Systems and Solutions Ideal for the application. Customized. More than just components

Systems and Solutions

Ideal for the application. Customized. More than just components

3 www.balluff.com

As the leading sensor specialist and system provider with more than 90 years of company tradition, Balluff GmbH has been a recognized partner in factory automation for decades. With 56 locations, Balluff has a strong presence on every continent.

The corporate headquarters in Neuhausen a.d.F. is located right by Stuttgart.

Balluff offers a wide array of products with varied operating principles taking advantage of the broad spectrum of technology available, including high-quality sensors and systems for position measure-ment and identification, as well as sensors for detecting objects and measuring fluids. The full-range assortment includes optimal network and connection technology and a comprehensive line of accessory products.

Technological Variety,

Individual Service

Comprehensive sensor and networking expertise

We offer innovative, first-class products tested in our own accredited laboratory and maintain certified quality management in accordance with DIN EN 9001:2008. Our technology speaks for itself in internati-onal applications since it also meets regiinternati-onal standards.

Balluff is synonymous with application-specific customer solutions, comprehensive services, individual consultation and prompt service. Our staff of more than 2600 employees is committed to providing outstanding service worldwide.

Systems and Solutions 1

Technological Variety, Individual Service 3 Systems and Customized Solutions 4 Balluff RFID Software 5 Customizable Software for Industrial RFID 6 Customized Software for Industrial RFID 10 Tool ID Upgrade – Upgrading from a Single Source 12 Mold ID – Transparency in Mold Handling 14 Driver License Manager 18

Pr

oducts

Professional project management at Balluff is available for imple-menting systems. As a result, we offer customized solutions that are tailored to meet your needs. This guarantees the most workable and efficient applications.

We assemble your solution specifically for your application with our systems. In addition, you will receive custom software for mobile and stationary communication. This is the way to employ well-founded manufacturer expertise.

Systems and

Customized Solutions

In-depth manufacturer expertise provides perfect systems.

Our project management guarantees customized solutions.

Targeted use of manufacturer

expertise

Example of a customized solution with Tool ID Products

RFID reader, antenna, data carrier and power supply

System ■

■Hardware – Base, control cabinet, panel PC and accessories

■

■Visualization – Preparing (software) read data and displaying it on the monitor

■

■Intelligence – Communicating with the machine control system, converting the RFID log into the machine language

We guarantee perfect integration to fit your needs, because we handle installation and startup as well as adjustments on site. This increases both productivity and efficiency.

Learn more about our customized solutions.

Solution ■

■Installation – Fastening the base to the ground or machine, securing the supply of electrical power (pulling cables, etc.)

■

■Startup and adjusting – Establishing communication with the machine, adjusting the interface to the customer's data mapping, adjusting the visualization to customer requests (configuration) and similar actions down to individualized training for the system used by the customer

■

■Coordination – Determining, ordering and coordinating third-party companies, e.g. installation companies or machine manufactur-ers, coordinating installation and startup after consulting with the customer, etc.

Installation

Startup and adjusting

Coordination

Solutions

Visualization

Hardware

Intelligence

5 www.balluff.com

Software

Mobile Applications

Stationary

_Applications

Template

Portal

Customizing

Visual

_Builder

Customizing

Balluff RFID software solutions include a wide performance spectrum for mobile communication with the RFID handheld and stationary data entry on the desktop. Configurable software and customized solutions are offered for both handhelds and desktops. This provides flexibility in applications and contributes to cost-effectiveness.

Balluff RFID Software

Individually configurable and customized solutions.

For mobile applications and stationary data exchange

About the process

After explaining the possibilities of RFID, the on-site conditions are determined (machines, tools, assembly situation, etc.) and a require-ments profile is drawn up according to your specifications. The cost framework is set and an optimal system configuration is suggested. We coordinate with you to select the appropriate hardware and determine the time frame for the startup.

During implementation, we tend to the hardware and software and make customized adjustments. Once all of the specifications are met, the functionality is ensured with testing. Each machine is accepted by both parties. Additional training can also be provided.

Template and portal software for RFID handhelds BIS and Visual Builder for the desktop enable mechanical engineers and system manufacturers to provide their customers with customized solutions. Each version includes a specific performance spectrum that you

Customizable Software

for Industrial RFID

Define the features specifically for your customers

and guarantee a customized range of applications.

For Mobile Applications

Template Software ■

■Protection from unauthorized access using password security

■

■A menu design adjusted to the processes enables intuitive operation

■

■Interpretation of data in plain text by displaying ASCII code

Ordering code: BAI0001 (BIS C) BAI0002 (BIS M)

can adjust to the needs of your customers with customized user interfaces and various features. This guarantees proximity to your customers. At the same time, the software can be reused.

Portal software

The portal software offers the same features as the template version plus additional advantages

■

■Overcome system discontinuities by reading barcodes and writing to RFID

■

■Compare data with the query function

■

■Everything in view: fast data search via the search function

■

■Special templates for each type of information

■

■Manual exchange with databases that also communicate in XML

■

■Save data as XML or CSV files for further applications

Ordering code: BAI0003 (BIS C) BAI0004 (BIS M)

Application examples Initializing pallets

This makes it possible to put workpiece carriers with pallets into a defined status without moving into the system. They are conve-niently initialized using the handheld and ready-made set-ups.

Tool ID

Simple and mobile reading out of tool data. This way you can directly view service life, last use, etc.

Portal

Expanded functionality and option of selecting multiple screens

Template

Simple screen with read and write button

Configuration on a computer

For the stationary workstation

Visual Builder software – configure your own RFID interfaces without any programming knowledge.

Are you working with a stationary computer? And would you like to view RFID data, display work progress or make status changes? Then you can match the user interface to your application using Visual Builder, the configuration tool for desktop computers. You can choose from three different versions of the software. All three have a dongle.

■

■Developer – for configuring a customized screen for your customers. With user dongle.

Do you, as a mechanical engineering company, plan to offer your customers individually configured software? If so, Developer is the right choice. If can be used to display the user's tool data, process data or status information. The dongle is needed to run the software.

■

■Admin – for configuring your own screens for different ap-plications. The user dongle can be freely selected.

Will you need to visualize the data of various applications in your system? You have this flexibility with the Admin version. It enables you to configure any number of applications and decide for each one whether it should be protected by a dongle.

■

■User – for using individually created screens. With user dongle.

Do you have a preference for individually created user interfaces? The User version is ideal if you only wish to have information displayed. This application also requires a dongle.

Ordering code: BAI0005 (Admin) BAI0006 (Developer) BAI0007 (User)

Application examples

Quality assurance at the end of the assembly line (end user)

Displaying all work steps and their results on an assembly line that uses RFID on the workpiece carrier to log production pro-gress.

Visualization of tool data (OEM)

The mechanical engineering company offers its customers the option of reading out tool data on the chip again and displaying it before the tool is laid into the machine (safety). The Devel-oper version lets the mechanical engineering company create a customer-specific screen (including content such as a customer logo and specific mapping) and offer it to the customer as added value. To run this application, the customer needs the User versi-on provided by the mechanical engineering company.

Design interface

for your project

Tools

for designing the interface

Properties

Customized software is needed if data communication with RFID is intended to be optimally matched to your requirements and proces-ses. Although standard software is certainly suitable for a wide range of applications, certain tasks require custom work.

Customized Software for

Industrial RFID

Have your software customized for you.

For increased flexibility and efficiency.

Mobile Applications Stationary Applications

Template Portal Customizing Visual Builder Customizing

Reading barcodes ■ ■

Comparing data ■ ■

Password function ■ ■ ■

Writing data to tags and reading from tags ■ ■ ■

Search function ■ ■

Saving and transferring data to a handheld ■ ■ ■

Saving and exporting data as XML or CSV files ■ ■

Template based on Windows™ interface (second software package on external PC) ■ ■ ■

Availability of various templates ■ ■ ■ ■

Displaying data in a customer-specific context ■ ■ ■ ■ ■

Acoustic signal when the process ends ■ ■ ■ ■ ■

Wi-Fi connection ■

Process status is indicated by a green, yellow and red light ■ ■ ■ ■

This is why we program software for mobile and stationary appli-cations according to your specifiappli-cations. Because with custom-fit software, data is processed at the speed and flexibility that is most efficient for you. The user interface also offers optimum feasibility. Opt for customized software—and more efficiency.

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Mobile Applications Stationary Applications

Template Portal Customizing Visual Builder Customizing

Reading barcodes ■ ■

Comparing data ■ ■

Password function ■ ■ ■

Writing data to tags and reading from tags ■ ■ ■

Search function ■ ■

Saving and transferring data to a handheld ■ ■ ■

Saving and exporting data as XML or CSV files ■ ■

Template based on Windows™ interface (second software package on external PC) ■ ■ ■

Availability of various templates ■ ■ ■ ■

Displaying data in a customer-specific context ■ ■ ■ ■ ■

Acoustic signal when the process ends ■ ■ ■ ■ ■

Wi-Fi connection ■

Tool ID Upgrade – Upgrading

from a Single Source

Upgrade your machine facilities. And transfer all

tool parameters.

Tool ID Upgrade is a complete solution for upgrading the tool ID on existing machines. This all-around package with an industrial RFID system provides the optimal interface between the setting device and the machine control system. It is ideal for all common technolo-gies.*

Each solution is tailored to your individual requirements.

* The system can be implemented in most controllers, such as those from Siemens, Heidenhain, Fanuc or Mazak. If you work with a diffe-rent manufacturer, please contact us.

Features for optimizing your processes ■

■Safe transmission of the tool parameters

■

■Correct machine assignments by scanning on the tool magazine

■

■Visual depiction of tool data on the monitor

■

■Faster set-up times through automation

■

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System description

Hardware – control unit ■

■ Panel PC with touch screen

■

■ RFID reader with BIS C series interface

■

■ 24 V power supply for reader and panel PC

■

■ Holder for the installation

Hardware – tool holder, e.g. for HSK, ISO ■

■Mechanical holder for the tools

■

■ Holder for the read/write head

■

■ BIS C series read/write head

■

■ Holder for the installation

■ ■ Cabling

Software ■

■Pre-installed with the option for the relevant controller

Startup ■

■ Installing tool holders and the control units on each machine

■

■ Configuring the readers

■

■ Connecting to the relevant controller

■

■ Starting up individual machines

■

■ Tests and validating function

■

■ Collective acceptance of the installation

Training and instruction ■

■Creating specific documents

■

■Your authorized personnel will be instructed in operation.

Tool ID Upgrade – application description

A machine is to be upgraded with a tool ID. First, the components of the system are selected so that they perfectly match the present machine control system (for example, Heidenhain iTNC 530). Then, a separate control unit with integrated RFID technology is installed on each machine outside of the tool room; this control unit communicates with the machine control system.

Tool ID

Upgrade

Pocket

Table

Loading

Tools

Tool

Table

Unloading

Tools

Setups

Functions

The control unit and a tool holder with RFID read/write head can be used to take data that is on the data carrier and read it into the con-troller as well as write it back to the data carrier. The touch screen controls the process of reading or writing to the data carrier. All data and commands are displayed in plain text.

After the tool holder and control unit are installed, the read/write heads are configured and the connection to the machine control system is established. Now the machine can be put into operation. Tests are performed to validate functionality so that the installation can be accepted together with the user.

Mold ID makes the use of injection molds traceable and ensures their optimal utilization. Each mold has to be clearly identified, because all relevant data—such as drawing number, last maintenance or service life—is saved to the mold and can be retrieved at any time. This makes incorrect assignments and missing forms a thing of the past. Production cycles are also counted, which enables preventive main-tenance of the molds. This extends the runtime and supports reliable operation. It increases the productivity of the systems and improves the efficiency. Ensure transparency with Mold ID.

Mold ID – Transparency in

Mold Handling

Optimize the use of your injection molds.

And enable preventive maintenance.

The benefits to you

■

■Recording of the production cycles by an autonomous system

■

■All data is available directly on the mold via RFID

■

■Optimum mold change by visualizing the inspection intervals

■

■Worldwide access to the Mold ID system using a standard web browser

■

■Can be integrated into higher-level systems using a web service interface

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■Reliable – Balluff apps for access to the mold

Mold ID is backed by an autonomous system. All machines can be upgraded individually, without the manufacturer and regardless of the location.

Another plus: You can access the Mold ID system from anywhere in the world using a standard web browser, smartphone or tablet PC. An app with functions protected by configurable passwords enables access to the data directly on the mold by using Near Field Communication (NFC).

Molds are subject to wear and tear and must be regularly maintai-ned as a result. The regularity of inspection often depends on the experience values of individual employees or handwritten notes that are not available to everyone. In many cases, therefore, mainte-nance and inspection are frequently carried out only if the produced parts no longer meet the required quality standards or if the mold malfunctions.

The benefits to you with an autonomous Mold ID ■

■Fewer unplanned downtimes as the result of − continuous counting of the shots

− automatic documentation on the mold

− visualizing the mold status

− notice for the operator about the next scheduled

maintenance

■

■Transparency through the level of use of identically designed molds

■

■Overview of all molds currently running on the machines, through access to the systems over the company network via TCP/IP.

■

■Mobile reading out of the documented mold data via smartphone or RFID handheld, for example, during an audit or when selecting the correct mold.

Mold ID makes the mold usage transparent and creates the prere-quisite for optimizing the processes and monitoring your production.

Mold ID – components Data carriers

− for each mold

− variant depends on the ambient conditions

Shot counter

via an inductive sensor

RFID unit

for communication with the data carrier

Mold ID unit

− industrial computer − software

− gateway to the company network − visualization with the SmartLight signal light

Mobile end devices

− for reading data

− for initializing data carriers − for setting limit values − for password protection

■ ■Attaching data carrier ■ ■Specifying limit values ■ ■Defining names ■ ■Describing data carrier ■ ■Shot counter ■ ■Detecting movement ■ ■Response to system ■ ■RFID ■

■Data from the system

■

■Writing to the data carrier on the mold

■ ■System

■

■Comparing data

■

■Updating the status

■

■Activation of SmartLight

■

■ Reading out data

■

■Defining new limit value

■

■Writing data to data carrier

Initializing Counting Writing Comparing Resetting

One-time Cyclical Maintenance

Initializing ■

■Attaching data carriers: The data carriers are attached to the

mold taking into account the installation instructions. Adhesive or screw-on designs can be selected to match the mold (size, accessibility, machining options, etc.).

■

■Defining limit values: You can define the limit values for the

respective mold. This requires defining two values:

− Number of shots until the next instance of maintenance (red lamp)

− Number when to issue a warning (yellow lamp)

■

■Defining names: A unique name can be assigned to the mold,

for example, the mold or drawing number supplemented by one number. This makes it so that molds with the same design can be reliably differentiated from one another.

■

■Writing to data carriers: The data carrier is written with the

pre-viously defined limit values. Additionally, the shot counter for the mold is initially set to "0". This value can no longer be reset.

Cyclical ■

■Counting: Each production cycle (shot) is detected by the sensor

installed on the machine. The number of edges that belong to a shot can be configured with the software. The counted edges are reported back to the system.

■

■Writing: The system records the data and writes the information

directly to the data carrier on the mold. This ensures that no infor-mation is lost when the mold leaves the machine. Then the data carrier contains the actual values—not estimated planned values from the ERP system.

■

■Comparing: The system monitors limit values and visualizes the

status via SmartLight. If the shot counter is within the defined values, the lamp lights up green. The system switches over to a special display mode if the value for the WARNING is reached. The lower part of the lamp remains green. The upper part is incrementally filled with yellow. If the maximum value is achieved, the lamp turns red.

Maintenance ■

■Resetting: If the mold reaches the previously defined limit,

main-tenance or repairs are performed on it according to the schedule. Before it can be used again, the limit values have to be adjusted and written back to the data carrier. The counter for all parts pro-duced with this tool cannot be tampered with. The limit values for warning and maximum can be individually defined.

Application description

The functions of Mold ID can be divided into various phases. Examp-les of these phases are shown here.

Overview

Detailed information about the mold and the system

Managing the driver licenses of a vehicle fleet goes hand-in-hand with expense and complexity. This is not the case with license tra-cking through RFID using an automated driver license management tool.

Driver License Manager is used to give driver licenses an RFID identification seal. All associated data (about the driver, inspection interval, etc.) is stored in a database.

Once it is recorded, this data is available at all times. And, at regular-ly scheduled check dates, it is automaticalregular-ly synchronized with the RFID identification seal and evaluated. Additional security: It is not possible to tamper with the identification seals. If an attempt is made to remove them, they are reliably destroyed.

Driver License Manager

Simplify driver license management for your vehicle fleet.

And save time.

Hardware

■

■RFID handheld with Wi-Fi

■

■Inspection terminal for reception area

■

■Reader station for master data maintenance

Software

■

■Interface for master data maintenance

■

■Cockpit for the person in charge of the vehicle fleet

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■App for testing with a smartphone

The benefits to you

■

■Time and cost savings through automatic testing

■

■Transparent, legally compliant documentation

■

■System-controlled reminders

■

■No need for resubmissions

■

■Regardless of location with flexible terminals and smart- phone apps

■

■All data remains in the company

Further fields of use

All regular inspections that must be documented can be maintained with the driver license manager:

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■Maintenance – Scheduling working times on machines

■

■Service – Documenting completed tasks, e.g. on gates

■

■Inspection – Documenting as part of the low-voltage directive The system sends automatic reminders for inspecting the driver license. For the vehicle fleet manager, each control is documented exactly and can be verified in a report.

License tracking with RFID provides users with legal certainty. This reduces maintenance effort and saves time.

Headquarters Balluff GmbH Schurwaldstrasse 9 73765 Neuhausen a.d.F. Germany Phone +49 7158 173-0 Fax +49 7158 5010 balluff@balluff.de Object Detection

Linear Position Sensing and Measurement

Condition Monitoring and Fluid Sensors Industrial Identification

Industrial Networking and Connectivity

Accessories Systems and Service