Bus-capable position indicators and actuators from SIKO are suitable for an array of machine builds today. The motion sensors and adjusters make size changeover processes more efficient and reliable — which in turn supports the flexible conversion of modern production systems for ever-smaller batch sizes.

It doesn’t matter if such machine conversions are done manually (with position-indicator monitoring) or in a way that’s fully automated (using the SIKO actuator with position feedback). SIKO position-feedback and adjustment devices prevent incorrect settings that cause waste and tool damage.

By Moritz Müller, PositionLine product manager | SIKO

Fully leveraging intelligent size changeover depends on efficient and reliable communication with machine controls. This is why SIKO’s smart AP10 position indicator and AG03/1 actuator are now also available with IO-Link interfaces. This interface enables fast and cost-effective integration with point-to-point connection using simple I/O connections. The open-source IO-Link interface also simplifies integration into control systems from all leading providers. IO-Link Master Islands work for modular networking of several AP10 position indicators. This minimizes complexity and wiring overhead (and speeds commissioning). Simple wiring and built-in diagnostics improve serviceability and reduce downtime.

An IO-Link Master also allows use of parameter data from field devices — and the storage of that information — and allows hot swapping of components where needed … even while processes are still running and without needing maintenance personnel to have special knowledge of the design.

Seamless communication to the Cloud for IIoT connectivity

Industry 4.0 smart factories must also process data (such as final stage temperature, motor current, and voltage values) for diagnostic purposes.  SIKO devices’ electronic plates offer clear identification with serial numbers and hardware and software versions to make it easier to schedule ad-hoc maintenance intervals. SIKO’s position indicators and actuators provide this information via the IO-Link interface, from where it can be used for tasks such as condition monitoring and predictive maintenance in centralized higher-level systems, all the way to systems using cloud services. Since the IO-Link standard is open, a multitude of network components from various manufacturers is available to enable seamless communication from the field level all the way to the cloud in a straightforward and secure manner.

Manual positioning gets better ergonomics and 100% reliability

The AP10 position indicator ensures that product and size changeovers are performed safely and ergonomically. Setpoints, actual position values, and positioning status are exchanged with the machine control system for monitoring manual spindle adjustment. AP10S variations with an externally connectable magnetic sensor can measure and display linear positions with a precision of ±35 µm. This makes operator guidance and process monitoring easy to implement for both linear slides and threaded spindles.

The AP10 also includes an inverted backlit LCD display for easy readability, even in dark or remote settings. Directional arrows on the LCD complement two dual-color status LEDs. These signal the positioning status (InPos or OutPos) and indicate the needed rotational direction for direct access to the target point.

The new IO-Link AG03/1 actuators excel where operations aim to boost efficiency by helping technicians position machine axles in a precise and automated manner.

All-in-one axle adjustment for confined installation spaces

Even if axle spacing is just 37 mm, there’s still ample room for two AG03/1 actuators to work unobstructed. A compact 80-mm-tall housing integrates the position measuring system, electronic controls, and the IO-Link interface. The unit’s absolute magnetic measuring system, with its 1,600 steps per revolution, provides position values with a high resolution – in fact, this data is provided over the entire travel path of ±6,250 revolutions. Reference movements upon drive startup are now a thing of the past. Furthermore, the magnetic measuring system has proven to be resistant to dirt accumulation, moisture, shock, and vibrations.

Powerful drive on the axis-adjustment actuator for a wide range of applications

The brushless 24-V electrically commutated (EC) motor on the AG03/1 actuator has an output of 50 W and 3.2 Nm of torque with speeds to 100 rpm for quick changeover of sizes, stops, and tools. Such positioning tasks are common in packaging, woodworking, printing and paper, food and beverage, and electronics industries.

Easy mounting with a hollow shaft

As with other SIKO position indicators, the AP10 and AG03/1 also feature a hollow shaft for easy assembly on standard adjustable axles. The size and distance dimensions of the torque support ensure installation compatibility with the world’s best-selling SIKO meter DA09S. So users can switch from manual adjustment with a mechanical position indicator to monitored size changeover or to full automation without changing the machine frame. Due to the high protection class of IP65 and a hollow shaft made of stainless steel, the AP10 and AG03/1 also work in the food, beverage, and pharmaceutical production. For more information, visit www.siko-global.com.