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Smart Sensors with Intelligent Functions

Provide and aggregate additional information with universal smart sensors

With the Smart Automation and Monitoring System (SAMS), we provide you with added value by enhancing our products with additional functions and measurement values, thus providing a system that not only fulfills its primary functions, but goes far beyond them and enables process and even plant monitoring.

To make it easier to work with the various functions and to align them across products, we have standardized our features as we developed SAMS. For example, vibration in inductive sensors and in the Digital Position Indicator is always found on the same indexes.

The Smart Features of the sensors unlock a variety of new possibilities for the automation of your machines and plants.

The vibration monitoring function of the Smart Sensors

With vibration monitoring, you are given meaningful information about vibrations in the device itself, as well as the entire plant. If undetected, excessive vibrations can lead to machine failures. The smart sensors of the Smart Automation and Monitoring System warn you about this so that you can carry out more accurate analyses and perform maintenance in a timely fashion.

Keeping an eye on sensor temperature

One of the additional functions of our SAMS devices is internal temperature monitoring. Taking into account a number of physical factors, such as the different reactions of encapsulated devices to fluctuations in ambient temperature, this allows you to draw valuable conclusions. Temperature increases can be detected at an early stage and counteracted.

LED diagnostics: Smart control in industry

SAMS devices are equipped with multicolor LEDs to provide clear signals. You can freely choose between the Balluff standard and the NAMUR standard for the light setting. The configuration of the device and the selection of the two settings can be done easily via IO-Link. Different states of the smart sensors are assigned to a specific color. For example, when a device requires maintenance, a permanent blue light signal is sent; when the signal quality is poor, the sensor lights up orange.

Device detection ("device discovery"): Locating the installed sensors and devices

The smart sensors and devices are equipped with a device discovery function. By sending a command to the sensor, it will flash blue to help you find its location. The flashing can be set for a duration of up to 30 min.

Signal quality of the Smart Sensors

The signal quality is output as a percentage value between 0 and 100 %.

This can not only be a useful indicator during setup, but also help you implement predictive maintenance.

Adjustment aid for deviating inclination angle

When setting up the system, a "reference position" must be taught in at the beginning. This allows deviations from the defined position to be detected and reported. With this you will always know when the sensor is in the correct position. If the sensor is accidentally misaligned, this function can be used to adjust it back to the correct angle.

Moisture detection

You do not need a separate system like our SAMS to know that moisture is not good for electrical equipment. However, it is helpful to get a report as soon as moisture has been detected inside a device. If moisture enters the device, an alarm is triggered. This way, the device can be replaced before the machine fails, avoiding high repair costs and production downtime.

Current and voltage monitoring

With this feature, these smart sensors notify you as soon as the nominal voltage is below or above the tolerance range — i.e. there is an under- or over-voltage.

Short circuits are also detected and reported. With the help of this alert, you can quickly and efficiently initiate troubleshooting of the affected machine or system.

Status of extreme ambient conditions

This shows you as soon as a product is in extreme environmental situations and how long this status has already been occurring. You can set your own limit values and define for the different parameters when their measured variables are considered to be extreme conditions. Secondary data sources are also used for this purpose, such as vibration, internal temperature and humidity.

Switch counter

The switch counter can count any binary signals present in the device. It counts up to an adjustable limit and can be reset automatically or manually depending on the configured mode.

Boot cycle counter for monitoring start-up processes

The boot cycle counter, also called the startup cycle counter, monitors every machine startup. The number is incremented by one with each machine start. In this way, it is possible to monitor how often a machine or system is started and switched off again in a given period of time.

Signal delay

In order to avoid undesired, early or frequent changes due to the signal transmission of the sensors, it is possible to use the signal delay to change a binary signal (switch-on/switch-off delay or one-shot). This does not necessarily have to be the switching signal of a sensor. This function also makes it possible, for example, to apply the vibration alarm or the result of a logic block only with a delay. The only requirement is that it is a binary signal.

Signal velocity monitoring of sensors

For signal velocity monitoring of sensors, you must first define a time window, which you can determine individually as required. This allows you to get information if signals are recorded and processed within this time window. In this way, you can directly detect and eliminate undesired signal delays.

Logical links through logic blocks

The available data and signals can be logically linked to create new information. Up to four signals per block and four blocks total can be used and linked together in the evaluation. If inputs of the block are not needed, they can simply be left free. All unused inputs are ignored, which means that, for example, you can link just two values together. Any Boolean input signal can be used for the connection. The result of a block can be used as input signal for another block. The logical links AND / OR / NOR / XOR are available.

Pin configuration and setting

This feature of the Smart Sensors sounds simple, but it offers potential: While pin 4 is always a digital output, pin 2 can be assigned as a digital output, digital input or analog output. For example, it is possible to use this component without IO-Link by outputting the switching and measuring signals directly to pin 2.

Counting operating hours of machines and systems using smart sensors

Our smart sensors basically count the operating hours every second, but they save the status dynamically starting with every minute (or after 2, 4, 8 or 12 minutes). Alternatively, it is possible to switch the counter to a static mode. In this case, the status is saved only every 12 minutes, thus saving memory. In static mode, the operating hours can be recorded in this way for up to 20 years. A total of three different counters are available: Time since last start-up, a total counter and a manually resettable counter.

Basic statistics

Basic statistics functions allow you to use any process data objects, with the exception of Boolean values, as input values for statistical evaluation. This makes it possible to, for example, calculate the minimum or maximum, the average, or even the moving average of a selected input variable directly at the point of use of the sensor.