If you are looking for the widest range of sensors which offer the important combination of best-in-class precision, optimum measuring ranges and frequencies, backed-up by in-depth expertise, Baumer delivers the complete connectivity solution from Sensors to PLC and lloT. Whatever challenges you face in your application, you will find the right sensing solution in the Baumer toolbox.

Sensing applications requiring precise position control, quality inspection and thickness measurement performed to the highest levels of precision and repeatability, is where Baumer’s OM60 Laser Distance Sensors excel. Typical applications are in the automotive, electronics and robotics industries where the benefits of OM60 sensors include the ability to measure distances up to 1000mm, linearity deviation up to 0.03 % MR, measurement frequency up to 3.3 kHz, along with a digital interface such as IO-Link or RS485.

Furthermore, thanks to an exceptionally fine line beam shape, reliable measurement performance, even on challenging surfaces, can be achieved, means these sensors are ideal for applications requiring very precise positioning, or tight tolerances in quality inspection.

Other highlights of Baumer’s IO-Link sensor portfolio include the 50 Series Process Sensors, which the company says offer best-in-class precision, measuring range and response time. Although a compact design, they feature an-easy-to-view large touch colour display within a robust, sealed stainless steel housing, along with easy and standardised operation across the entire 50 series. When a processing application demands the need to measure pressure precisely and reliably across different media, the 50 series are ideal for demanding hygienic and other similar applications.

Baumer’s Incremental Encoders are another important product in the range offering Low Harmonics signal correction and wear-free design for precision under the most testing conditions. Other key features include auto calibration which eliminates temperature and mechanical signal errors, resolution up to 65,536 ppr, accuracy up to 0.05deg, along with smart condition monitoring and flexible configuration of switching output.

Completing the Baumer portfolio are Ultrasonic Sensors which meet the latest IO-Link standard of 1.1 and ensure outstanding ultrasonic object detection and distance measurement. Features include modification of the sensor cone, filtering, individual sensor setting, fast implementation and easy sensor exchange with automatic parameter transfer.

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‘Smart’ sensors have become an essential component in many manufacturing systems as the demand for ever more sophisticated automation continues apace across a huge range of processing applications. In many automated processes specific information is essential to ensure the smooth running of systems, typically provided by optical, inductive, ultrasonic sensors, or cameras. However, a more versatile, lesser known alternative are smart 2D profile sensors.

A good example of where these smart sensors have proven to be very effective is on a production line at Weber Maschinenbau, which specialises in developing slicing systems for food industry applications. The company’s latest production line accommodates over 70 sandwiches rolling off the line every hour, perfectly topped with sausage or cheese.

For this application, precise edge control, margins and positioning data are essential to smooth operation, for example; what is the exact position of the sandwich or filled roll on the belt? We need to know its height and is the edge even? For example, the robot in the roll section needs to know roll height and centre (lengthwise and crosswise) and whether the roll may not be properly aligned on the belt.

The OXM sensor delivers all this information thanks to integrated measurement and evaluation functions. In other words, the entire measured value calculation is provided by the sensor including the calculated coordinates in millimetres – as specifically required. The sensor also measures the bread height and every edge to calculate the centre of the roll which enables suction pads to gently lift off the finished product without causing damage.

On the sandwich line, the sensor also determines the lateral position and height of the sausage and cheese slices on the belt allowing the gripper to position the slices accurately on the bottom half of the sandwich.

Weber Maschinenbau exploits this functionality not only on its sandwich lines but also on the slicers that cut and portion cold cut optimally prepared for packaging. Here, the sensors deliver the position data required for precisely aligned slices of salami, ham or cheese, which is essential for allowing the finished product to always be placed in the same position in the packaging process.

Marco Nichau, head of automation at Weber Maschinenbau, commented: “It’s important for us that we don’t have to spend too much time and effort in integrating sensors and because the OXM sensor transmits all the position information directly to the machine controller we don’t need an additional controller, saving space and reducing costs.

“As the sensor is very compact and easy to connect, we were able to parameterise it via the intuitive web interface. Furthermore, its ideal for the sandwich line as its performance is unaffected by variations in surfaces and ambient light. These factors, combined with excellent support and response from Baumer, were the key factors in our choice.”

The latest versions of these smart 2D profile sensors are compact and lightweight with simple connectivity using a single cable via IO-Link, Ethernet and more. They provide measurement ranges of up to 500mm with a field view of up to 300mm and operate with a precision of up to 5µm. These features make the sensors ideally suited to height checks of assembly parts, control and positioning tasks in robotics, such as position checks of feeder parts for pick-and-place applications, or gap checks in automotive manufacturing.

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These 2D profile sensors are ideal for manufacturing applications wherever OK/NOK inspections or positioning tasks are possible via the evaluation of height information. They enable measuring ranges of up to 500mm with a field view of up to 300mm, ensuring design ‘freedom’ for numerous applications. A comprehensive set or integrated tools can be parameterised directly via an intuitive web interface to ensure complete processing of the profile data directly in the smart sensor.

Without the need for any external steps, the sensor can transmit the X/Z position value to the controller – with a precision of up to 5µm. This standard of performance means that the OX sensor enables more cost-efficient sensing solutions in quality control, web edge control and robot positioning. Another advantage is the live visualisation of the measurement tasks in the web interface, where settings in the sensor can be directly checked, adjusted and optimised.

The new OX sensors are compact and lightweight and can be simply connected with a single cable thanks to PoE (Power-over-Ethernet). They are ideally suited to height checks of assembly parts, control and positioning tasks in robotics, such as position checks of feeder parts for pick-and-place applications, or gap checks in automotive manufacturing.

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In many applications surface coating such as electroplating is an important part of the manufacturing process and if performed manually, will require a considerable amount of space and human resources. However, a good example of the benefits of advanced automation and robotics is the development of an innovative robot cell which enables fully automated electroplating and has proven to be a big benefit to Swiss automation company Roth Technik.

A three-way collaboration between the customer, surface coating specialist Collini based in Dubendorf, near Zurich, with automation company Roth Technik and sensor specialist Baumer, has resulted in the development of a fully automatic system for plating racks.

Minimal space was a key factor for the customer which is why they were looking for a space-saving solution that would enable a fast and reliable way of hanging small parts on racks in preparation for transfer to the electroplating bath.

Marco Fuchs, head of product engineering at Collini explains: “Boxes containing small metal parts were stacked in a narrow niche with barely enough space to manoeuvre a single pallet between the wall and the liquid tanks. Behind this assembly are rows of tightly packed electroplating tanks and this lack of space was a key factor in why we were looking for a space-saving solution that would deliver a fast, reliable way of hanging small parts on racks for the electroplating bath.”

The conventional method of loading the racks by hand requires lots of space and human resources because several racks need to be loaded at the same time. Collini confirmed: “This is why we wanted to switch to a new automated coating system. However, this type of system had yet to be created so we embarked on a search for pioneering companies that we could collaborate with to take up the challenge.” The search resulted in a collaboration between Collini, automation specialist Roth Technik, which in turn relies on smart sensor solutions from Baumer.

Working together, the team began the development of a fully automatic and compact loading line. At the heart of the loading line are four robots that automatically load parts onto the empty hooks on the racks, with the biggest challenge being that no two racks are the same. The hook positions are not located in exactly the same place on the welded racks and some hooks may be bent or missing entirely.

Whilst this isn’t a problem for a manual system, it is a big challenge for robots that require precise positioning data. Furthermore, the huge variety and high throughput of parts presented other challenges. So how did the ‘team’ solve the problem of rack positioning accuracy, enabling the robots to ‘learn’ the exact positions of the hooks for each rack?

A simple, yet effective solution from Baumer, the ultra-compact OXM200 profile sensor proved to be a key component in the efficacy of the system. Mounted on the robot arm, the sensor detects the exact position of each individual hook as it moves down the rack and reports this data back to the robot control.

With the help of a camera, the robot then picks up one part after the other from the separating carousel and hangs it on a hook. The robot uses the position coordinates previously collected by the profile sensor to finely adjust the position of the part and this enables the profile sensor to guide the robot precisely and quickly on the electroplating rack.

Markus Roth, CEO of Roth Technik, explains: “Whilst the process might sound simple it requires the sensor to deliver an outstanding performance, we had to install a sensor that detects and precisely measures very thin hooks, not just in 2-dimensional space but in a 3-dimensional one too.”

Initially, the Roth Technik team tested various camera-based systems and other laser-based scanners, but eventually decided that the sensor was the way to go. Markus confirmed: “In the end, we chose the Baumer OXM200 profile sensor because it was the best solution for our strict requirements regarding accuracy, ultra-compact design and ability to detect objects.”

The OXM200 offers another major advantage, thanks to powerful, integrated measuring tools, the sensor outputs the measured values for the X and Z coordinates directly in mm, significantly reducing the number of calculations in the control. This resulted in less integration work on software and enabled the project to be up and running faster.

Also, thanks to Power over Ethernet (PoE) a single cable is all that was needed to connect the sensor to the control and supply it with power, an important detail when it comes to mounting the sensor on a mobile robot arm. Further time savings are achieved by scanning the hook positions only once when the rack is inserted and as the control stores all the hook positions, the racks don’t have to be scanned each time. The result is two robot cells which enable a throughput of 15 million parts per year using minimal space whilst eliminating the issues associated with a manual system.

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Examples of this include the EB200E programmable incremental encoder, a very ‘smart’, flexible and cost-effective sensor with IO-Link and designed to precisely record many different measured values. The IO-Link ensures cost-effective integration and parameterization, provides easy speed feedback and is a reliable, long-term solution – even in applications where dirt, dust or fibres are present.

Under the mantra that ‘Digitisation begins with the Sensor’ and by exploiting the latest in digital communication interfaces Baumer now offers a wide range of IO-Link sensors covering control applications across many industry sectors. These include inductive, ultrasonic, light barriers, optical distance, flow, level switches, conductivity, radar and pressure sensors.

Also on display at Drives will be the new Baumer Sensor Suite (BSS) control software which helps engineers to test and evaluate IO-Link devices more efficiently thanks to features such as intuitive visualisation of sensor functions. This latest software is an important centre piece for application development by allowing the connection of all IO-Link devices to many IO-Link masters on the market.

BSS means users can access a wide variety of sensor functions and settings for new control models, such as Dual Channel and new parameterisation concepts, basically allowing engineers to better exploit the full functionality with minimum effort and maximum flexibility. For example, a plug and work feature to speed-up development processes, while intuitive visualisation supports fast and precise parameterisation which benefits commissioning engineers and collaborators.

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The new Baumer Sensor Suite (BSS) helps engineers to test, implement and evaluate IO-Link devices more efficiently thanks to features such as intuitive visualisation of sensor functions. This latest software is a centre piece for application development by allowing the connection of all IO-Link devices to many IO-Link masters on the market. BSS enables users to access a wide variety of sensor functions and settings for new control models, such as Dual Channel and new parameterisation concepts.

Many of these functions are new, or have been simplified in terms of condition monitoring, teaching capabilities, format alignments, special filters or secondary data. All these represent opportunities for improved plant efficiency and increased flexibility, yet they also raise the complexity in the selection and parameterisation of IO-Link sensors.

The new BSS sensor suite allows engineers to exploit the full potential of these functionalities with minimum effort. For example, a plug and work feature significantly speeds up development processes while intuitive visualisation supports fast and precise parametrisation which benefits commissioning engineers and collaborators. A save and restore function helps users to easily transfer the prior optimised parameters to the IO-Link devices whilst also supporting error analysis helping to improve ongoing maintenance. Faster access to diagnostic data and clear visualisation also helps external servicing technicians to quickly grasp the sensor and application situation, which may help to reduce downtime.

The BSS sensor suite is based on future-proof software architecture utilising elements of the Microsoft Azure Cloud which maximises access to the latest software versions and functionalities at all times. BBS in its basic version including Apps Catalogue, Device Library and Device Cockpit can be downloaded from the Baumer website. The basic version is the starting point for other Baumer Apps and digital services and therefore represents the ideal tool to fully exploit IO-Link device potential, both now and in the future.

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Among the important features of VeriSens sensors it was the intelligent calibration target SmartGrid (patent pending) innovation with its Chessboard application of the bit pattern, which proved pivotal in their success in the awards. Crucially for robot operators the SmartGrid feature not only enables unique automated coordinate alignment it also eliminates the conventional issues and limitations of manual ‘hand-eye’ coordination. The result is that only a few minutes are needed to give ‘eyesight’ to Universal Robots and at a higher accuracy in parallel.

In addition, the SmartGrid feature supports automatic teaching of image rectification for image distortion correction in real time. Basically, a simple mouse click will suffice in eliminating any impairments by lens or mounting, without affecting the following processing time. Also the teaching of 3D orientation enables automatic adjustment to distance. When converted to World coordinates VeriSens is receiving the scaling specifications directly via the SmartGrid.

Installation and calibration of these vision sensors is simplified via the VeriSens URCap interface specifically developed by Baumer to optimise robot control. Only a few steps are required to ensure the benefits of the diverse range of image processing options that this interface provides.

For the programming of the robot, only two additional commands (nodes) are necessary to realise the benefits and advantages of vision guided robotics across a wide range of control applications.

Set-up and calibration is also simplified because instead of pre-determined waypoints, free positions are used on which objects are then visually recognised while the already established functions are able to check for object overlaps and gripper clearances. Furthermore, VeriSens sensors can also be used for additional functions such as verifying free storage areas, fulfilling quality controls of objects which are in various positions, as well as identifying and measuring objects.

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A good example of this is a new ‘smart’ multi-profile sensor the OXM200 introduced by sensing and instrumentation specialist Baumer which is ideally suited to inspection and measuring applications. It provides an almost unlimited operating range, providing users with ultra-efficient inline checks and multi-dimensional control of their manufacturing and processing systems,

The compact and lightweight all-in-one OX200 Sensor is designed for integration into image processing systems and thanks to an extensive set of integrated measurement functions, they are able to support inline or offline testing without the need for operators to have detailed image processing experience.

They are designed for checking and inspection applications along with checks and verification of object geometrics such as height measurement of seals, inspection of surfaces etc. Also, inline quality controls of object geometries in the 1/10mm range, plus measuring operations, such as axial diameter measurements, plus edge, crack, gap and flush measurements. They can also be used for control and regulation tasks, including position control of feed parts, vision guided robotics (control of robot positioning), pick and place (control of robot grabber arms) and position control of parts.

As a smart multi-tool they enable the linking of measurement tools for multi-faceted analysis, free configuration of up to 7 measured values in a web browser and position tracking of evaluation windows for checking varying positions of a measured part. They feature a compact, lightweight design with IP65 housing and simple wiring for mounting on a robot arm, no external illumination is required and thanks to Power-over-Ethernet (POE) functionality, can be used with a single cable. Set-up and handling is easy thanks to graphic support via the intuitive Baumer web interface.

Storage of up to 3 sets of parameters in the sensor is possible while additional sets can be stored externally if required. Plug and play functionality, without the need for software installation or special training, helps with quick commissioning of the calibrated sensor. Also, live analysis and monitoring (seeing with the eyes of the sensor in real time) means quick analysis through intuitive visual feedback of the algorithms.

Easy integration into automation systems is possible courtesy of a wide selection of protocols including; PROFINET, Modbus TCP, IO-Link and analogue output. Direct connection to IT systems and cloud integration with OPC UA, in addition to image processing systems with an SDK (profile data via UDP streaming), is also possible.

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