Presses in metal machining
Presses in metal machining

Sensor solutions guarantee high system availability

Metal machining without mechanical presses is unimaginable. The pressing 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. Because every minute counts. And every persistent production delay ultimately costs a lot of money. Especially if damage to expensive assets makes it necessary to replace them.

To detect the exact press position during operation cycles, sensor solutions are therefore used in many locations. They enable you to detect malfunctions immediately and prevent collateral damage. This is because your presses that are equipped with such sensors automatically shut down immediately in an emergency.

Application examples

  • Switching eccentric presses

    Switch mechanisms have been proven over many years for small strokes and large numbers of strokes

    The solution

    In presses with small strokes and large numbers of strokes, our switch mechanisms have been proven over many years: In both a mechanical and an inductive version.

    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 type and requirements of the press, the process is supported by switch mechanisms with or without occupational insurance approvals.

    The features

    • Proven in presses having small strokes and larger numbers of strokes
    • Mechanical and inductive version
    • Determine multiple on- and off-points for the controller
    • Switch mechanisms with or without occupational insurance approvals
    Metal machining, switching eccentric presses
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  • Controlling hydraulic presses

    Optimum machine use via magnetostrictive linear position sensors

    The solution

    Hydraulic presses reach their nominal force over the entire stroke length. Our BTL magnetostrictive linear position sensors reliably handle position monitoring.

    The position encoder is applied to the movable profile with position measuring element in the stationary part of the press. The system is insensitive to mechanical shocks that may occur. In this way, the high measured value precision and update rates enable you to have optimum machine use.

    The features

    • Reliable position monitoring
    • Insensitive to mechanical shocks
    • Optimum machine use via high measured value precision and update rate
    Metal machining, control hydraulic presses
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  • Changing press tools

    Inductive couplers automate the tool change

    The solution

    To protect expensive press tools, sensors frequently must be attached to the tool itself.

    With the inductive BIC couplers from Balluff, they can be supplied with power. Moreover, the contact-free system transfers data recorded by the sensors between press tool and press controller. In this way, the system ensures that you can change press tools in an automated way, that is, without manual connection of plug connectors.

    The features

    • Reliable power supply of sensors
    • Contact-free data transfer
    • Automatically change press tools
    Metal machining, change press tools
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  • Monitoring sheet metal thicknesses

    Reliably check sheet feed with inductive distance sensor

    The solution

    BAW inductive distance sensors prevent the incorrect delivery with sheet material.

    They monitor whether sheets are double fed and detect the sheet thickness. A continuous output signal or IO-Link is available for this purpose. Depending on the application, requirements for precision and sheet mounting type, one or two sensors are used.

    The features

    • No incorrect delivery with sheet material
    • Continuous output signal (e.g.. 0…10 V) or IO-Link
    • One or two sensors depending on the use, precision requirements and mounting type of the sheet
    Metal machining, checking sheet thickness
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  • Checking metal strip sag

    Protect automatic feed of sheet strips via ultrasonic distance sensors

    The solution

    Our BUS ultrasonic distance sensors with continuous output signal support the automatic feeding of sheet strips.

    The tempo here is harmonized with the clock rate of the press or stamping operation. The distance between sheet and sensor serves as a signal for controlling the motor speed.

    The features

    • Automatic feeding of sheet strips via reliable distance measurement
    • Tempo of the feed harmonized with clock rate of the press / stamping operation
    • Sheet – sensor distance as a signal for controlling the motor speed
    Metal machining, checking sheet strip sag
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  • Monitoring press forces

    A high-quality tool for the dynamic pressing force monitoring

    The solution

    Using our BSP pressure sensors, you determine the pressing forces in a simple manner via the accumulated pressure.

    Thus, you as the user of hydraulic presses get a high quality tool for the dynamic monitoring of these forces.

    The features

    • Ideal for users of hydraulic presses
    • High quality tool for the dynamic monitoring of pressing forces
    Metal machining, monitoring pressing forces
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