Application Spotlight

Automated Size Change on a Filling Line

Moving products from one point in the process to another is a rather common occurrence in many packaging lines. Guide rails are often used for this simple
task of gathering products before the next stage. When running multiple sized products, however, changing position becomes necessary. Balluff offers a
simple, flexible, and cost effective solution for automating the size change process. A BIW pulsed-inductive linear position sensor used in conjunction with
distributed modular I/O enables a virtually unlimited variation of sizes that can be run on a single line and automates the adjustment process as well. An
industrial analog input hub makes wiring simple with a standard 3-conductor cable and also eliminates an additional analog input card that a typical servo
system would require.
Benefits:
n More flexibility allows users to run various sizes of product down the same line
n Low cost uses a DC motor rather than a servo and uses distributed modular I/O, eliminating an extra analog card
n Simple to install can be run back through an analog input hub, using a simple 3-conductor cable

Guide Rail Positioning

Before

After

In this example, the customer was unable to do automatic size change with their current setup. By implementing Balluffs solution, they are able to Connectivity
increase Solutions
M12 4-wire+PE, 5-wire, 8-wire
M12
shielded cordsets
the flexibility of their production line with minimal cost. A Balluff BIW is coupled to a ball screw assembly that moves the guide rail in and out to allow
for
various sizes of product. The BIW provides absolute position feedback throughout the entire motion of travel. This allows for precise positioning even under
a loss of power. The ball screw is driven by a simple DC motor, making the total cost of the system under $1000. This feedback allows the customer to run
many different product sizes on the same line.
M12 4-wire+PE, 5-wire, 8-wire, 12-wire
M12 Female

M12 Female

M12 Male

Straight

Right Angle

Straight

Right Angle

Voltage Rating

(4p+PE, 5p = 125 V), (8p = 60 V), (12p = 30 V)

(4p+PE, 5p = 125 V), (8p = 60 V), (12p = 30 V)

(4p+PE, 5p = 125 V), (8p = 60 V), (12p = 30 V)

(4p+PE, 5p = 125 V), (8p = 60 V), (12p = 30 V)

Output Type
Amperage

BIW1-C310-M*_ _ _ _-P1-S115

*Available lengths (mm)

(4p+PE, 5p = 4 A), (8p = 2 A), (12p = 1 A)

(4p+PE, 5p = 4 A), (8p = 2 A), (12p = 1 A)

(4p+PE, 5p = 4 A), (8p = 2 A), (12p = 1 A)

(4p+PE, 5p = 4 A), (8p = 2 A), (12p = 1 A)

Conductor Cross-Section

(5p = 0.34 mm2), (8p, 12p = 0.25 mm2)

(5p = 0.34 mm2), (8p, 12p = 0.25 mm2)

(5p = 0.34 mm2), (8p, 12p = 0.25 mm2)

(5p = 0.34 mm2), (8p, 12p = 0.25 mm2)

4-wire+PE, non-LED

BCC M415-0000-1A-034-PX0534-_ _ _

BCC M425-0000-1A-034-PX0534-_ _ _

BCC M415-0000-2A-034-PX0534-_ _ _

BIW1-A310-M*_ _ _ _-P1-S115

0...20
mAPNP-LED, N/O & N/C
0075,
0100, 0130, 0150, BCC M425-0000-1A-040-PX0534-_ _ _
4-wire+PE,
signals
5-wire, non-LED
BCC M415-0000-1A-017-_X_534-_ _ _
M425-0000-1A-017-_X_534-_ _ _
0175,
0225,
0300, 0360, BCC
5-wire,mA
PNP-LED, N/O & N/C signals
BCC M425-0000-1A-039-PX0534-_ _ _
4...20
8-wire, non-LED
BCC M418-0000-1A-044-PX0825-_
__
BCC M428-0000-1A-044-PX0825-_ _ _
0375, 0400,
0450, 0500,
1
12-wire, non-LED
BCC M41C-0000-1A-049-_X_C25-_ _ _Solutions
BCC M42C-0000-1A-049-_X_C25-_ _ _
0...+10
V
0600, 0650,Connectivity
0750
M12
field attachables

BIW1-G310-M*_ _ _ _-P1-S115

-10...+10V

BIW1-E310-M*_ _ _ _-P1-S115

Ordercode

Description

BCC04MC

8-wire, shielded, female

field attachable - BIWM12
side
2
Female Field Attachables
M12 Shielded Cordsets

BCC034K
BNI0007
BNI0008
BCC05MH
BNI004A

M12 Male

BCC M418-0000-2A-044-_X_825-_ _ _

BCC M428-0000-2A-044-_X_825-_ _ _

BCC M41C-0000-2A-049-_X_C25-_ _ _

BCC M42C-0000-2A-049-_X_C25-_ _ _

2
M12 Female

M12 Female
M12 Male

M12 Male

Configuration

Straight
Right
Angle

Straight

Voltage Rating

(3p, 4p = 250 V),Housing

(4p+PE, 5p = 125 V), (8p = 60 V)

Amperage
(3p, 4p = 4 A), Connection
= 4 A), (8p = 2 A)
4 analog + 8 PNP input
hub, 4...20 mA (3p,
(10
bit)(5p mm
Conductor Cross-Section
4p, 5p = 0.34
), (8p
= 0.25 mm )
Conductor
Range
4 analog + 8 PNP input
hub, 0...+10 V (10
bit)No. of
3-wire, non-LED, N/O signal, shielded
BCC M415-0000-1A-036-_S_334-_
__
Allowable
2

Right Angle Right Angle

Plastic250 V

250 V

Plastic

(3p,
4p =Terminals
4 A), (5p = 4 A), (8p = 2 A) Insulation Displacement
Screw

A
Spring4Clamp

4A

Screw Terminals

2
(3p,
4p, 5p =mm
0.34 (26...18
mm2), (8p
= 0.25 mm
)
0.14...0.75
AWG)
0.14...0.34
mm (26...22 AWG)

(3p, 4p,
5p(26...20
= 0.34 AWG)
mm )
0.14...0.50
mm

2
(3p, 4p = 0.34
mm2), (8p(26...18
= 0.25 mm
)
0.14...0.75
AWG)

BCC M413-0000-2A-036-_S_334-_ _ _

M12Standard
Female Cable Jackets:

M12 Female

Straight
Straight

Plastic
(3p,
4p = 250 V), (4p+PE, 5p = 125 V), (8pPlastic
= 60 V)

BCC
M425-0000-1A-036-_S_334-_
__
Order
Code/Part Number

M12Female
Female
M12

M12 Female

3-wire, shielded, male,

2 m cable - hub Straight
side
Configuration

BCC M415-0000-2A-017-_X_534-_ _ _

Type

Type

Standard Lengths Available:

020 = 2 meters
050 = 5 meters
100 = 100 meters

BCC M423-0000-2A-036-_S_334-_ _ _

VS8 = PVC (grey, 8)

PS0 = PUR (black, 0)

Straight

Metal (shielded)

Standard
Lengths Available:
Screw
Terminals

3-wire, non-LED, N/C signal, shielded

Conductors
Cable_
BCC M415-0000-1A-037-_S_334-_
_

BCC M425-0000-1A-037-_S_334-_ _ _
BCC
M425-0000-1A-014-_S_434-_ BCC06ZY
__
BCC06Z9

BCC M414-0000-2A-014-_S_434-_ _ _

BCC M424-0000-2A-014-_S_434-_
__
BCC06ZA

4-wire+PE, non-LED, shielded

BCC M415-0000-1A-043-PS0534-_ _ _

BCC
_ _ M435-0000-1A-000-43X434-000
BCCM425-0000-1A-043-PS0534-_
M435-0000-1A-000-41X475-000 BCC

BCC M415-0000-2A-043-PS0534-_ _ _

BCC M425-0000-2A-043-PS0534-_
__
BCC M445-0000-1A-000-41X475-000

4-wire, non-LED,
BCC M415-0000-1A-014-_S_434-_
__
4-wire
4...6 mm
4-wire, double-ended,
5 m shielded
cable - hub to
master

EtherNet/IP distributed
modular I/O master
8-wire, non-LED, shielded
BCC M418-0000-1A-046-PS0825-_ _ _
5-wire, non-LED, shielded

BCC M415-0000-1A-016-PS0525-_
__
5...8 mm

6...8 mm
5-wire

www.balluff.com/Packaging

BCC M413-0000-2A-037-_S_334-_ _ _

020 = 2 meters
050 = 5 meters
100 = 100 meters

0.14...0.75 (26...18 AWG)

BCC M423-0000-2A-037-_S_334-_ _ _

BCC06ZM

BCC M428-0000-1A-046-PS0825-_ _ _

BCC M475-0000-1A-000-01X475-0

BCC06F6

BCC06Y6

BCC06Y8

BCC M435-0000-1A-000-51X475-000

BCC M435-0000-1A-000-55X450-000

BCC M445-0000-1A-000-51X475-000

2.1...3 mm or

BCC09JP

4...5 mm

BCC M435-0000-1A-000-A1X575-000

4...6 mm

BCC06ZF

BCC06ZH

BCC M435-0000-1A-000-41X575-000

BCC M445-0000-1A-000-41X575-000

n www.balluff.com/networking

5...8 mm

Balluff, Inc. n 8125 Holton Drive Florence, KY 41042 n 1-800-543-8390 n www.balluff.com

6...8 mm

BCC06W9

BCC M435-0000-1A-000-51X575-000

8-wire

4...6 mm

BCC06ZN

BCC M475-0000-1A-000-01X575-0

BCC06ZJ
BCC M445-0000-1A-000-51X575-000

BCC04MC

AS_054 Automated Size Change on a Filling Line 2011-05

Part Number

Standard Cable Jackets:

V = PVC (grey, 8)
P = PUR (black, 0)

Type
Configuration

BCC04ME (IDC)