Process monitoring ensures productivity

Machine data can be decisive when it comes to efficiency and quality in manufacturing. To implement predictive maintenance, repair or replacement work, it is essential to have information about the condition of the sensors, the process chain and the workpieces.

We monitor your machines (PDF file)

Continuous process monitoring enables you to properly control and utilize production resources, all while saving you money. Our sensors not only provide information about system control. They also gather machine data which serves as information in higher level systems: For logistics and procurement, planned service activities, static process monitoring, and in general for documentation purposes.

Balluff process sensors and systems developed for machine monitoring can be installed directly in the desired production system or retrofitted simply. Balluff distinguishes between diagnostics-capable sensors and sensors for process monitoring. The former monitor their own condition, whereas sensors for process monitoring are designed to check ambient conditions such as pressure or temperature.

Inductive sensors with self-diagnostics

Inductive sensors have long been used in industrial applications to detect metallic target objects. But over time, the sensors have been further developed to take on a variety of diagnostics tasks. Depending on the version, the sensors detect short-circuits in their cables, damage to the sensor coil, or report when the distance to a detection object is within a specified range.

In metalworking, DESINA sensors per ISO 23570-1 are often used. These inductive sensors can visualize the sensor status (self-diagnostics) via an additional monitor output. Dynamic Sensor Control Sensors, or DSC sensors for short, output switching and error signals along with warning and trend messages. The sensors provide a picture of quality deviations during production in real-time. Inductive sensors with IO-Link technology provide additional information such as sensor temperature data. Inductive sensors offer many advantages over mechanical switches: They are non-contact, short-circuit proof, contamination resistant, and wear-free.

Thermal flow controllers provide thermal stability

For industrial machining processes to achieve the highest possible product quality, machines and their components must maintain a defined, optimal temperature.

To ensure that the temperature remains constant, our thermal flow controllers offer effective process monitoring. They measure flow with technology based on the calorimetric principle. The temperature of the process medium, such as water or another coolant, is slightly increased by a small heater element built into the sensor. Depending on the flow velocity and heat capacity of the medium, there is a brief and slight temperature change. An integrated temperature sensor delivers the machine data to a processing unit for analysis. The values are compared with a preset value and reported via a signal output. In this way, flow sensors can warn you before a machine overheats.

You can easily integrate thermal flow controllers thanks to their compact sensor housing. One sensor type can be used for a variety of tube diameters. The sensors are low-wear and economical, since they are associated with only a very slight pressure loss. They are also suited for harsh applications with high operating pressures up to 100 bar.

Thermal flow controllers for process monitoring

Media-contacting temperature sensors

“Keep cool” is the motto for machining. As the machines and their components are cooled, the medium in the cooling circuit heats up. This heat must be dissipated to keep the machine temperature constant. To regulate cooling units, our temperature sensors provide measurement values that can be sent to higher level systems for process monitoring. The temperature is measured directly in liquid or gaseous media and output as analog signals or predefined switching points. The process sensors are available with or without rotating display, so that you can meet your visibility requirements when installing them in various space conditions.

Media-contacting temperature sensors for regulating cooling units

Pressure sensors for process monitoring in hydraulics

Pressure sensors provide machine data from hydraulic systems. You can also use them for process monitoring and error detection within production processes. In process monitoring of hydraulically controlled processes, measurement of the pressure reflects the condition within the control loop. The often-high cycle rates deliver a large amount of machine data within the shortest amount of time so that deviations from normal levels can be immediately identified.

Pressure sensors can also be used for hydrostatic level measurement of process fluids. They detect slowly changing levels to enable automated triggering and running of logistics and procurement processes. This takes the burden off employees, and it reduces the risk of inventory shortages.

Pressure sensors for process monitoring

HEARTBEAT® power supply units with diagnostics functions

The Heartbeat® power supply units from Balluff power process sensors, actuators, controllers and Human Machine Interfaces reliably and efficiently. Developed especially for challenging applications, they meet the highest requirements for quality, long service life and diagnostic capabilities. These power supply units are available in power classes of 60, 120, 240 and 480 W. You can regulate their output voltage, which has very low ripple. The Power Boost function enables a 150% reserve capacity for peak demands. Our Heartbeat® power supply units use the highest quality components.

A three-color LED status indicator provides you with continuous information about the current load or equipment. Thanks to its continuous internal process monitoring, the power supply unit gives an outage warning before a failure occurs. The indicator also communicates the amount of stress on the internal devices and the remaining service life of the power supply. This lets you get the longest possible useful life from the unit. Versions of the power supply with IO-Link can indicate the current consumption at any given moment for process monitoring. Any slow increase in current consumption is detected, which may be caused by wear factors.

The narrow footprint of the Heartbeat® power supply units in IP20 housing allows them to be installed efficiently and easily in control cabinets while taking up the least possible space. IP67 versions for powering modules in the field are also available.

Heartbeat® power supply units for demanding automation requirements

Heartbeat® power supply units with IO-Link interface

Tool identification with RFID

RFID is an important component of process monitoring. Tool identification using this non-contact technology has become indispensable to modern production. RFID makes it possible to store tool-relevant machine data (i.e. specific information about the respective tool) without contact on a data carrier which is integrated into the tool holder. This ensures accurate identification of the tool in every process step.

Balluff’s industrial BIS C RFID systems (low frequency) or BIS M (high frequency) provide the CNC controller in milling machines and machining centers with the correct tool data. The parameters are continually recorded as the tool is loaded and unloaded. This reliably guides subsequent use of the tool. In addition, machine monitoring with RFID allows you to document the amount of life the tool has used and to optimize its use accordingly. This is especially advantageous in series production with medium lot sizes. Tool identification is also used more and more for logistics and procurement purposes.

For many machining companies, the tools are also a relevant component of asset management. Modern manufacturing demands maximum transparency in process monitoring. This is the only way to meet the high requirements for flexibility and quality while keeping costs at a minimum. This makes RFID a key technology for tool tracking.

Industrial RFID system BIS M (13.56 MHz)

Industrial RFID system BIS C (70/455 kHz)

Application examples for monitoring

  • 全程透明



    对于工业4.0,生成、传输和处理信息是过程中不可或缺的部分。这使得本地智能传感器的重要性进一步增大。我们的光电多功能传感器可记录实际工作条件,并能收集和处理信息。经由 IO-Link,它们可提供远不止于开关信号的大量数据。BOS 21M ADCAP LED 红光型多功能传感器非常适合以最佳方式对工件进行装配定位。为了满足您的功能需求,您可以使用 IO-Link 方便地从四种不同的传感器模式中进行选择。这些让您能够根据具体应用使用最佳、最可靠的检测方法。传感器还同时传送诊断数据。现在,您可以评估光敏度,并检测传感器的污染增加情况。通过这种方式,可以设计维护和清洁时间表,以便在故障发生之前清洁传感器。您还能够知晓在清洗之后传感器的调节是否仍旧理想。但 BOS 21M ADCAP 还有其他功能:它能持续监测 LED 所发出光束的光度和亮度,几乎完全消除了错误的传感器切换。包含各种计数和重置模式的内置计数功能还允许在不进行任何额外编程的情况下让控制器进行数量核查。如果您的检测要求更为严苛,推荐使用巴鲁夫的高精度光电激光器 (BOS 21M HPL),它拥有多项附加功能。得益于多种检测和处理模式,这款高性能设备还能够精密检测复杂物体和微小细节。

  • 一款用于动态压紧力监测的高质量工具

    使用我们的 BSP 压力传感器,您可以通过积聚压力简单地测定压紧力。因此,作为液压机的用户,您可以得到一款对这些力进行动态监测的高质量工具。


    • 液压机用户的理想之选
    • 用于对压紧力进行动态监测的高质量工具

  • 模具识别 — 实现最佳模具利用率

    通过 RFID 自动记录模具利用率,可以让您减少意外停机时间。独立式注射计数器记录了所有生产循环。所有数据均可在直接装在模具上或多路耦合器上的数据载体上获得。通过这种方式,您可以直接在机器上查看模具状态,并能一直关注当前模具的生命周期。


    • 有关模具使用状况的即时信息
    • 通过智能电话或 RFID 手持式阅读器读取数据




  • 储罐中的液位检测

    在酿造过程中,发酵后,生啤需要在储罐中存放一段时间,才能成为熟啤,之后再装瓶。巴鲁夫 BSP 压力传感器能够可靠地检测储罐中的液位。


    • 不锈钢 IP69K 外壳,符合 FDA 标准
    • 即使安放在远离储罐一小段距离的地方,也能监测液体静压力
    • 可配备 IO-Link
    • 可提供卫生型工艺配件




Monitor your machines

Discover the possibilities offered by process monitoring using machine data sent via Ethernet TCP/IP to higher level IT systems. For additional information, please use our form.