Smarter weighing for high-dynamic systems
As high-speed packaging lines and robotic systems continue to increase in speed, precision and autonomy, weighing is evolving – from a simple control point into a core element of modern automation architectures, delivering actionable real-time process data. The new PW22i IO-Link single-point load cell from HBK provides precision, speed and intelligence – embedded at sensor level
In high-dynamic environments, such as multi-head combination weighers, dynamic filling processes, or robotic systems exposed to variable load profiles, manufacturers are under growing pressure to achieve short cycle times, high throughput and high repeatability, whilst maintaining Overall Equipment Effectiveness (OEE) and advanced diagnostic capabilities. As a result, conventional weighing solutions are increasingly reaching their mechanical and digital limits.
To address these cross-industry requirements, HBK has developed the PW22i single point load cell, specifically designed for high-dynamic mechatronic systems, spanning both high-speed packaging applications and advanced robotic use cases. By embedding IO-Link communication directly at sensor level, the PW22i turns weighing into an intelligent automation component, seamlessly connected to the control layer.
Thanks to its exceptional mechanical stiffness and very high natural resonant frequency, the PW22i has an extremely short settling time, which is a critical requirement for fast cycle applications. These characteristics enable precise and repeatable measurements, supporting giveaway reduction in packaging processes, as well as measurement stability under dynamic loads in robotic systems. Available in 10 kg, 20 kg and 50 kg capacity – and certified to accuracy class C3MR – the PW22i ensures reliable results under demanding operating conditions.
“The PW22i was designed for environments where mechanical dynamics are high and measurement reliability is critical in real time,” said Product Manager Weighing Sensors at HBK, Simon Kleefeldt. “Whether in high-speed packaging lines or robotic applications with rapidly changing load profiles, we combine ultra-fast dynamic weighing with IO-Link intelligence directly at sensor level. This enables plug-and-play integration, faster commissioning and direct use of weighing data within existing control architectures.”
The standardised IO-Link interface and M12 4-pin connector simplifies commissioning, replacement and retrofit of existing systems. Smart functions such as data preprocessing, self-monitoring and diagnostics provide continuous visibility into sensor condition and process behaviour, supporting predictive maintenance strategies and OEE optimisation, across both packaging lines and robotic cells – or end-of-arm tooling systems.
Designed for demanding industrial environments, the PW22i features an IP67 degree of protection and a patented overload stop, allowing it to withstand up to five times its nominal capacity. This robustness ensures reliable operation under mechanical stress, eccentric loading and transient forces, which are common in high-dynamic industrial and robotic applications.
The PW22i supports machine builders, system integrators and manufacturers in designing faster, more connected and more intelligent systems, where weighing becomes a key enabler of operational performance, product quality and data-driven process control, across packaging automation and industrial robotics.
