Mr. Hornung, you advertise the 'BCM' sensor as 'unique in the world' - what are its properties?

Stefan Hornung: Because of the sensor's flexibility based on the principle of 'simply select and use': The condition monitoring sensor is multifunctional and can be precisely adjusted to any application. Thanks to the compact housing, it is easy to install anywhere - but above all, it offers the recording of four different measured variables in just one device! It also uses IO-Link and offers onboard data pre-processing and evaluation directly in the sensor.

Which four variables does the sensor measure? And what exactly do you mean by data pre-processing?

Stefan Hornung: Among other things, the sensor records the physical variables of vibration across three axes, temperature, humidity and air pressure. The resulting data is aggregated and pre-processed in the sensor. For example, it determines the RMS or effective values directly from the raw vibration data. The sensor also calculates mean values or peak-to-peak values. This eliminates the cumbersome and time-consuming transfer of raw data to separate evaluation devices or the calculation of useful values in external systems. Instead, meaningful information is available directly from the sensor, which can be used directly for analysis and evaluation.

Does the sensor select important and less important data before passing it on?

Stefan Hornung: The parameterization of the sensor via IO-Link offers the user many possibilities here: The content of the process data is freely definable. Up to five measured or pre-processed data can be selected and transmitted cyclically. Depending on the application, the data that is most important and meaningful can be selected. Ultimately, the 'BCM' makes an important contribution to smart data, as only the data that is really needed is communicated. If further data and detailed information is required, this can be read from the sensor acyclically at any time on request.

How is the sensor connected to the machine and system environment?

Stefan Hornung: The condition monitoring sensor uses IO-Link as an industrial interface, which greatly simplifies data transfer and parameterization, as no special software or programming environment is required. Many users are already familiar with IO-Link and can therefore easily integrate the 'BCM' into their machine and system environment.

Can you tell us more about how the whole thing was technically implemented?

Stefan Hornung : It was a major challenge for our developers to fit all the functions and the individual sensors for recording the aforementioned measured variables into such a compact housing. State-of-the-art microelectronics - so-called MEMS - play a major role here. These Micro-Electro-Mechanical Systems are tiny components that combine electronics, sensors and micromechanical structures on a single chip. A powerful microprocessor then processes the signals from these microsensors into useful data and information.

What do you think future sensor technology for condition monitoring will look like?

Stefan Hornung: Condition monitoring will continue to grow in importance in automation. This also means that the corresponding sensors will have to keep pace with this development. I therefore expect the functionality and flexibility of sensors for condition monitoring to continue to grow. In the long term, artificial intelligence will be an essential component of such sensors: These will then independently initiate the optimization of production and maintenance processes based on the data they collect, thus further advancing the digitalization of the modern factory.

And when can we expect to see the first sensor with AI functionality from Balluff?

Stefan Hornung: Even though AI is currently a buzzword on everyone's lips, real AI functionality is above all a question of definition. Because making a sensor more intelligent is one thing, defining the task and the purpose for it is another. This is a topic that Balluff is working on intensively; I don't want to reveal any more at this point...