"Our BFD sensor complements our extensive position measurement portfolio and also closes an important gap with regard to short-stroke cylinders," says Balluff Product Manager Christian Seyfried. "Manufacturers of the corresponding components in particular benefit from this - but also machine manufacturers and production companies that require a complete solution for position monitoring."

Ultrasonic sensors determine distances by measuring the time of an ultrasonic wave between transmission and reception. The BFD sensor from Balluff emits ultrasonic waves into the hydraulic fluid of short-stroke clamping elements such as swing clamps or block cylinders. It uses the ultrasonic waves to directly, continuously and quickly record the respective clamping process and the clamping status. By recording both values economically in one sensor, the solution meets the requirements for machine safety. Possible deviations in the oil supply, casting errors, contour differences or deformed workpieces can therefore be detected at an early stage. "Because the entire clamping process is monitored, the customer can also detect and rectify pressure fluctuations in the hydraulic unit, defects in the swivel mechanism or damaged seals in good time," says Seyfried.

Ultrasonic position sensor: Ideal for plug-and-play

The ultrasonic position sensor offers high-performance measurement over the entire measuring range from 0 to 80 mm, a high repeat accuracy of ±50 µm and a linearity deviation of ±250 µm. Thanks to its compact design, it can be easily integrated into the machining table. High pressure resistance up to 350 bar, protection class IP67 and an operating temperature of 0 to 85 °C make it suitable for use in most hydraulic clamping elements. The sensor also offers position monitoring and control of hydraulic valves and is also used for monitoring workpiece clamping in metalworking and in production lines with a high degree of automation.

"The measuring system continuously adapts to the respective hydraulic oil as well as pressure and temperature fluctuations. In addition to a small form factor and standardized, freely configurable interfaces, this makes the BFD sensor ideal for plug and play in different media and enables reliable operation without calibration," says Seyfried.

Keeping an eye on the status via sensor

In IO-Link mode, the sensor provides further important status data on signal quality or device temperature and detects critical changes such as air or particles in the hydraulic system. "The measuring system works with high precision and detects even the smallest tolerance deviations of the clamped raw parts," says Seyfried. "The position data of the clamps is automatically assigned to the individual workpieces. This enables effective quality assurance." With inductive couplers, analog-digital hubs or IO-Link wireless components, solutions for wireless integration are also available.