SensoControl supports you in monitoring your processes safely and preventing failures
Downtime is the biggest threat to manufacturing efficiency. Every minute a piece of job-critical equipment is down equals lost revenue, but the costs don’t stop there. The effects of downtime can be felt throughout the company.
With SensoControl, end users can monitor their equipment for any system changes in real time, and optimize their equipment before an issue results in downtime. Effective diagnostics can also help users become more efficient by helping them to identify and remove process bottlenecks.
SensoControl: Precise Sensor Technology and Control for Industrial Vacuum and Pressure Applications
SensoControl components from Parker provide reliable measurement and control functions in manufacturing processes where pressure and vacuum monitoring, responsiveness, and interface versatility are crucial. The product family includes electronic pressure and vacuum sensors, compact control units for monitoring suction systems, and variants with integrated switching output logic or fieldbus/IO-Link interfaces. The designs are suitable for installation in field enclosures, directly on suction cups, or in decentralized valve islands. Typical measuring ranges cover fine vacuum to several bar overpressure, with accuracies sufficient for positioning, handling, and leak testing tasks.
Technical Details: Measuring Principle, Measuring Range, and Accuracy
SensoControl sensors primarily use piezoresistive pressure transducers or MEMS-based sensor elements. For vacuum applications, measuring ranges from -1 bar (vacuum, evacuable range) to 0 bar are common; for pressure measurements, variants extend up to +10 bar and higher. Typical accuracies vary depending on the series, from ±0.5% FS to ±2% FS. Temperature compensation enables stable readings over wide operating temperature ranges (e.g., -20 °C to +80 °C); some versions offer extended ranges and special calibrations for gas and liquid measurements.
Materials, Housings, and Seals
Housing materials are corrosion-resistant materials such as anodized aluminum, stainless steel (1.4301/316L), or glass-fiber reinforced plastic. Media-neutral seals made of NBR, FKM (Viton), or EPDM ensure tightness against oil, water, or chemical media; for special media, PTFE-coated seals or metallic sealing surfaces are available. Pressure connections and diaphragms are hardened or made of stainless steel, depending on the version, to minimize abrasion and chemical attack. Plug-in electrical connections are available as M8 or M12 connectors, free wires, or D-SUB variants, with mechanical connection threads often in G1/8, G1/4, or NPT versions.
Connections, Interfaces, and Integration
SensoControl was designed for easy integration into control and fieldbus systems. Electrical outputs include switching outputs (PNP/NPN), analog signals (0–10 V, 4–20 mA), and digital communication via IO-Link or industrial bus systems. Some units offer multiple switching outputs with adjustable hysteresis and delay times for debouncing, while others provide direct digital feedback for PLCs or safety controllers. Mechanical mounting options include front or side mounting, L-DIN rail adapters, and special brackets for robot arms. External gateways can be used for wireless integration.
Application-Oriented Designs and Accessories
The product range covers compact inline sensors for limited installation spaces, robust industrial housings for harsh environments, and special variants with high protection ratings (IP67/IP69K). Accessories include connection cables, mounting adapters, sealing sleeves, fittings, and calibration accessories. For suction systems, complete control blocks with integrated manifold, solenoid valves, and filter options are available to build vacuum circuits in a space-saving and service-friendly manner.
Practical Application Examples
Pick-and-Place in Electronics Manufacturing: A SensoControl vacuum sensor is mounted directly on the suction cup line and dynamically monitors the vacuum profile during the picking and placing of sensitive SMD components. The sensor system immediately detects leaks or missing components through altered pressure curves and sends a switching signal to the line control. By combining it with an IO-Link-enabled device, historical process data can be recorded and gripping cycles evaluated for predictive maintenance.
Packaging Machines with High-Speed Suction Systems: In packaging and cartoning machines, SensoControl monitors the suction force of the suction cups during cycle changes. Sensors with short response times ensure that misalignments of packaged goods are detected and the gripper sequence is interrupted before parts fall. Compact designs with a high protection class are useful here, as cleaning cycles and splash water can occur.
Robot Applications and Automatic Loading and Unloading: In robotic handling, SensoControl monitors the status of multiple grippers in a cluster. Using multiple outputs or IO-Link, several gripping cycles can be aggregated. One application is the automatic loading of machine tools: After clamping the workpiece, the sensor checks whether the component has been securely transported and only then gives the release signal for clamping. This reduces scrap and machine damage.
Leak Testing in Production: For inline leak tests on vacuum- or pressure-loaded components, SensoControl provides precise pressure drop curves from which a test result is automatically derived. High-resolution sensors detect even the smallest leak rates; test criteria can be adapted to product families via central control.
Installation and Mounting Tips for Reliable Operation
During mounting, ensure short, straight pressure lines without unnecessary diameter reductions to avoid dead spaces and signal delays. For applications with chip accumulation or splash water, sensors with IP67/IP69K protection and a stainless steel diaphragm should be chosen. Electrical connection cables should be routed to minimize mechanical stress and vibrations; additional strain relief prevents contact disturbances. Regularly check seals, select appropriate sealing materials for changing media, and use filters or oil separators if necessary to protect sensor elements. For calibration-relevant applications, regular calibration intervals should be defined in maintenance planning.
Typical Error Scenarios and How SensoControl Addresses Them
Leaks in vacuum lines lead to slow pressure drops; SensoControl detects altered drop rates and can trigger fault messages via adjustable thresholds. Contamination of the measuring diaphragm by oil or particles reduces measurement quality; for this, versions with PTFE coating or additional filter elements are available. Electrical disturbances are minimized by robust protection circuits, galvanic isolation, and EMC-compliant design. In the event of short-term pressure peaks, the sensors offer adjustable time filters to prevent false alarms.
Compatibility with Complete Vacuum Systems and Expandability
SensoControl products can be integrated into existing Parker vacuum systems or third-party installations. Modular valve islands and manifold solutions allow measurement and control functions to be placed close to the points of consumption, reducing line losses and improving response times. For data-driven optimizations, combining with IO-Link gateways and cloud data services is recommended. Further technical information on peripherals, technology, and system solutions can be found at https://maku-industrie.de/technik and specific machine examples at https://maku-industrie.de/anwendungsbeispiele.
Selection Criteria: Which SensoControl Suits Your Application?
Choose a model based on the relevant measuring range (vacuum, overpressure), required accuracy, protection class, and electrical interface. Consider the medium (gas, liquid, aggressive media) when selecting diaphragm and sealing materials. Installation location, ambient temperature, and cleaning cycles are also crucial. If multiple grippers or measuring points need to be monitored, IO-Link variants or multi-output modules can reduce wiring and evaluation effort.
- Important selection parameters: Measuring range, accuracy, temperature range, protection class, connections (G/NPT), electrical interfaces (PNP/NPN, 0–10 V, 4–20 mA, IO-Link), sealing material.
FAQs
1. What measuring ranges does SensoControl cover and how accurate are the sensors?
SensoControl models cover vacuum ranges down to -1 bar as well as pressure ranges from a few bar up to the double-digit bar range. Accuracies typically range between ±0.5% FS and ±2% FS, depending on the design and calibration. Specially calibrated variants are available for high-precision testing tasks.
2. What connection and interface options are available?
Electrical connections are designed as M8/M12 connectors, open wires, or special connectors. Output signals range from simple switching outputs (PNP/NPN) to analog signals (0–10 V, 4–20 mA) and digital interfaces such as IO-Link. Pressure connections are often G1/8, G1/4, or NPT.
3. How can I integrate SensoControl into my existing control system?
SensoControl can be connected directly to a PLC via switching output, or integrated into modern automation networks via analog inputs or IO-Link. For decentralized installations, manifolds with integrated sensor technology are suitable; for data-driven applications, an IO-Link gateway is recommended for central evaluation and historization.