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of the sensors full 1 kHz measuring
frequency along with the additional
buffer for frequency analysis. Also, the
actual measured values combined with
the drive-controlled target values can
be superimposed and synchronised in
real time to provide valuable additional
insights into the complex interaction of
the drives and mechanics.

Furthermore, as the initial robot
development was based on the near
series of the machine design, the
sensors can be used in the development
stage and the ongoing design of the
system without the need for further
modification – saving valuable
development time. This also eliminates
the need for an elaborated prototype
which may need to be further modified
to fit the final machine design.

Press Fitting: Intelligent Monitoring
in Series Production
Optimum Speed and Precision
It would be fair to say that present day IO-Link sensors achieve speeds which are,
at the very least, on par with conventional signals. However, the latest IO-Link
technology offers decisive advantages in process automation systems, although
the potential of the digital interface is far from being fully exploited. Only the
intelligent interaction of sensors combined with powerful masters and independent
configuration tools can take machine performance to the next levels of higher
speed and precision. For example, in terms of precision during positioning improves
due to faster communication between position sensors and the control system.

Furthermore, with digital IO-Link there is no general signal loss in comparison to
analog signals, such as 4…20mA.

Let’s take a look at two specific scenarios…
Robotics: High precision monitoring of position and oscillation
You are a company pursuing the idea of
designing your own handling systems
and robots utilising the latest drives
for control straight from a machine
control system. To achieve this, design
engineers need to get a handle on
positioning precision and oscillation.

Ideally this would be the development
of an easy-to-use system that would
monitor the robot optically in various
12 positions and also at high positions
(while in parallel) whilst also reliably
detecting oscillation up to 40 Hz.

Sensor specialists BAUMER offers
the ideal solution by combining two
of their OM30 laser distance sensors
integrated into an EtherCAT controller
via their new CM501 IO-Link Master.

The key benefits of this combination
are that it enables the exploitation
Where processing applications demand
high throughput it’s important to
determine the maximum production
speed and at which the required
quality is guaranteed. This is the
point where the fast data exchange
provided by the all-inclusive Baumer
IO-Link package of smart sensors,
master and cabling results in added
benefits. The force sensors measure
the press-fit pressure, while the high-
precision distance sensors monitor
the position of the part to be pressed
in. The combination of both provides
a force development diagram with
prominent force points during the
press fit process which clearly provides
information confirming whether the
generated force is within the required
tolerance, or is too strong. Additionally,
it will indicate whether a component
has been tilted during the process,
especially at positions where minimal
force is an important requirement.

Data Transmission- in Real-Time
The ability to allow engineers to easily
identify optimum machine configuration
INTERNATIONAL BOTTLER & PACKER | JUNE 2025