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10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 1
Pólik Zoltán
Kutató-fejlesztő mérnök
Corporate Innovation Management, Veszprém
BALLUFF Elektronika Kft.
Veszprém
Ultrahangos, magnetorstrikciós érzékelők
Irodalom:
[1] Lambert Miklós: Szenzorok – elmélet és gyakorlat[2] Oláh Ferenc, Rózsa Gábor: Automatikai építőelemek[3] Balluff katalógusok
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BUSUltrasonic Sensors
Basics
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AgendaThese questions and topics are covered in the Ultrasound Basic Training
What is ultrasound? How does ultrasound propagate? Infrasound – audible sound – Ultrasound – Hypersound Propagation in a medium Propagation in air How does an Ultrasonic Sensor function? Coverage of an Ultrasonic Sensor Limitation of the switching distance How fast is an ultrasound wave? Reflection and Absorbtion of an ultrasound wave What to consider if using Ultrasonic Sensors in applications? Ultrasonic Sensors in nature Industries and Applications
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What is ultrasound?
To answer this question you need to know first what sound actually is.
Known Encyclopedias explain:
1. Accoustic sound
2. (Physic) a propagating wave with sine oscillation in a medium that can be heard
The sound is a mechanical wave. If you take a closer look then you notice that sound is a
oscillation of pressure and density in a medium.
If you speak, the sound will propagate through the air.
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How does Ultrasound propagate?
Sound has 2 kinds of propagations
in a medium:
1. As a longitudinal wave
2. As a transversal wave
Longitudinal propagation is possible in
gas and liquid.
Both propagations are possible in solid
mediums.
longitudinal wave transversal wave
t
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Infrasound – audible sound – Ultrasound – Hypersound
Sound is classified in different category groups depending on frequencies:
Infrasound less then 16 Hz
Audible sound between 16 Hz and approx. 20 kHz
Ultrasound between 20 kHz and approx. 1 Ghz
Hypersound more then 1 Ghz
The frequency interval between 16 Hz and 20 kHz is the audible sound that
a human can hear. The older a human is the less he can hear higher
frequencies.
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Propagation in a medium
If the sound is a mechanical wave then it needs a medium. Which means in
turn that there is no sound in vacuum.
But sound can propagate in any different mediums (gas, liquid and solid
mediums) and even swap from one to another medium. The best known
example for that effect is the tin can telephone.
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Propagation in air
Ultrasonic Sensors are mostly designed for usage in the medium air. There
are also special types.
Ultrasonic Sensors emit a focused field. This field is getting larger with
longer distance. The further the field the less power is there, relative to an
area.
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This has two reasons:
1. The sound spreads in the area. The original power is getting less. Example:
Inflating a Balloon. The skin gets thinner the bigger the ballon gets.
2. The sound energy is getting absorbed by air. Heat is generated by the
rubbing/oscillating of the air molecules.
These are the two reasons why the detection range of an Ultrasonic Sensor
is limited.
Propagation in air
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How does an Ultrasonic Sensor function?
The Ultrasound is generated e.g. with a piezo element.
If voltage is applied to the piezo element it will oscillate and generate
Ultrasound. The item works as a speaker.
With the impact of Ultrasound waves on a piezo element a oscillating
voltage is generated. That effect is explained with the piezoelectric effect.
The item works as microphone.
TransducerTrigger
Amplifier
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How does an Ultrasonic Sensor function?
An Ultrasonic Sensor is comparable with a optical diffuse sensor.
• Ultrasound is generated with the piezo element.
The piezo element still oscillates after turning of the voltage. In this time no Echo can be detected.
That means the sensor has a blind zone!
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How does an Ultrasonic Sensor function?
An Ultrasonic Sensor is comparable with a optical diffuse sensor.
• The Ultrasound wave hits a medium and gets reflected.
• The Echo hits the piezo element.
The sound speed is known in a specific medium. You can measure the time between emission and reception. With these data the distance of the object can be calculated.
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How does an Ultrasonic Sensor function?
An Ultrasonic Sensor is comparable with a optical diffuse sensor.
That‘s why the ambient
temperature should not vary
or vary slowly. The sound
speed depends on the
ambient temperature. If it
varies slowly the sensor can
compensate this effect with its
electronics.
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Coverage of an Ultrasonic Sensor
type: M12 Sensor
Switching Distance: 25 mm – 200 mm
Measuring plate A: 100 x 100 mm
Round rod B: Ø 25 mm
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Coverage of an Ultrasonic Sensor
Plate rod sensor
type: M12 Sensor
Switching Distance: 25 mm – 200 mm
Measuring plate A: 100 x 100 mm
Round rod B: Ø 25 mm
Ultrasound cone
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Coverage of an Ultrasonic Sensor
The opening angle defines the 3db limit. Objects which are not within the 8° opening angle can still be detected but they must be in the near field.
(see previous slide).
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Coverage of an Ultrasonic Sensor
Ultrasonic Sensors with higher frequencies have shorter and more focused sound cones.
100 kHz 200 kHz 300 kHz
That‘s why they are ablte to detect smaller objects!
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Limitation of switching distance
The damping of sound in air depends on the following three factors:
1. Sound Frequency
2. Air Temperature
3. Air Humidity
4. Air pressure
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Limitation of switching distance
The higher the sound frequency, the lower the switching distance.
Switching distance vs Frequency
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
11000
0 100 200 300 400 500 600 700
sound frequency in kHz
swit
chin
g d
ista
nce
in
mm
1. Sound Frequency
2. Air Temperature
3. Air Humidity
4. Air pressure
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Limitation of switching distance
The higher the air temperature and humidity, the lower is the switching
distance.
This relation is simplified!
If yo have an application with a change of air
temperature and air humidity you have to pay
attention. The Ultrasonic Sensor varies his
switching distance with the change of
environmental conditions. That could cause
wrong switching operations.
1. Sound Frequency
2. Air Temperature
3. Air Humidity
4. Air pressure
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Limitation of switching distance
At higher air pressure, the damping is less. Consequently the sensor has a
greater range!
Attention: The Ultrasonic Sensor but must be
designed for positive/negative pressure.1. Sound Frequency
2. Air Temperature
3. Air Humidity
4. Air pressure
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How fast is a Ultrasound wave?
The sound speed depends on the medium!
sound speed (longitudinal) for different mediums
342
500
1483
2250
3300
5180
5400
80
1740
2670
4700
0 1000 2000 3000 4000 5000 6000
PVC-P
Air (20°C)
Cork
Water (20°C)
Oil
PVC-U
acrylic glass
beech wood
oak wood
steel
quartz glass
sound speed in m/s
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How fast is a Ultrasound wave?
Since most Ultrasonic Sensors, as mentioned earlier, are used in air the consideration of other mediums is not necessary:
Sound speed in air
295
315
335
355
375
395
415
435
-55 -5 45 95 145 195
temperature in °C
sou
nd
sp
eed
in
m/s
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As can be seen from the formula, the temperature has a large influence on the
speed of sound! This can be compensated within the sensor with its electronic
circuit. Condition is, however, that the change of temperature takes place not to quickly.
sound speed in air
295
315
335
355
375
395
415
435
-55 -5 45 95 145 195
temperature in °C
soun
d sp
eed
in m
/s
How fast is a Ultrasound wave?
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Reflection and Absorbtion of an Ultrasound wave
Distinction of surfaces in „sound hard“ and „sound soft“
Ultrasound waves propagate in air with their specific speed. If these sound waves hit
a medium with a different sound speed (see slide with sound speeds) then there will
be a reflection of the sound.
„Sound hard“
The sound will be reflected if the sound speed in the new medium is higher than in the
previous one.
„Sound soft“
The sound will be absorbed if the sound speed in the new medium is less than in the
Previous one.
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Reflection and Absorbtion of an Ultrasound wave
Important!
• Soft and airy materials have a bad reflection• Soft, thin materials can be permeable for the Ultrasound.• On the contrary hard materials have a good reflection.
Good reflecting materials Poorly reflecting materials
Water, Color / varnish, concrete, Metal, wood, glass,hard foam, plastic
Soft carpets, cotton woolsoft clothsSoap water - beer foamsoft foam, felt
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Important
However, almost all objects can be detected, also those with a bad
reflectance. But on those objects you have to accept the reduction of the
switching distance.
The detection properties of an object are independent of color, gloss and
transperancy, but depend on the surface properties.
Reflection and Absorbtion of an Ultrasound wave
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Reflection and Absorbtion of an Ultrasound wave
1. Case – plane surface
2. Case – rough surface
Incident angle is equal to emergent angle!
The surface is considered as rough if the roughness is in the order of the wavelength λ.
Tends to be higher.
frequency λ (air)
80 kHz 4,3 mm
130 kHz 2,6 mm
200 kHz 1,7 mm
300 kHz 1,1 mm
400 kHz 0,8 mm
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3. Case – plane Surface, Tilted Sensor
Reflection and Absorbtion of an Ultrasound wave
4. Case – roug Surface, Tilted Sensor
On the plane surface the Ultrasound wave is reflected completly away. Tilting of max. 3° is allowed.
Rough surfaces are less sensitive to tilting. You can tilt the sensor significantly more than 3°.
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Reflection and Absorbtion of an Ultrasound wave
Examples for rough and plane surfaces
Plane surface Rough surface
Pane Sand
paper sugar
Wood plate gravel
Plastic foil Air bubble film
varnished surface stucco
tile rough sawn wood
Bulk good has usually a rough surface that‘s why it reflects always diffuse! Bulk materials are therefore clearly detectable.
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What to consider if using Ultrasonic Sensors in applications?
Ambiente temperature?
You can use a Ultrasonic Sensor in warm and cold ambiente temperature.
Temperature changes have to process slowly so the sensor can compensate it.
The switching distance changes if the ambiente temperature changes.
Hot Objects?
Detecting hot objects can be difficult. The air turbulence weaken the sound so that it
can hardly or not be received.
Air pressure Variations?
Ultrasonic Sensors can not be used in vacuum. With positive air pressure
the absorbtions gets less, with negative air pressure the absorbtions
increases dramatically. This changes the range of the sensor. In principle you
can use the sensor in positive and (minor) negative pressure however the sensor
must be designed for that case.
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What to consider if using Ultrasonic Sensors in applications?
Rain and humidity?
Ultrasonic Sensors can be partially used in rain. The transducer surface
should be kept dry. In humid areas the sound speed changes.
Convex surfaces?
The ultrasound gets reflected in all areas. The maximum distance range
continues to decrease with a smaller radius.
Liquid?
You can detect liquids with a Ultrasonic Sensor. The beam axis must not
deviate by more than 3° from vertical relative to the liquid surface.
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What to consider if using Ultrasonic Sensors in applications?
Strong air movements and turbulences?
This leads to instability in the measurement. Air velocities of few meter per
second are not critical. You have to try!
Redirecting of the sound?
Redirecting is possible with hard plane surfaces (like metal). With this
feature you can solve applications where the object can’t be reached
easily. But the maximum range decreases. The sound should not be
redirected more than 2 times.
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Sensors in Nature
Bats
Orientation with Ultrasound waves. The bat detects the time difference
between the arrival of the echo in the left and right ear. With that
information it can position the object around him.
Humans
We are capable to position things like the bat. But not as good as it.
Whales and dolphins
Locating fish under water.
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Industries for Ultrasonic Sensors
• Handling und Automation
• Special machinery
• Automotive Industry
• Filling and packaging
• pharmaceutical industry
• Plastic and rubber industry
• Wood and furniture industry
• Paper and Printing Industry
Adatlap M30
Adatlap M18
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Applications
Setting the foil hag!
z.B.:
• Paper and Printing Industry
• textile industry
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Applications
Monitoring of filling level!
z.B.:
• Filling and packaging
• Special machinery
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Applications
Measuring the roll diameter!
z.B.:
• Paper and Printing Industry
• Packaging
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Applications
Monitoring the distance!
z.B.:
• Automotive Industry
• metal processing
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Applications
Detect and Count!
z.B.:
• Packaging
• Wood and furniture industry
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Applications
Measure stack height!
z.B.:
• Packaging
• Wood and furniture industry
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Why Use Continuous Linear Positioning?
Constant growth in automation technology has produced several trends:
The need for non-contact wear-free sensors to ensure greater machine uptime A switch from simple binary/discrete switching to continuous measurement sensors Higher accuracy and production rates
These trends will continue to grow rapidly in the quest for faster and more efficient machines.
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Uses for Linear Position Feedback
Three Major Fields of Applications:
1. Control Linear Motion /Closed-Loop Servo Motion Control(i.e. applications requiring high moving dynamics, and high position repeat accuracy)
2. Monitor Linear Position(i.e. Applications requiringprecise positioning, and highposition repeat accuracy)
3. Make Measurements(i.e. Applications requiring preciselinearity for measurement ofgeometrical shapes)
Example:Move it fast, then slow down,
then move fast again
Example:Cut to defined Length
Example:Did it get there yet?
Is it all the way back?How far did it move?
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MICROPULSE Transducers - BTL… extremely rugged and reliable
Balluff MICROPULSE Transducers …
are position sensing devices designed to provide linear position feedback
operate 100% contactless and are therefore wear- and maintenance-free
are extremely rugged and reliable
Operating Principle = Magnetostriction
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What is Magnetostriction?
Mechanical wave
Electromagnetic field
Dampingelement
Position marker (magnet)
Mechanical wave
Signal converter (Balluff patented process)
ReceiverMagnetostriction
wire
Initialpulse
Waveguide
A magnetic field has the effect of locally deforming the wave guide.
This effect is called magnetostriction.
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How does Magnetostriction function?
1. The magnetic field of a permanent magnet has theeffect of locally deforming thewave guide.
2. The short current pulse throughthe copper conductor causes amagnetic field.
3. This magnetic field interfereswith the existing field of thepermanent magnet(position element).
4. In result, an ultrasonic waveis generated.
5. The sonic wave travels alongthe waveguide until it is detected by the pickup.
6. The time between the start of the pulse and receiving of the receiver impulse is measured. The elapsed time indicated by the timer then represents the distance between the position magnet and the pickup.
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Components of Magnetostrictive Technology
Power- +
Counter
Start
StopD/A
PowerReg
N
S
Wave GuidePick-up Coil
Damping element
Magnet
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Transducer Operation
Power- +
Counter
Start
StopD/A
PowerReg N
S
Taking a measurementAdatlap
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Available Interfaces
Voltage 0 to10 V
-10 to +10 V
Current 4 to 20 mA 0 to 20 mA
Pulse START/STOP
DPI / IP PWM
Synchronous Serial 16, 24 or 25 bit
Network OptionsAnalog Output
Digital Output
Digital I/O 4 programmable
switched outputs
Quadrature Interfaces directly to
standard encoders
BUS interface modules WAGO
Phoenix ContactMade in
DeviceNet
CANopen
PROFIBUS DP
VARANNEW!!
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Active Stroke
Analog Interface
Analog type BTL transducersare available in various output configurations:
0...10 V -5…+5V -10...10 V 4...20 mA, 0...20 mA
Analog outputs
Made in
transducers with :• Voltage output have 2 outputs, one rising and one falling.
• Current output are available with 1 rising or falling output signal.
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Analog Interface … the Characteristics
Characteristics: Popular wide spread standard signal Can be processed by every PLC or other control system A standard feedback signal used in control engineering Cable break monitoring possible via 4-20 mA-signal Resolution 0,1 mV / 1,6 µA (typical values depending on BTL style) Operation using rising or falling signal output mode
Restrictions regarding cable length must be observed Observe installation guidelines to avoid problems concerning
Electromagnetic compatibility (EMC)
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Analog Interface:Basic operation “Rising” Output
0V 10V5V
“Rising” Output
0V 10V5V
Mag
net
Magnet is attached to:
Moving Machine Part (e.g. piston of hydraulic or pneumatic Cylinder)
Float (Liquid Level)
Output signal goes to: PLC Analog Input Card
Motion Controller Digital Display, …etc.
UA (Pin 5)
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Analog Interface:Basic operation “Falling” Output
Mag
net
10V 0V
“Falling” Output
5V
Magnet is attached to:
Moving Machine Part (e.g. piston of hydraulic or pneumatic Cylinder)
Float (Liquid Level)
Output signal goes to: PLC Analog Input Card
Motion Controller Digital Display, …etc.
UA (Pin 3)
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1 to 3 µsecInterrogation pulse
START / STOP Operation
Digital P(ulse) Interface:Basic Operation (Start / Stop and Gate)
5V
0V
0V
5V
PLC, Motion Controller
or Interface Module
Pulse-Width-Modulated (PWM) “Gate”- Operation
Benefits:
• High Noise Immunity
• Native Signal• Lower Cost
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Digital P(ulse) Interface … the Characteristics
Characteristics: Cost-effective Trouble-free RS-485 differential
output signal transmission Position resolution 1µm Noise-immune up to 500m Absolute distance measurement value
Block diagram of Digital Pulse-Interface
Digital output versions available:
Do not use fornew applications.
I, K, and L types will be phased
out shortly.
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High-accuracy digitizing chip for pulse interface
High-accuracy digitizing chip for pulse interface Balluff digitizing chip available for companies developing
their own control and processing electronics interface. Position data from 4 magnets can be processed simultaneously High-resolution 1µm
BalluffDigitizing
Chip 44QFP
P-pulsesignal
MICROPULSE transducer with 1 to 4 Magnets
Controller or Processing electronics
4 / 8bit bus
1 2 43
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P111 Interface with DPI / IP Protocol
• DPI / IP (Digital Pulse Interface / Integrated Protocol) for direct data interchange between controller and transducer.
• Signal lines are used to send additional information (i.e. manufacturer, serial number, stroke length, gradient).
Features include: Bi-directional communication Transducer controlled using Init
and Start/Stop signals Integrated diagnostic functions Plug and Play Automatic parameterization reduces downtimes Sending of sensor model, stroke length,
specific parameters
Cost savings using DPI / IP for start-up and installation
AT -Series
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SSI Interface … the Characteristics
Characteristics Standard SSI (Synchronous Serial Interface): Synchronous serial data transmission for variety of controls. Noise immune RS-485/ 422 differential line drivers and receivers. Reliable signal transmission over cable lengths of up to 400 meters
between control and BTL transducer.
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Digital I/O Interface … the Characteristics
Characteristics: 4 switched digital outputs (PNP / NPN) 100mA load current / Output 4 switchpoints / cams freely programmable
via removable calibration device or via 2 programming inputs.
High resolution and repeatability. Value update: 1 KHz : stroke ≤ 1300 mm 500 Hz : stroke > 1300 mm Noise immune IP 67 per IEC 60529 Eliminate multiple external proximity sensors, Auto-Tuning™ circuitry allows use of Balluff or
competitors’ magnets Connection to controller max. cable length 500 m
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Characteristics: Evaluation of up to 4 Magnets simultaneously Intelligent transducer recognizes itself the
number of magnets currently active Data transmitted includes: 4 x current magnet position 4 x current magnet velocity Status of 4 freely programmable cams. High data security Resolution 5µm (Standard), BUS configurable Device address can be set by DIP switch. Less and simple wiring Signal transmission over distances of up to
2500 m (1200m PROFIBUS)
Network Interface:CANopen, DeviceNet, PROFIBUS
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Power
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10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 61
The New PROFIBUS BTL Bus Coupler:BNI PBS-551… / BNI PBS-552…
Two new BNI PBS decentral input modulesfor connecting to Profibus-DP Network
BNI PBS-551… connects: up to 4 MICROPULSE transducers with M1 or P111 interface and up to 8 Standard digital sensors
BNI PBS-552… connects: up to 4 MICROPULSE transducers with M1 or P111 interface and up to 4 Standard analog voltage and / or current type sensors
INDUSTRIAL NETWORKING
Economically connect BTL transducers to Profibus!!
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Automatikai építőelemek
10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 62
How the BNI PBS-551… / BNI PBS-552…Interfaces to the PROFIBUS
Power
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Balluff BTL_-P-111/ M1 Transducers
Balluff BTL5- T…. Profibus Transducers
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Automatikai építőelemek
10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 63
Potentiometer
Stroke 1
NewConducting Layer
Stroke n
Unchanging Performance !BTL
IP67
Benefits of MICROPULSE Technology
100% contact-less and wear-free
Effectscaused by
wear, scratches
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Automatikai építőelemek
10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 64
Kialakítások
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Automatikai építőelemek
10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 65
Alkalmazások
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Automatikai építőelemek
10.08.2014 Balluff Kft, CIM Veszprém, Z. Pólik 66
Alkalmazások