Metal forming
Metal forming

Mechanical presses have become indispensable tools for metal forming. The 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 is valuable and any lengthy production delay costs a lot of money. Especially if you discover that your expensive assets have been damaged and need to be replaced. Sensor solutions are ideal for precise press position during the stamping process. They allow malfunctions to be immediately detected and consequential damage prevented, since a press equipped with sensors can be safely shut off.

Application examples

  • Securing access areas

    With BLG photoelectric protection devices

    The solution

    By using light curtains comprised of multiple parallel light beams you can save space, since light curtains can replace cumbersome protective gate constructions or a bundle of multiple individual through-beam sensors. If a person moves into the defined protected zone, the safety light curtain immediately triggers a stop command and all safety-critical movements of the equipment are stopped.

    The features

    • Finger, hand and body detection for convenient and fast interaction between man and machine
    • Defined protected area with infrared protection field – suitable for safety applications up to PLe/SIL3
    • Safe machine stoppage in safety-critical applications
    • Better space utilization by eliminating the need for protective fence structures
    • High level of manipulation protection
    Securing access areas
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    Industry team

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  • Switching eccentric presses

    With BSW rotary cam switches

    The solution

    For presses with short strokes and high stroke counts our BSW rotary cam switches – available in mechanical and inductive switching versions – have proven themselves for decades. 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 press type and requirements, rotary cam switches are offered with our without safety regulations.

    The features

    • Proven, classic solution
    • Highly economical
    Switching eccentric presses
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    Industry team

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  • Controlling hydraulic presses

    With BTL magnetostrictive linear position sensors

    The solution

    Hydraulic presses (long strokes, low stroke counts) achieve their rated force over the entire stroke travel. Magnetostrictive linear position sensors handle position monitoring. The magnetic position marker is attached to the slide or ram, and the rod with the measuring element is fixed to a location on the press along the axis. These systems with high measurement value precision and update rate are insensitive to mechanical shock, so you can still operate the machine optimally.

    The features

    • High machine availability, since the sensors are insensitive to shock and vibration
    • For long strokes and low stroke counts
    • Wear-free: high durability and long service life
    Controlling hydraulic presses
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    Industry team

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  • Changing die sets

    With BIC inductive couplers

    The solution

    To protect expensive press tools, sensors often need to be attached to the die itself. With our inductive couplers you can provide the sensors with power. At the same time this non-contact system transmits the data between the press tool and the press controller. This enables automated changing of dies – without the use of mechanical connectors.

    The features

    • Non-contact: No manual connection, no plugs
    • Bi-directional: sends signals in both directions
    • Fast format changes with plug-and-play
    Changing die sets
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    Industry team

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  • Monitoring sheet metal thicknesses

    With BAW inductive distance sensors

    The solution

    With our inductive distance sensors you prevent improper loading of sheet material. They can be used to monitor whether sheets have been double fed and to detect the thickness of the sheet. They provide a continuous output signal (e.g. 0...10 V) or use an IO-Link interface.

    You deploy one or two sensors depending on the application, precision requirements and how the sheet is held.

    The features

    • Fast startup, short stoppage time
    • Ease of use with continuous output signal or IO-Link
    • Material variants can be distinguished
    Monitoring sheet metal thicknesses
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    Industry team

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  • Checking metal strip sag

    With BUS ultrasonic sensors

    The solution

    Our BUS ultrasonic sensors with a continuous output signal assist in automatic feeding of metal strips. The speed is matched to the cycle rate of the press. The distance between the sheet metal and the sensor is provided as a signal for controlling the motor speed.

    The features

    • Extreme precision with high resolution and no blind zones
    • Irrespective of color, transparency, reflection properties and surface finish on the object
    • Unmatched in critical environments
    Checking metal strip sag
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  • Monitoring press forces

    With BSP pressure sensors

    The solution

    By using our BSP pressure sensors you can simply determine press forces based on the hydraulic pressure. This provides users of hydraulic presses with a rugged and economical solution for dynamic monitoring of the press forces. You can install the sensors as needed and operate them conveniently and comfortably due to the rotating housing and simple VDMA-conformal programming. Using the bright LED display, you can track current system pressure quickly and reliably.

    The features

    • Pressure rated –1 to 600 bar
    • Process connection G¼", G½", R¼", NPT¼"
    • Flush with the front surface in G½" and TriClamp 1.5"
    • Selectable outputs (analog, digital, IO-Link)
    Monitoring press forces
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Metalworking (PDF file)