- No errors during guided format change
- Ultra-flat sensors for wafer production
- Intelligence included
- Faster cartoner changeovers with Balluff’s Guided Changeover Solution results in 50% less downtime
- Enhancing maintenance strategy with Balluff's Condition Monitoring Toolkit (CMTK)
- Never run out of compressed air
- Precision gearbox assembly machine for residential water meters
- Continuous production monitoring in folding machines
- Reliable container test with artificial intelligence
- Flexibly expandable and modular image processing system
- Image processing in hospitals
- Not just “click clack”
- Easy guided format change
- Condition Monitoring for a clear view
- Reliable Tap Water Supply – Setting a Sustainable Standard
- Flexible feeding systems using reliable sensors
- Reliable clamping processes and reduced downtime with ultrasonic sensors
- An AI-powered pharma line clearance solution
- Efficient cleaning of food tanks
- Industrial cameras in steel processing
- UK Battery Industrialisation Centre
- Training Tomorrow’s Engineers with Balluff IO-Link and Condition Monitoring
Easy guided format change
Better – Faster – Safer
Industry: Special machine builder | Customer: AKE Systemtechnik GmbH, Germany
In modern manufacturing, frequent format changes in production lines are a common challenge. These changes can be time-consuming and complex, requiring precise adjustments and manual settings. Mistakes in this process often lead to increased downtime, product defects, and additional costs. To enhance efficiency and ensure quality, companies seek solutions that enable fast, error-free, and reliable machine adjustments.
Situation
AKE Systemtechnik was faced with the challenge of carrying out frequent and time-consuming format changes on its machines. These changes needed to be carried out as easily, quickly and safely as possible. This is because AKE knows from experience that manual format changeovers can lead to considerable downtime, increased error rates and reduced production efficiency if the machine is operated incorrectly.
And this is exactly what AKE wanted to prevent.
Challenge
The main issues were that the manual adjustments required for format changes were time-consuming and prone to errors. Operators had to perform multiple steps and manually make settings, which prolonged setup times and increased the risk of operator errors. This resulted in high costs and negatively impacted the company's competitiveness.
Solution
AKE Systemtechnik decided to use the Balluff IO-Link position indicator BDG. This system automates and monitors the necessary settings when changing formats. The position indicator provides precise feedback and ensures that the machines are quickly and correctly set to the new formats. This significantly reduces set-up times and minimises the risk of operating errors.
In addition, the position indicators can be easily integrated and configured in the control system. Hardly any mechanical changes are required to replace the mechanical version.
How does it work?
After installing the Balluff BDG position indicator, the machine configurations were digitally recorded and programmed. The operators were now able to carry out the manual adjustment, with the position indicator displaying and checking the exact positions for the various formats.
Do I have to turn to the left? Do I have to turn to the right? The Balluff BDG displays this intuitively and leaves no room for adjustment errors.
This enables a quick and error-free change of machine formats.
Thanks to the digitalisation of the process, there is now a decisive advantage: the machine only starts when all settings are correct. This directly prevents expensive errors and mechanical damage.
What is the benefit?
Thanks to the Balluff position indicator, the company was able to reduce set-up times by up to 50%. The error rate during set-up fell significantly, resulting in higher production quality. Overall, AKE Systemtechnik was able to increase its production capacity and significantly improve efficiency.
The investment in the position indicator paid off within a very short time, resulting in improved competitiveness and even more satisfied customers.
Implementing the Balluff Position Indicator drastically reduced our setup times and nearly eliminated operator errors. This solution has significantly improved our production processes and helped us enhance the quality of our products.
Benefits
The IO-Link position indicators offer many advantages for you and your production!
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Reduced Setup Times: Setup times decreased by up to 50%, improving efficiency.
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Fewer Operator Errors: Automated monitoring minimized errors, enhancing product quality.
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Increased Production Capacity: Faster changeovers boosted overall production output.
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Cost Savings: Optimized processes led to lower operational costs.
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Enhanced Competitiveness: Improved processes and quality strengthen market position.
Products
Which products were used by AKE Systemtechnik? Find the overview and the links to the product pages here:
SmartLight – LED stack lights
Network blocks for Profinet
Digital Position Indicators
Condition Monitoring Toolkit
SmartLight – LED stack lights
- Principle of operation
- Indicator light with sound module
- Interface
- IO-Link 1.1
- Operating voltage Ub
- 18...30.2 VDC
- Connection
- M12x1-Male, 4-pin
- Segments, number max.
- 5
- Predefined colors
-
yellow
white
green
Blue
red
orange
configurable - Function indicator
-
Runlight Mode
Level Mode
Segment Mode
Flexi-Mode - Volume (at a distance of 1m)
- 95 dB/m
- Setting
-
Function indicator
Volume - Additional function
- Expanded process data
- Dimension
- 60 x 60 x 330.5 mm
- Housing material
-
PC, Transparent, Cu 15 µm, Ni 15 µm
Die-cast zinc - Mounting part
- Screws M18
- Ambient temperature
- -5...50 °C
- IP rating
- IP30
- Transfer rate
- COM2 (38.4 kBaud)
- Process data cycle min.
- 7.2 ms
- Process data IN
- 1 byte
- Process data OUT
- 8 bytes
Network blocks for Profinet
- Interface
- Profinet
- Auxiliary interfaces
- 8x IO-Link
- Port-class
- Type A (4x) + Type B (4x)
- Output current max.
- 2 A
- Fast Start-Up (FSU)
- yes
- Display
- yes
- Operating voltage Ub
- 18...30.2 VDC
- Connection (COM 1)
- M12x1-Female, 4-pin, D-coded
- Connection (COM 2)
- M12x1-Female, 4-pin, D-coded
- Connection (supply voltage IN)
- M12x1-Male, 4-pin, T-coded
- Connection (supply voltage OUT)
- M12x1-Female, 4-pin, T-coded
- Connection slots
- 8x M12x1-Female, 5-pin, A-coded
- Digital inputs
- 12x PNP, Type 3
- Digital outputs
- 12x PNP
- Configurable inputs/outputs
- yes
- Current sum US, sensor
- 12.0 A
- Current sum UA, actuator
- 12.0 A
- Housing material
- Die-cast zinc, nickel-plated
- Dimension
- 68 x 31.7 x 224 mm
- Ambient temperature
- -5...70 °C
- IP rating
- IP67
- IO-Link version
- 1.1
- Safety Hub Support
- yes
Digital Position Indicators
- Display
-
Digital display
12 characters - Shaft type
- Hollow shaft
- Shaft diameter
- 20 mm
- Resolution rotary
- 14000 ppr
- Repeat accuracy
- ± 1 Inkrement
- Non-linearity max.
- ±1°
- Connection
- M12x1-Male, 4-pin
- Speed max.
- 600 1/min
- Interface
- IO-Link 1.1
- Housing material
- PA 12
- IP rating
- IP69K, IP68
- Approval/Conformity
-
CE
UKCA
cULus
Ecolab
WEEE - Secondary features
-
Identification
Device Discovery
Measurement Profiles
Signal Delay
Switching Counter
Basic Statistics
Logic Blocks
Operating Hours Counter
Boot Cycle Counter
Voltage and Current Monitoring
Extreme Environment Status
Storage Usage Monitoring
Variant Configuration
Pin Assignment - Secondary features for condition monitoring
-
Vibration monitoring
Inclination monitoring and installation aid
Internal temperature monitoring
Internal humidity detection
Condition Monitoring Toolkit
- Processor
- 1.8 GHz / 400MHz
- Working memory
- 2 GB RAM
- Connection slots
-
2x LAN: RJ45-Female, 8-pin
4x IO-Link: M8x1-Female, 4-pin, A-coded
PWR: Phoenix MC1.5/3-STF-3.81
USB: USB 2.0 Standard-A - Dimension
- 101 x 126 x 50 mm
- Data storage
- 8 GB EMMC