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Solutions for Hydraulic Systems

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Page 1:Solutions for Hydraulic SystemsPosition measurement systems and sensors for a wide range of applications

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Page 3:3As a leading sensor specialist and system provider with a compa-ny tradition of over 90 years, Balluff GmbH has been a recognizedpartner of factory automation and industrial hydraulics for decades.The global player has a strong presence with 56 sales branches andrepresentative offices as well as nine production sites on all conti-nents. The corporate headquarters in Neuhausen a.d.F. is locatednear Stuttgart.Balluff masters the entire technological variety with various operatingprinciples, including high-quality sensors and systems for positionmeasurement and identification, as well as sensors for detectingobjects and measuring fluids. The full-range assortment includesoptimal network and connection technology and a comprehensiveline of accessory products.We offer innovative, first-class products tested in our own accreditedlaboratory and maintain certified quality management in accordancewith DIN EN 9001:2008. Our technology speaks for itself in inter-national applications. since it also meets regional standards.Balluff is synonymous with application-specific customer solutions,comprehensive services, individual consultation and prompt service.Our staff of more than 2,600 employees is committed to providingoutstanding service worldwide.www.balluff.comSolutions for Hydraulic Systems 1Inhalt3Balluff Sensors Support High Power Density 4Civil Engineering – Everything Under Control 6Mining and Open-pit Mining/Raw Material Extraction 8Steel and Metallurgical Industry –Continuous Processes Around the Clock 10Pressing – Always in High Quality 12Sensors for All Areas of Power Generation 14Wood and Pulp Industry – with Large Bandwidth 16Oil and Gas Extraction – Under High Pressure 18Offshore and Ship Technology –Failsafe with Winds and Waves 20Purposeful Movement on all Levels –Dynamically Controlled 22Capacitive Sensors for Level Detection 24High-pressure Rated Inductive Sensors 26High-pressure Rated and Explosion ProtectedInductive Sensors 28Fieldbus Modules P111 30Filling Level Sensor in Zone 0/1 31Inclination Sensors 32Micropulse Transducers 34Pressure Sensors 36Inhalt

Page 4:4Sensor signalsHydraulics circuitWhen great forces and torque are to be generated, hydraulicsystems are used. They enable compact design and, therefore,high power density. They are self-lubricating, robust and providelong-term stability.With the suitable sensors, the hydraulic systems provide solutionsfor almost every application. From the super-fast control in flightsimulators to the most heavy-duty applications underground or intunnel construction.Balluff sensors and position measurement systems are designedfor this wide range of applications.Whether individual applications or large-scale projects, durableand robust Balluff technology supports the maximum availabilityof systems and supports their long service life. Balluff sensorsare optimized in our accredited in-house laboratory throughHighly Accelerated Life Tests (HALT). While doing so, theproducts are already subject to extreme loads duringdevelopment, possible weak points are removed and a robustproduct design is ensured. Through extremely durableproducts, Balluff offers first class quality for all areas ofhydraulics:■■ Products for position sensing and endposition detection in hydraulic cylindersand valves■■ Capacitive sensors for monitoring liquids■■ Pressure sensors for monitoring the hydrauliccircuit■■ Network and connection technology forindustrial communication■■ Worldwide locations with technical consulting,sales, after-sales service and spare parts supplyBalluff works closely with suppliers of subsystems,plant engineers and research institutes to achieve this.Balluff Sensors SupportHigh Power DensityFirst-class quality is durable,robust and has a wide variety of uses.

Page 5:5www.balluff.comwww.balluff.com

Page 6:6When building bridges, special heavy-dutycylinders carry out horizontal feed andvertical lifting motions to move the bridgeelements, which weigh multiple tons. TheMicropulse transducer rod CD is installed inthe pressure area of heavy-duty cylindersand high pressure cylinders to positionthese extreme loads synchronously andwith millimeter precision.■■ For pressures up to 1000 bar■■ Resolution down to 1µm for synchronouspositioning with millimeter precision■■ Ex area zone 2; non-incendive "nA"Positioning heavy bridgesEvery second counts when raising andlowering movable bridges, as impact ontraffic must be kept to a minimum. High-precision position measurement systemsintegrated into the hydraulic cylinders ensurethat the bridge raises and lowers quickly andefficiently. High-pressure resistant inductivesensors reliably identify the end position ofthe cylinder.■■ Position andspeed detection■■ High-pressure resistant rated to 500 bar■■ Cost-effective solution formonitoring end positionsLifting and lowering bridgesConstantly expanding our infrastructure is nearly unthinkable withouthydraulics. With hydraulics, new waterways are accessible.Tides and level differences are controlled by locks and road networksare expanded. New tunnels and bridges are developed. Hydraulicsystems are used all over the world for controlling machines andplants. Even under the most extreme conditions. Balluff positionmeasurement systems and sensors offer perfection because theyare highly precise and exceptionally durable.Civil Engineering –Everything Under ControlWhen every second counts or when heavy loads need to beprecisely positioned, high-quality technology offers long-termstability.

Page 7:7Hydraulic cylinders move the powerfulgates of the large locks, which can take onenormous dimensions in seaports. BTLProCompact HB transducers are used inhydraulic cylinders to exchange the waterefficiently and monitor the position of thegates.■■ Stainless steel for use in coastal areas■■ with a cable guard system, canalso be temporarily used under water■■ nearly limitless service lifethrough an effective contact-free principleThe requirements for a weir go much furtherthan just opening and closing the gate. Fishladders must be taken into account andthe fully automatic control of the water levelmust be ensured. BSI inclination sensorsreliably and precisely measure the interme-diate position of the gate.■■ Absolute angle tracing for exactpositioning■■ Wide temperature range for outdoor use■■ Metal housing and high degree ofprotection – ideal for harsh environmentsControlling the gatesFloating debris at the infeed end of hydro-electric power plants causes efficiency lossand thus diminishes cost-effectiveness. Theworst-case scenario could result in plantdowntimes with high costs. With the high-pressure resistant inductive sensors BHS,the end positions on the rake cleaner canbe easily and reliably detected.■■ High pressure rating■■ Easy to install■■ From M5 to M18 – for all cylinder typesDetecting rake cleaner end positionswww.balluff.comOpening and closing locks©RWS

Page 8:8Tunnel construction – Controllingpushing cylindersWhether under or above ground, sensor requirements are extensive.Temperatures are high deep underground. There are also extremevibrations and shock loads. Under these conditions, durable andresistant technology is a must.Balluff offers the best security for position measurement in mining;.through robust, wear-free and high-precision position measurementsystems and over 25 years of experience in this field.Tunnel boring machines remove rockcentimeter by centimeter. Pushing cylinders,which continuously force the drill head intothe rock, provide the strength needed forthis. Micropulse transducers BTL correctlyreport the piston position and allow for asmooth drilling process.■■ Reliable■■ Wear-free: long life for the highestsystem availability■■ Vibration-resistant: for use underextreme conditionsMining and Open-pit Mining/Raw Material ExtractionDurability is a must.

Page 9:9www.balluff.com©HerrenknechtAlways know where the driller is:When searching for new raw material sup-plies, soil samples are taken with mobiledrillers to confirm potential deposits. Micro-pulse transducers BTL PF ensure reliabilityfor the correct drilling depth.■■ Flat design, space-saving for mobilemachines■■ Robust profile housing■■ Wear-free, since it is contact-free withup to 15 mm distance from the positionencoder to the transducerPositioning drillsIn raw material extraction, Micropulse BTLprofile position measurement systemsinstalled outside the cylinders monitor thedrilling of the blast holes below ground.This is the only way that safe and reliabletunnel mining and efficient raw materialexcavation can be ensured.■■ Easy installation and fast exchange,since they are externally attached■■ Extremely robust against shock andvibration■■ Reliable, even at high ambienttemperaturesMonitoring drill depthIn mining, shields prevent rocks from fallingin the working area and injuring miners.To support longwall mining, hydrauliccylinders are used. Micropulse BTL posi-tion measurement systems of the K seriesintegrated in the hydraulic cylinders provideexact positioning and secure monitoring ofthe shields.■■ Compact design■■ Explosion-protected versions■■ made from stainless steelSupporting longwall mining

Page 10:10Steel and Metallurgical Industry –Continuous Processes Aroundthe ClockMonitoring ladle movementsCoke oven – Controlling movementsThe production of steel is highly complex and is carried out usinghigh temperatures, shock and vibration under the most difficultconditions. This places high demands on producers and mechani-cal engineers. Ensuring a safe and reliable process with optimalquality management is critical. A fundamental prerequisite for this isthe highest quality of systems and machines. Balluff offers optimal,internationally approved sensors, as well as corresponding networkand connection technology.Ladles ensure replenishment of steelin production. Optimal control over theprocess and ensuring the addition of thecorrect quantity of steel in the continuouscasting line is only possible through preciseladle movements. Micropulse transducersBTL7 (double and triple-redundant) provideabsolute security and the best reliability forthe continuous casting process.■■ Redundancy for absolute security■■ The highest availability through completelyindependent systems in one head■■ Easy to retrofit, since it is compatiblewith the standard BTLMicropulse transducers BTL are used forcontrolling flaps and valves on the blastfurnace in order to regulate the supply andexhaust air during production of pig iron. Al-ternatively, standard inductive sensors BESdeliver convincing performance. Additionalsecurity: A temperature sensor is integratedin the electronics head for all micropulsetransducers BTL with a bus interface. Thisguarantees the correct temperature mea-surement.■■ Temperature measurement integratedin the transducer■■ Explosion protection versions■■ Non-contact operating principleThe Micropulse transducer BTL in thehydraulic cylinder controls all movementsat the coke oven battery up to 100°C. Itsrobust metal housing with IP 67 and PTFEcable for up to 200°C makes it ideal forparticularly hot environments.■■ High-temperature resistant for use on thecoke oven battery■■ Metal housing in IP 67■■ Different interfacesBlast furnace – Controlling air and gassupplyReliably manage high temperatures, shocks and vibrations.

Page 11:11www.balluff.com©ThyssenKruppAGSetting the roll gapControlling the slab guidanceThe roll gap can be set with high accuracyusing the Micropulse transducer BTL in IP69K during hot or cold rolling. The vacuum-sealed BTL does not require any additionalprotection for continuous water cooling ofthe rolling stand.■■ Outstanding accuracy for precise work■■ Stainless steel housing for tough applica-tions■■ Vacuum sealed, even during constantwater coolingMicropulse transducers BTL in the hydrauliccylinder are ideal for positioning and guidingthe slabs. They check for the correct config-uration of the lateral guides and accompanythe slabs on their path through the rollingstand. The large forces in the reshaping arereliably compensated for in this process.■■ Rapid Replacement Module (RRM) for fastchanges without interrupting the hydrauliccircuit■■ Vibration and shock resistantPositioning the rollersMicropulse transducers BTL guarantee highaccuracy when winding the coils. The pres-sure roller is guided, for example, depend-ing on the roll diameter.■■ Absolute output signal■■ Extremely exact for precisely guidingpressure rollers■■ Also with IO-Link for easy wiring

Page 12:12Whether in the automotive industry, the rubber industry or whenprocessing wood and composite materials, such as carbon fibers:presses are indispensable in today's industry. They are used tomanufacture metal parts of all kinds. Particle boards for houseconstruction and carbon fiber body parts for the cars of tomorrow.In individual parts production or on long press lines that ideallywork continuously 365 days a year. While doing so, great repeataccuracy and continuously high precision is required. The extensiveBalluff portfolio fulfills all requirements.Pressing –Always in High QualityEnsuring consistent product qualitymeans constantly monitoring every movement.Balluff stands for both.Productivity and flexibility are importantgoals of the automotive supply industry.Micropulse transducers measure the move-ments of the press with absolute precision.For a wide variety of moldings. For everypart produced. This supports the produc-tion of a wide variety of lot sizes and optimalprocesses.■■ Different designs for external or internalinstallation■■ Multifaceted mechanical accessories■■ Various interfaces for easy connection tothe controllerPressing metals

Page 13:13www.balluff.com©SchulerAGWhen producing components from carbon-fiber-reinforced plastic (CFRP), the carbonfibers that are woven to mats are pressedinto shape under heat and pressure. Inthis process, they must be monitored andharden uniformly. Micropulse transducersensure uniform pressure with every press-fitting process without being impeded byheat.■■ High temperature range■■ High repeat accuracy■■ Also has multiple position encoders tomonitor both sides of the pressForming composite materialsIn hydraulic heat presses, green tiresreceive their correct shape. It is importantto achieve consistent quality. Micropulsetransducers BTL ensure high repeat ac-curacy and the exactly identical result at alltimes. They satisfy the highest requirementsof the manufacturing process.■■ Contact-free measuring principle formaximum service life, even with shortcycle times■■ Extremely precise for consistent quality■■ Profile housing for easy installationVulcanizing tiresUp to 60 cylinders ensure an optimalresult in fiberboard systems. The Micropulsetransducers integrated in the hydraulic cyl-inders monitor closing height and parallel-ism of the press with outstanding reliability.Therefore, the dimensions of the particleboards can be successfully maintained. Thehigh ambient temperature does not affectthe transducers.■■ Explosion protected■■ Extended temperature range■■ Can be installed in the cylindersMonitoring parallelism of the presses

Page 14:14Climate change, demographic trends and the limited availabilityof fossil fuels have led to new solutions in the energy industry: tooffshore wind farms or solar power plants in the desert. The dis-tribution of power generation leads to a large number of individualsystems and the immediate influence of extreme environmentalfactors place stringent requirements on the quality of the compo-nents used.Whether renewable energy or the conventional power generation,Balluff products are used in all areas. Balluff sensors and systemsfeature excellent quality. Their security, durability and reliability aretrue hallmarks.Tracking the sun with parabolic troughsAdapting pitch to the wind speedWith the parabolic trough power plant,collectors concentrate solar energy ontoa receiver tube positioned in the focal lineand heat up the oil flowing in it. For high ef-ficiency, all troughs have to be continuouslyadjusted to follow the sun's path and befocused exactly on the receiver tubes. Thisis achieved by magnetically coded positionand angle measurement systems BML thatare positioned directly on the rotating shaft.■■ Direct measurement■■ Precise position detection■■ Determining reference pointsThe guide and rotor blades on Kaplan tur-bines can be adjusted with help from BTLmicropulse transducers. For example, aBTL profile controls the position of the guidevanes as needed. Another BTL integrated inthe shaft ensures optimal adaptation of theimpeller to the water volume.■■ No reference run required after voltageinterruption■■ Rugged, non-contacting■■ High protection class■■ Pressure-rated for installation insidehydraulic cylindersBalluff position measuring systems BTLwere developed specifically for use in thehydraulic cylinders of wind power plants.Using the systems' pitch adjustment, therotor blade angles can be adapted accu-rately to the wind speed to maximize powergeneration and ensure plant reliability.■■ Contactless = low-maintenance■■ Pressure rated to 600 bar■■ Vibration and shock-resistant for stableuse in adverse conditionsAdjusting guide and rotor bladesSensors for All Areas ofPower GenerationThe extensive performance spectrum appeals with advantagesfor renewable energy and conventional solutions.

Page 15:©Sener/TorresolEnergy15www.balluff.comControlling flapsMonitoring valvesFlaps are used in all areas of power plantsto control gases and fumes. Robust hy-draulic cylinders with the position measure-ment system BTL reliably open and closethe flaps and support safe operation of thepower plant.■■ Additional temperature range for outdooruse■■ Can be installed in the cylinders■■ ReliableThe highest safety requirements foremergency shutoff control valves requireredundant systems. In compact redundantMicropulse transducer BTL 7, up to threeindependent measurement sections andthree independent electronics systems areintegrated in a rod. The robust, absoluteposition measurement system is freelyconfigurable and easy to operate.■■ 2 or 3 completely separate systems in onehousing for maximum safety■■ Compact and space-saving■■ Non-contact and wear-free■■ Monitoring of all channels via LEDsControlling diverter positionsDiverters guide gas turbine fumes. Either tothe bypass chimney or to the steam genera-tor. With help from hydraulics and micro-pulse displacement sensors integrated inthem, the diverter can be opened or closedin increments.■■ Ex-variants for use in the potentiallyexplosive area■■ Compact design■■ suitable for dynamic applications

Page 16:16Wood is a multi-use material. Processing ranges from raw boardsto fine paper. The wood and paper industry has a wide array ofrequirements for this reason. In forestry and in the sawmill industry,sensors are subjected to the harshest ambient conditions andmust work with the highest reliability. Precise, smart sensors andposition measurement systems are used in wood processing andpaper machines for an efficient machining process.Balluff fulfills the entire range of requirements of the wood and pulpindustry. Innovative sensor technology is robust, precise, reliableand enables fast, automated processes.Sensors for debarkers are exposed tostrong vibrations. Transducers in hydrauliccylinders monitor the piston position of theinfeed unit. This enables logs of differentthicknesses to be optimally fed.■■ Reliable, with high protection class■■ Rugged housing■■ Direct signal evaluation or in conjunctionwith processor units for all control andclosed-loop systemsVertical band saws adjust to maintain thedesired board thickness after each cut. Mi-cropulse transducers are excellently suitedto configuring these settings quickly andwith great versatility.■■ Pressure-resistant for integration inhydraulic cylinders■■ High repeat accuracy■■ Electronic head can be replaced in theevent of serviceSaw units with single-blade adjustmentmake it possible to change the cross-section extremely fast. Hydraulic cylinderscontrol the saw blades and Micropulsetransducers reliably and accurately returnthe position. As a result, using them sup-ports optimum exploitation of the wood.■■ Multiple position encoders are possible■■ Vibration-resistantMonitoring hydraulic cylinders Positioning logs Adjusting the saw bladeWood and Pulp Industry –with Large BandwidthRaw boards to fine paper: innovative sensor technologymasters different requirements.

Page 17:17©DeutscheSäge-undHolzindustrieIn veneer production, logs are peeled layerby layer. For an optimal result, contactpressure and the position of the peelingknife must be precisely controlled. This canonly be successful through smart cylinderswith a built-in position measurement systemBTL.■■ Rule-compatible■■ Tolerant of shocks■■ IP 67 metal housing – protection againstswarf, sawdustFor paper production, hydraulic compo-nents must often work reliably under ag-gressive ambient conditions. For example,the headbox evenly applies the stocksuspension on the wire mesh and thusinfluences the paper quality. Deckle platesand headbox bottom lip are hydraulicallycontrolled. Precise position measurementsystems in hydraulic cylinders ensure anoptimal result.■■ For use in aggressive environments: sen-sor head made from stainless steel■■ Tolerant of vibration■■ IP 69KProduced paper is wound up around largerolls. At high production speeds, theserolls grow very fast and become extremelyheavy. The most up-to-date hydraulic andposition measurement technology ensuresthe best possible winding process. Micro-pulse transducers BTL that are securelypacked in the hydraulic cylinder report theposition.■■ Different interfaces■■ High sampling rates are possibleTracking the peeling knife Hydraulically controlling the head box Controlling the winding process

Page 18:18Oil and Gas Extraction –Under High PressureSafety is not disputable.Oil and gas still make a critical contribution to generation of energy.But the growing scarcity of resources demands even greatereffort for extracting fossil fuels and the use of new, more efficientmethods. Raw ambient conditions and hard mechanical strains area tough endurance test for people and material. This requires safe,durable technology. Robust, precise and low-maintenance Balluffsensors support efficient oil and gas extraction. These offer explo-sion protection and are internationally approved.After tapping an oil field, crude oil pumpsdo their work entirely autonomously for themost part. Pump parameters are continu-ously monitored via sensors and, usually,via automated remote systems. BalluffMicropulse transducer profiles prove them-selves in the difficult application directly onthe pump and guarantee reliable monitoringof position and path.■■ Robust design■■ Exact measurement of path and position■■ Up to 7.6 m in lengthMonitoring artificial liftsTo minimize load and wear, crude oil pumpshave to be aligned exactly over the drill hole.Balluff inclination sensors BSI are ideal foruse in harsh outdoor environments. Thanksto their analog angle values, the pumps canbe positioned with extreme precision.■■ High protection class IP 67 – suitable foruse under rough conditions■■ Precise, absolute angle measurement■■ Compact housingPositioning artificial liftsControl and shutoff valves are used in manyareas of oil and gas extraction, in refineries,as well as in petrochemical plants. Theymust reliably work in very harsh environ-ments. In corresponding vulnerable environ-ments, explosion protection is a top priority.The certified Micropulse position measure-ment systems BTL ensure reliable andsecure use.■■ High reliability■■ with ATEX, IECex and many additionalinternational approvalsControlling valves

Page 19:19©Statoilwww.balluff.comPipehandlers take drill pipes out of themagazine and position them directly overthe borehole. Quick and efficient drilling isthus ensured. Powerful hydraulics movethe heavy rods with ease and bring themdirectly into place and position. Balluff posi-tion measurement systems are critical forprompt, correct positioning.■■ High temperature range■■ Long-lasting■■ RobustCompensation cylinders must maintaina specified tension of the marine riserand balance all fluctuations. To do so, thehydraulic cylinders are attached betweentensioner ring and rig and equippedwith position measurement. These smarthydraulics level the sea movement andensure continuous tension of the productionriser, independent from the upward anddownward heave of the floating drilling rig.■■ Length of up to 7.6 m■■ Explosion protected in the stainless steelhousingPositioning drill pipes Drilling riser – Monitoring tensionWire-lines connect floating drilling rigs tothe seabed. These are held under tensionat all times to prevent damage. Duringswelling, tension is hydraulically adjusted tothe clamping device. When this occurs, thepiston position of the cylinder must be reli-ably reported back. Micropulse transducersBTL execute this perfectly.■■ Many interfaces■■ Space-saving with installation in thecylinder■■ Non-contact and wear-freeHolding wire-line tension

Page 20:20Offshore and Ship Technology–Failsafe with Winds and WavesHigh swelling, strong breezes and aggressive salt waterare always factors to control.When building a ship, heavy-duty is the order of the day. To easilymove the enormous loads, hydraulics are superior to other solu-tions. Hydraulic systems are also required to make ships jut out intothe sea and stay on target. Balluff offers suitable sensors for therough sea climate. With maximum reliability and durability. Frompropeller adjustment via stabilizers to various superstructures.Security on the sea: Even with swelling,people from the supply vessel can safelyreach the platform or the offshore windpower plant.Smart hydraulics with a triple-redundantposition measurement system compensatefor all boat movements and allow for safeaccess.■■ Redundant for maximum security■■ Rule-compatible – perfectly suitable forcomplex controlCompensating motionCranes are used not only in the harbor,but also on the sea. So that safe work ispossible, hydraulics and sensors attuned tothe harsh sea are needed. Thus, explosion-protected high-pressure resistant inductivesensors reliably measure the end position ofthe offshore crane, even with high swelling.■■ Flameproof up to 500 bar■■ Wide portfolio for installation inevery cylinder type■■ High-temperature versionsVariable pitch propellers bring criticaladvantages to the ship propulsion system.This is particularly worthwhile when thereare frequently changing speeds, such as onferries or cruise ships. Angle adjustment ishydraulic and is controlled by triple-redun-dant Balluff position measurement systems.■■ Compatible with retrofit of safety■■ status LED, 3x■■ GL approval (Germanischer Lloyd)Controlling variable pitch propellersLifting loads