Compact and high-precision edge sensors set new standards

BAUMER has expanded its extensive ‘Toolbox’ range of high-performing sensors following the introduction of new edge sensors, the OE60 and OE40.

The combination of these new sensors with the established smart 2D OX series of profile sensors supplies users with ultra-reliable and flexible edge measurement options to suit different precision levels and available space conditions over a broad range of applications.

Key features and benefits include edge detection with up to 1µm precision with repeat accuracy at a distance of up to 100mm, flexible design to serve different functional principles, compact and easy to integrate along with connectivity options including IO-Link, EtherCAT and Modbus RTU.

The portfolio incorporates the high-performance OE60 and OE60C, delivering best-in-class precision of up to 1µm across a measuring range of up to 10mm; the sensors, which provide measuring precision of up to 24mm, detection of transparent edges along with plug-and-play ability thanks to a reflection bracket. Completing the edge sensing ‘portfolio’ are the OXS smart profile sensors for measurement of multiple edges and step heights, providing resolution of up to 30µm in the X-direction and up to 5µm in the Z-direction.

The high-precision sensors are claimed to be the only ones in their class that can be deployed as stand-alone devices without needing a controller unit because the sensor heads are created to directly integrate into the control via the standardised Modbus RTU protocol. This eradicates the necessity for an extra device and reduces overall costs.

Examples of applications where these sensors will be particularly beneficial include battery cell production, where edge measurements must be extremely precise as the individual layer positioning (anode, cathode and separator foil) in the winding process defines service life, capacity and even battery safety.

Reliable detection of the individual tracks, even at high speeds, is crucial in battery production, and the OE60 succeeds due to the very short response time combined with excellent precision of 1µm, which is accomplished without the necessity for any filtering. Another potential application is web edge control in the packaging industry, where edge detection of transparent films with optical sensors is a major challenge. The sensors play to their strengths with their reflector bracket reliably and precisely measuring edge positions on thin transparent films where optical sensors would reach their limits.

Finally, in the wood processing industry the smart 2D profile sensor can check floor planks to identify any non-compliance of tongue and groove. By measuring the edge position the sensor identifies depth or width of tongue and groove with the measured results delivered straight to the system so that issues such as tool wear can be detected early by any change in the height profile.