09.11.2023
Not just “click clack”
Jerko Sprühsysteme GmbH, a manufacturer of special machinery based in Kempen, Germany, relies on smart sensors with SAMS features made by Balluff. Not only do users benefit from these new features, the condition data they capture also helps continuously improve the equipment.
More meaningful data throughcondition monitoring- This was the starting point for the collaboration between the special machine manufacturer Jerko Sprühsysteme GmbH and Balluff. "For us and our customers, condition monitoring and the avoidance of unplanned machine downtime is becoming increasingly important," explains Niklas Dahmen, Managing Director of Jerko Sprühsysteme GmbH. "That's why we asked ourselves how we can collect more useful data from our systems - without additional effort."
Robot arm with Jerko spray system © Photo: Jerko Sprühsysteme
Increasing the process reliability of the supply
25 employees work for the special machine manufacturer based in Kempen. Jerko Sprühsysteme builds spraying systems for the forging and metalworking industry based on customer-specific requirements. Each one is unique. The systems range from small, manually operated hand sprayers to robot systems and manipulator spray systems for the safe handling of heavy loads, which operate fully automatically.
The supply of the sprayers and systems plays an important role in machine availability. If defects occur here due to contamination, wear or blockages in the line, the systems come to a standstill. "Our aim was to stabilize process reliability when supplying the systems via a pneumatic piston pump by providing more useful data. The additional information is then to be used for predictive maintenance and targeted condition monitoring," says Dahmen.
Use of smart sensors
Together with application expert Marius Edler from Balluff, a solution was developed using sensors from theSmart Automation and Monitoring System (SAMS)was developed.
In addition to the process data, these new sensors also record and transmit operating data such as temperature, operating hours, stroke rate, signal quality and vibration. "For example, the signal quality provides information about the machine environment; it decreases if the sensors are dirty. And the vibration value shows whether everything is mechanically in order," says Dahmen, explaining the additional functions. This significantly improves condition monitoring.
Forging press with spray system for cooling and lubrication © Photo: Jerko Sprühsysteme
Intelligent sensors to optimize production
The Smart Automation and Monitoring System (SAMS) includes intelligent sensors and devices that can be individually programmed, configured and thus universally attached to all machines and offer many smart features thanks to the additional supply of relevant operating data.
Simple integration thanks to IO-Link
"As the customer opted for IO-Link at a very early stage, integrating the new, smart sensors was child's play," says Edler, who supported the project at Balluff. The solution had to be easy to integrate and the costs had to be in proportion to the benefits. "Because nobody needs Industry 4.0 if they can't afford it," Dahmen is certain.
Little effort, great added value
"Our smart sensors can do more than just click-clack. They have a lot more to offer: Vibration, temperature, installation position, operating hours and much more operating data," explains Edler.
The additional data for condition monitoring provides Jerko Sprühsysteme customers with enormous added value. "Our goal of getting a lot of useful data into the system with little effort was completely fulfilled thanks to Balluff's support," says Dahmen. "We now know things about our systems that we didn't know before and that also helps us enormously with follow-up projects."