 × NO 1 × NO

Magnetic contacts 2 × positive opening contacts

2 × positive opening contacts



Connection M12 connector, 5-pin

M12 connector, 8-pin




E-Stop BAM02HAContacts 2 × positive

opening contactsConnection M12 connector,

5-pin

Accessories BAM0270 BAM0271 BAM0272Description Actuator,

angledActuator, swinging doors handle

Actuator, sliding doors handle

Application for Finger protection Hand protection Body protectionRange < 6 m < 19 m < 50 mResponse time 11…50 ms 9…28 ms 14…16 msResolution 14 mm 30 mm > 315 mmPhotoelectric light grid

150 mm BLG000A BLG000T300 mm BLG000C BLG000U450 mm BLG000E BLG000W515 mm BLG0006600 mm BLG000F BLG000Y750 mm BLG000H BLG000Z815 mm BLG0007900 mm BLG000J BLG0010915 mm BLG00081050 mm BLG000K BLG00111200 mm BLG000L BLG00121215 mm BLG00091350 mm BLG000R BLG00131500 mm BLG000M BLG00141650 mm BLG000N BLG00151800 mm BLG000P BLG0016

Switching output OSSD OSSD OSSDPL (EN ISO 13849-1)/SIL CL (EN/IEC 62061) PLe/SIL CL 3 PLe/SIL CL 3 PLe/SIL CL 3Connection Emitter M12 male, 4-pin M12 male, 4-pin M12 male, 4-pin

Receiver M12 male, 5-pin M12 male, 5-pin M12 male, 5-pin

R LISTED4PA1"ESPE"

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Product SelectorThe right sensor for every application

Application Product family Example Functions, interfaces and propertiesTurningBar loader monitoring Inductive sensors BES0068 M12 × 1, PNP NO, switching distance

4 mm, flush mountable, M12 connectorBES0055 M12 × 1, NPN NO, switching distance

4 mm, flush mountable, 3 m PUR cableBES008M M18 × 1, PNP NO, switching distance

8 mm, flush mountable, M12 connectorBES007M M18 × 1, NPN NO, switching distance

8 mm, flush mountable, M12 connectorBES00AH M30 × 1.5, PNP NO, switching distance 15 mm,

flush mountable, M12 connectorTailstock positioning Magnetostrictive position sensors,

profile seriesBTL...-P-... Profile, measuring range max. 7620 mm,

analog interface 0...10 V or 4...20 mA, SSI, Start/Stop Pulse Interface, CANopen, Devicenet, Profibus DP, Profinet, EtherCAT

BTL...-PF-... Profile flat, measuring range up to max. 4572 mm, analog interface 0...10 V or 4...20 mA, IO-Link

Steady rest alignment Magnetostrictive position sensors, rod series

BTL...-B-... Rod, measuring range max. 7620 mm, analog interface 0...10 V or 4...20 mA, SSI, Start/Stop Pulse Interface, CANopen, Profibus DP, Profinet, EtherCAT, IO-Link, mounting flange with M18 × 1.5, or inch threads in Z-version

BTL...-K-... Compact rod, measuring range max. 7620 mm, analog interface 0...10 V or 4...20 mA, SSI, Start/Stop Pulse Interface, CANopen, mounting flange Ø 18 mm

Checking workpiece clamping Inductive positioning systems BIP0002 Measuring range 40 mm, analog interface 0...10 V, teachable, M12 connector

BIP0004 Measuring range 40 mm, IO-Link, teachable, M12 connector

BIP000C Measuring range 70 mm, analog interface 0...10 V and 4...20 mA, teachable, M8 connector

BIP000R Measuring range 133 mm, analog interface 0...10 V and 4...20 mA, teachable, M8 connector

Detecting the turret position Inductive sensors BES00FT M5 × 0.5 mm, PNP NO, switching distance 0.8 mm, flush mountable, 2 m PUR cable, installation length 27 mm

BES00N4 M8 × 1, PNP NO, switching distance 1.5 mm, flush mountable, 2 m PUR cable, installation length 30 mm

BES00CN M8 × 1, NPN NO, switching distance 1.5 mm, flush mountable, 2 m PUR cable, installation length 40 mm

BES0060 M12 × 1 PNP NO, switching distance 2 mm, flush mountable, M12 connector

Monitoring drive belts Capacitive sensors BCS00LL M18 × 1, PNP NO, switching distance 15 mm, non-flush mountable, 2 m PUR cable

BCS00TR 40 × 40 × 10 mm, PNP/NPN and NO/NC select-able, switching distance 20 mm, flush mountable, 2 m PUR cable

This selection table lists the product families and examples to fit your application. At www.balluff.de you can enter the product family or sample product to obtain detailed technical information.

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Application Product family Example Functions, interfaces and propertiesMillingMonitoring tool clamping Inductive positioning systems BIP0001 Measuring range 14 mm, analog interface 0...10 V,

teachable, 2 m PUR cableBIP0008 Measuring range 14 mm, analog interface 4...20 mA,

teachable, 2 m PUR cableBIP0007 Measuring range 14 mm, IO-Link,

2 m PUR cableDecentralizing installation technology

Fieldbus blocks BNI003K Profibus, metal housing, 8 ports, 16 × in-/outputs, 4 × IO-Link, configurable

BNI005H Profinet, metal housing, 8 ports, 16 × in-/outputs, 8 × IO-Link, configurable

BNI007M Profinet, metal housing, 16 ports, 32 × in-/outputs, 16 × IO-Link, configurable

BNI0040 CC-Link, metal housing, 8 ports, 16 × in-/outputs, 4 × IO-Link, configurable

BNI0077 EtherCAT, metal housing, 8 ports, 16 × in-/outputs, 8 × IO-Link, configurable

Sensor hubs BNI005U 8 × M12 ports, plastic housing, 16 × in-/outputs, configurable

Monitoring end positions Inductive sensors BES01W2 20 × 32 × 8 mm (R01), PNP complementary, switching distance 7 mm, 0.2 m PUR cable with M12 connector

BES01UZ 20 × 32 × 8 mm (R01), NPN complementary, switching distance 7 mm, 0.2 m PUR cable with M12 connector

Mechanical position limit switches BNS 813-D...-100-...

Series 100 multiple position limit switch with safety switch elements per DIN EN 60204-1

Detecting the rotation angle on the C-axis

Magnetic encoder BML S1F_-Q... Compact size 25 × 12 × 13 mm, incremental, RS422 per DIN 66259, resolution 1...10 µm

BML ring Various form factors/polarities on requestIdentifying tools in the magazine Industrial RFID systems BIS0011 Data tag Ø 10 × 4,5 mm, standardized per

DIN 69873, BIS C with 455/70 kHz (LF), 511 bytesBIS004A Data tag Ø 10 × 4.5 mm, standardized per

DIN 69873, BIS C with 13.56 kHz (LF), 2000 bytesBIS005Z Read/write head Ø 14.5 mm, BIS C with

455/70 kHz (LF), 5 m PUR cable with M12 female, please order adapter BCC0FCK separately

BIS013Z Read/write head Ø 14.5 mm, BIS M with 13.56 MHz (HF), 0.3 m cable with M12 connector

BIS V...-C1... BIS V processor unit for BIS M, BIS L and BIS C, various fieldbus versions on page 18

Matching and tracking workpieces

Industrial RFID systems BIS00NZ Data tag 24 × 24 × 21 mm, rod antenna, BIS M with 13.56 MHz (HF), 2000 bytes, corner style

BIS00PT Data tag Ø 22 mm /M6, round antenna, BIS M with 13.56 MHz (HF), 2000 bytes, data screw

BIS0131 Read/write head 105 × 40 × 15 mm, BIS M with 13.56 MHz (HF), 0.3 m PUR cable with M12 connector

BIS0132 Read/write head M30 × 1.5, round antenna, BIS M with 13.56 MHz (HF), M12 connector

BIS V...-C0... BIS V processor unit for BIS M and BIS L, various fieldbus versions on page 18

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Application Product family Example Functions, interfaces and propertiesStampingSwitching eccentric presses Mechanical rotary cam switches BSW0040 259 × 190 × 140 mm, six switch positions

with forced opening contacts, BG certificateBSW003N 199 × 190 × 140 mm, three switch positions

with forced opening contactsControlling hydraulic presses Magnetostrictive linear

position sensors, profile seriesBTL...-P-... Profile, measuring range max. 7620 mm,

analog interface 0...10 V or 4...20 mA, SSI, Start/Stop Pulse Interface, CANopen, Devicenet, Profibus DP, Profinet, EtherCAT

BTL...-PF-... Profile flat, measuring range up to max. 4572 mm, analog interface 0...10 V or 4...20 mA, IO-Link

Changing press tools Inductive couplers BIC005C, BIC005A

40 × 40 mm, unidirectional version, working range 1...5 mm, IO-Link

BIC0072, BIC0071

40 × 40 mm, unidirectional version, working range 1...5 mm, IO-Link

Sensor hubs BNI003T Metal version, 8 ports, 16 × inputs, unidirectional, coding for tool identification

BNI005U Plastic version, 8 ports, 16 × in-/outputs, configurable, bidirectional, coding for tool identification

Monitoring sheet metal thicknesses

Inductive distance sensors BAW0056 M12 × 1, measuring range 0.2...7 mm, IO-LinkBAW0026 M18 × 1, measuring range 1...5 mm, flush mount-

able, analog interface 0...10 V, temperature outputChecking metal strip sag Ultrasonic distance sensors BUS005K M30 × 1.5, analog interface 0...10 V or 4...20 mA,

measuring range 65...350 mm, straight versionBUS004Z M18 × 1, distance and switching state via IO-Link,

straight versionBUS004Y M18 × 1, distance and switching state via IO-Link,

angled versionMonitoring press forces Pressure sensors without display BSP00JP 0...250 bar, 0...10 V, G1/4" external thread

BSP00JR 0...400 bar, 0...10 V, G1/4" external threadBSP00JT 0...600 bar, 0...10 V, G1/4" external threadBSP00PU 0...250 bar, PNP, IO-Link, G1/4" external threadBSP00PW 0...400 bar, PNP, IO-Link, G1/4" external threadBSP00PY 0...600 bar, PNP, IO-Link, G1/4" external threadBSP00TW 0...250 bar, NPN, IO-Link, NPT1/4" external threadBSP00TY 0...400 bar, NPN, IO-Link, NPT1/4" external threadBSP00TZ 0...600 bar, NPN, IO-Link, NPT1/4" external thread

Pressure sensors with display BSP0011 0...250 bar, 0...10 V analog, PNP switching outputBSP0012 0...400 bar, 0...10 V analog, PNP switching outputBSP0013 0...600 bar, 0...10 V analog, PNP switching outputBSP001A 0...250 bar, 4...20 mA analog, PNP switching outputBSP001C 0...400 bar, 4...20 mA analog, PNP switching outputBSP001E 0...600 bar, 4...20 mA analog, PNP switching outputBSP001T 0...250 bar, 0...10 V analog, NPN switching outputBSP003T 0...400 bar, 0...10 V analog, NPN switching outputBSP003U 0...600 bar, 0...10 V analog, NPN switching output

Adapters for pressure sensors with display

BAM01KP Process side G1/4" external threadBAM01KT Process side NPT1/4" external thread

29www.balluff.com

Application Product family Example Functions, interfaces and propertiesSpindles, chucks, rotary and swivel tablesMonitoring tool clamping distances

Inductive sensors BES013N M8 × 1, PNP NO, switching distance 1.5 mm, flush mountable, M8 connector

BES01C8 M12 × 1, PNP NO, switching distance 2 mm, flush mountable, M12 connector

Inductive distance sensors BAW003E 14 × 38.5 × 17 mm, measuring range 1...5 mm, analog interface 0...10 V, temperature output, 2 m PUR cable

BAW003A 14 × 38.5 × 17 mm, measuring range 1...5 mm, IO-Link, temperature output, 2 m PUR cable

Inductive positioning systems BIP0001 Measuring range 14 mm, analog interface 0...10 V, 2 m PUR cable

BIP0007 Measuring range 14 mm, IO-Link, 2 m PUR cable

BIP0004 Measuring range 40 mm, IO-Link, teachable, M12 connector

BIP000M Measuring range 48 mm, analog interface 0...10 V and 4...20 mA, teachable, M8 connector

BIP000N Measuring range 70 mm, analog interface 0...10 V and 4...20 mA, teachable, M12 connector

BIP000U Measuring range 103 mm, analog interface 0...10 V and 4...20 mA, teachable, M12 connector

BIP000R Measuring range 133 mm, analog interface 0...10 V and 4...20 mA, teachable, M12 connector

Sending signals and data on swivel tables

Inductive couplers BIC0078, BIC0077

M12 × 1, unidirectional version, working range 0...2 mm, 50 mA power, 2 × PNP signals

BIC0054, BIC0053

M30 × 1.5 mm, unidirectional version, working range 0...5 mm, IO-Link interface 4 x analog

Sensor hubs BNI0008 Plastic version, 8 ports, 4 × analog 0...10 V, 8 × inputs, IO-Link interface to BIC

BNI0007 Plastic version, 8 ports, 4 × analog 4...20 mA, 8 × inputs, IO-Link interface to BIC

Determining travel on rotary tables

Magnetic encoder BML-S1G... 97 × 17.4 × 18.5 mm, absolute, interface BiSS C or SSI

BML-M02- A55-...

Magnetic tape absolute, 10 mm wide, for angles < 360°

Detecting piston position in clamping cylinders

High-pressure-rated inductive Sensors

BHS0054 M8 × 1, pressure rated to 500 bar, PNP NO, switching distance 1.5 mm, M8 connector, installation length 45 mm

BHS002Y M12 × 1, pressure rated to 500 bar, PNP NO, switching distance 1.5 mm, M12 connector, installation length 56 mm

High-pressure-rated inductive distance sensors

BAW0040 M12 × 1, pressure rated to 500 bar, analog 0...10 V, measuring range 0.5...2 mm, M12 connector, installation length 78 mm

Magnetic cylinder sensors BMF008E Various slot styles, M12 connector, aluminum housing, with clamping holder (order separately)

BMF0076 Two sensors with one plug-in terminal, slides into the T-slot, PNP NO, 0.3 m PUR cable with M12 connector

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Application Product family Example Functions, interfaces and propertiesHandling, transport and process monitoringMonitoring grippers on gantry loaders

Magnetic cylinder sensors BMF00C4 Inserted in T-slot from above, PNP NO, 0.3 m PUR cable with M8 connector

BMF00C9 Two sensors with one plug-in terminal, inserted in T-slot from above, PNP NO, 0.3 m PUR cable with M12 connector

BMF0002 Slides into C-slot (Festo), PNP NO, 0.3 m PUR cable with M8 connector

BMF00A2 Slides into C-slot (SMC), PNP NO, 0.3 m PUR cable with M8 connector

Detecting end positions on gantry loaders

Inductive sensors BES0028 M8 × 1, PNP NO, switching distance 2 mm, flush mountable, M12 connector, installation length 65 mm

BES0068 M12 × 1, PNP NO, switching distance 4 mm, flush mountable, M12 connector, installation length 65 mm

BES008L M18 × 1, PNP NO, switching distance 8 mm, flush mountable, M12 connector, installation length 65 mm

BES00AF M30 × 1.5, PNP NO, switching distance 15 mm, flush mountable, M12 connector, installation length 65 mm

Controlling positioning of the linear drives

Magnetic encoder BML-S1G... 97 × 17.4 × 18.5 mm, absolute, interface BiSS C or SSI

BML-M02- A55-...

Magnetic tape absolute, 10 mm wide, max. 48 m long

Monitoring levels on the hydraulic power unit

Magnetostrictive linear position sensor, rod series

BTL...-B-... Rod, analog interface 0...10 V or 4...20 mA, Start/Stop Pulse Interface, CANopen, Profibus DP, Profinet, EtherCAT, flange connection M18 × 1.5, alternately inch threads style Z

BTL...-K-... Compact rod, analog interface 0...10 V or 4...20 mA, Start/Stop Pulse interface, CANopen, flange connection Ø 18 mm

Floats BAM024J Ø 32 × 53 mm, stainless steelBAM0146 Ø 44 × 49 mm, stainless steel

Detect process fluids and levels continuously or switching

Ultrasonic distance sensors BUS005Y M30, process connection G1", range 85...350 mm, analog interface 0...10 V/4...20 mA and PNP, NO/NC selectable, pressure rated to 6 bar, M12 connector

BUS005U M30, process connection G1", range 200...1300 mm, 2 × PNP, NO/NC selectable, pressure rated to 6 bar, M12 connector

BUS005W M30, process connection G1", range 200...1300 mm, analog interface 0...10 V/4...20 mA and PNP, NO/NC selectable, pressure rated to 6 bar, M12 connector

Leak detection Capacitive sensors BCS012T 16 × 34 × 8 mm, PNP NO, 0.3 m PUR cable with M8 connector, for non-conductive media, universal holder for leak detection included

BCS012Z 16 × 34 × 8 mm, PNP NO, 0.3 m PUR cable with M8 connector, for conductive media, universal holder for leak detection included

31www.balluff.com

Product family Example Functions, interfaces and propertiesAccessoriesDouble-ended cordsets BCC02M9 M8 female straight, 3-pin, 5 m PUR cable,

drag chain compatibleBCC02MJ M8 female right-angle, 3-pin, 5 m PUR cable,

drag chain compatibleBCC032H M12 female straight, 4-pin, 5 m PUR cable,

drag chain compatibleBCC032P M12 female right-angle, 3-pin, 5 m PUR cable,

drag chain compatibleJunction boxes BPI00HJ Plastic, sensor connection 8 ports (M8 female, 3-pin),

controller connection M12 connector, 12-pinBPI00JY Plastic, sensor connection 8 ports (M12 female, 4-pin),

controller connection M23 connector, 19-pinMachine Lights BAE00W8 Ø 20 × 250 mm, light field size 170 mm,

white LED with beam angle 120°, M12 connectorBAE00W9 Ø 20 × 358 mm, light field size 278 mm,

white LED with beam angle 120°, M12 connectorBAE00WA Ø 20 × 432 mm, light field size 562 mm,

white LED with beam angle 120°, M12 connectorBAM02ML 35 × 29 × 15 mm, clamp for machine light,

2 pieces included, attached using M6 screwFasteners BAM00E0 M12 clamp with positive stop, coated brass,

for thread lengths 30 mm and greaterBAM00CY M12 clamp with positive stop, coated brass,

for thread lengths 40 mm and greaterBAM00FT M18 clamp with positive stop, coated brass,

for thread lengths 30 mm and greaterBAM00FN M18 clamp with positive stop, coated brass,

for thread lengths 50 mm and greaterBAM00J6 M30 clamp with positive stop, coated brass,

for thread lengths 30 mm and greaterBAM00J4 M30 clamp with positive stop, coated brass,

for thread lengths 50 mm and greaterBAM00C4 M12 fastening cuffs without positive stop,

plastic PA 6BAM00F2 M18 fastening cuffs without positive stop,

plastic PA 6BAM00HN M30 fastening cuffs without positive stop,

plastic PA 6Switching Power Supplies BAE00TP IP67 Heartbeat power supply with IO-Link, input 100...240 V AC,

output 24 V DC/3.8 A, 91.2 W power rating

BAE00TL IP67 Heartbeat power supply with IO-Link, input 100...240 V AC, output 24 V DC/8 A, 192 W power rating

BAE00T4 IP20 Heartbeat power supply with IO-Link, input 115/230...V AC, output 24 V DC/5 A, 120 W power rating

BAE00M3 IP20 Heartbeat power supply with IO-Link, input 115/230...V AC, output 24 V DC/20 A, 480 W power rating

BAE00TF IO-Link adapter for IP20 Heartbeat power supply for controlling and diagnosing the power supply

www.balluff.comDoc. No. 930824/Mat. No. 255486 EN G16; subject to changes.

Please note: The applications described are examples only. Always refer to user manuals and data sheets.

Headquarters Balluff GmbH Schurwaldstrasse 973765 Neuhausen a.d.F.GermanyPhone +49 7158 173-0Fax +49 7158 [email protected]

Automation in Metalworking

Engineering

Transcript of Automation in Metalworking