SICK BCG05L1KM01PP Displacement Sensor

(Pedido nº.: 6039746)

Produto: EcoLine Series DrawWire Absolute Sensor de deslocamento (DrawWire Encoder)

Explicação do código do modelo

BCG05: Drawwire housing, maximum measuring stroke 1250 mm

eu: Output signal 0…10 V voltage output (K stands for 420 mA current output)

1K: Multiturn absolute

M01PP: Saída de cabo, fixed cable without connector

Principais especificações técnicas

Cable Pin Assignment (4núcleo do cabo)

1. Verde: +24 V (Poder Positivo)
2. Marrom: 0 V (Power GND)
3. Branco: Signal Output 010V
4. Preto: Escudo

Aplicações Típicas

Plataformas elevatórias, hydraulic telescopic mechanisms, equipamento de empilhamento, outrigger displacement measurement for construction machinery, linear displacement measurement for automation equipment; position value available upon poweron, não é necessário retorno.

Mechanical Notes

Housing made of modified polyphenylene ether plastic; dimensions 55×55×52 mm

Avoid kinking, impact and overtravel pulling of drawwire; keep drawwire outlet aligned with moving direction as much as possible

Mounting brackets and screws supplied; integrated ACM36L1K0K01 absolute encoder

Alternativa & Modelos compatíveis

1. Sameseries currentoutput version: BCG05K1KM01PP (420 mA)
2. Substituição doméstica: drawwire encoder with 1250 mm stroke, 010 V output, multiturn absolute output; match nonlinearity and hysteresis specifications.

Practical Application Cases for DOENTE BCG05L1KM01PP (6039746)

Recursos principais: 1250 mm measuring range, multiturn absolute, 010 V voltage output, position readout without homing after poweron, compact footprint 55×55 mm, IP50 (for indoor / sheltered installation; not for outdoor direct rain exposure).

010 V analog output for direct connection to PLC analog input modules, comissionamento simples; not intended for functional safety circuits. MTTFd = 850 years is for reference only; the device carries no safetyrelated certification.

Caso1: Closedloop Height Control for Scissor Lifting Platform (Indoor Aerial Work Platform)

Condição Operacional: Indoor scissor lift with maximum lifting stroke 1100 mm. PLC performs closedloop height control, approachspeed reduction and limit protection. Current height is directly recognized after powercycle without mechanical homing.

Instalação: Sensor fixed to base frame; drawwire lug attached to movable upper platform. Keep drawwire coaxial with outlet, deflection angle limited to ＜±3°.

Processamento de Sinal: 010 V connected to PLC analog input; 10 V corresponds to 1250 mm. Scale mapping implemented in PLC software with software upper/lower limits.

Justificativa de Seleção: 1.25 m range covers 1100 mm travel; multiturn absolute preserves position after power loss; compact size fits confined space inside lifting mechanism.

Perceber: IP50 rating not suitable for rainexposed outdoor aerial work platforms. Use BTF series for outdoor deployment.

Caso2: Stroke Measurement of Hydraulic Telescopic Cylinders (Hydraulic Mechanisms for Specialpurpose Automation Machines)

Condição Operacional: Builtin hydraulic pushpull cylinder with effective stroke ≤1200 mm. Realtime feedback of piston rod extension for closedloop position control and position detection.

Montagem: Externally fitted to cylinder side. No internal cylinder space occupied. Retrofitting on existing cylinders does not require cylinder disassembly.

Advantages vs. magnetostrictive sensors: Hollowbore cylinder is not required, leading to lower retrofit cost; absolute output retains position through power cycles.

Commissioning Tip: Use the sensor’s builtin analog teachin function to set zero and fullscale points, reducing PLC scaling programming work.

Case 3: Fork Height Monitoring for Narrowaisle Stacker Trucks in Automated Warehouses

Condição Operacional: Indoor narrowaisle stacker truck with fork lifting stroke approx. 1000 milímetros. Control system reads realtime fork height for shelflevel positioning and anticollision logic.

Instalação: Mounted in sheltered area inside mast assembly, protected from direct rain.

System Implementation: 010 V analog signal fed to onboard PLC. 0.04 mm resolution and ≤0.2 mm repeat accuracy satisfy shelflayer positioning requirements.

Constraints: Mast area subject to dust accumulation. Periodically inspect drawwire and prevent debris jamming the drawwire housing.

Case 4: Positioning of Lifting Slides on Overhead Conveyors in Automotive Assembly Lines

Condição Operacional: Lifting slide on automotive mainassembly conveyor with vertical travel 01100 mm, used for workpiece transfer at workstations and multistation height synchronization checks.

Ambiente: Indoor workshop with light cuttingoil mist. IP50 rating adequate for sheltered installation.

Sistema: PLC analog module acquires 010 V signal for closedloop lifting control and cushioned stop to avoid mechanical shock.

Case 5: Height Detection for Lifting Mechanisms on Indoor AGVs

Condição Operacional: Onboard lifting mechanism of indoor AGV with maximum lifting travel 1200 mm. Used for targetheight detection and softlimit protection. Lifting height is available immediately after poweron without rehoming.

Vantagens: Compact form factor for cramped AGV internals. Spring return force 1.01.4 N suited for smooth lowspeed motion. Max permissible acceleration ≤10 m/s²; not for highshock applications.

Case 6: Displacement Acquisition for Heightadjustable Medical Examination Beds

Condição Operacional: Heightadjustable medical examination bed with travel within 1000 mm for bedheight regulation. Mild indoor ambient temperature.

Principais benefícios: No homing required on powerup; compact for installation inside bed frame. Implement proper EMC grounding to avoid interference with medicaldevice signals.

⚠️ Critical Application Limitations (Armadilhas de seleção)

1. IP50 Ingress Protection: Only for indoor / sheltered installation. BCG05 series must NOT be deployed outdoors, in rainexposed or washdown environments. Select BTF drawwire sensors instead.
2. Maximum allowable acceleration 10 m/s². Not for highimpact or heavyvibration machinery.
3. Typical mechanical service life: 1 million cycles. Evaluate servicelife margin for highfrequency reciprocating motion.
4. Nonsafetyrelated sensor. Must not be used directly in personnelprotection safety circuits.

Alternative Products for Similar Applications

Currentoutput variant: BCG05K1KM01PP (420 mA output, improved noise immunity for long cable runs)

Extendedrange models: BCG05 series available up to 10 m stroke; select larger housing for travel over 1.25 m.

Foodindustry Application Cases for SICK BCG05L1KM01PP (Order No. 6039746)

Important Prerequisite: This sensor carries IP50 ingress protection and must not be exposed to splash water, spraysteam or cleaning chemicals. Installation is permitted only inside dry, sheltered cabinets / frame enclosures free of CIP/SIP washinplace procedures. Never install in direct washdown zones. A metal protective cover is mandatory to isolate moisture, dust and food debris. Multiturn absolute with 010 V analog output; no homing at poweron; 1250 mm measuring range. Suitable for downstream packaging, postprocessing and warehouselogistics equipment in food plants. Not suitable for wet zones such as cooking, washingup or filling stations.

Caso1: Lifting Hotseal Die for Food Packaging Machines (Snack & Pastry Packaging)

Condição Operacional: Vertical packaging machine. Hotseal die vertical stroke 9001100 mm. Realtime monitoring of die travel to control sealing depth and compression stroke. Multiple recipedriven height parameters for different bag formats. Position is retained across powercycles without mechanical homing.

Instalação: Sensor fully enclosed inside a dry metal protective cover mounted on machine frame, away from hotseal steam and splashes. Drawwire lug connected to movable sealing die. Drawwire deflection angle kept below ±3°. Keep clear of film debris and condensate.

Signal System: 010 V to PLC analog input; 10 V corresponds to 1250 mm. Multiple recipe height values stored inside PLC. Software overtravel limits prevent mechanical collision.

Justificativa de Seleção: Compact footprint for confined frame space. Absolute output eliminates homing after recipe change or restart. Repeat accuracy ≤0.2 mm guarantees consistent sealing performance batchtobatch.

Manutenção: Blow dust from protective housing using dry compressed air periodically. Never wash the sensor body with water.

Caso2: Lifting Pallet Positioning for Readymeal / Frozenfood Palletizers (Downstream Packaginglogistics Zone)

Condição Operacional: Palletizer for cartoned frozen prepared food. Lifting pallet stroke 1150 mm for layerbylayer carton stacking. Dry lowtemperature environment outside coldstorage chambers (not inside frostforming coldstorage areas).

Instalação: Sensor fitted inside dry electricalside protective enclosure, isolated from coldchamber humidity. Drawwire coupled to lifting pallet. Do not install directly inside coldstorage rooms subject to frost and condensation.

Functionality: Realtime palletheight feedback enables PLC to calculate stacking layers. Position remains valid after poweroff; machine resumes production quickly after pallet exchange with minimal setup time.

Constraints: Ambient relative humidity must remain moderate. Use IP67rated drawwire sensors (SICK BTF series) if installation inside coldstorage chambers is required.

Case 3: Heightadjustable Discharge Conveyor Table for Bakery Oven Output

Condição Operacional: Heightadjustable receiving table downstream from baking oven, stroke approx. 1000 milímetros. Adjust table elevation to match different downstream conveyors. Deployed in dry cooling zone after oven discharge with no water washing.

Problem Solved: Proximity switches only provide discrete position points. BCG05L1KM01PP delivers continuous height signal enabling smooth speedregulated lifting, reducing bread impact damage during transfer.

Notas de instalação: Keep away from radiant oven heat; ambient temperature must not exceed 70 ℃. Fit metal baffle to block bread debris and flour dust. Flour dust may ingress IP50 housing; periodic dryair purging is required.

Case 4: Liftingplatform Mechanism for Dairy Carton Depalletizers (Dry Packaging Zone)

Condição Operacional: Depalletizer platform for Tetrapack and cartonpacked dairy products, stroke 1200 mm. Deployed exclusively in dry downstream packaging area, well separated from bottlewashing and filling wet processes.

Process Requirement: Closedloop height positioning for carton picking at each layer. Platform height is read directly on nextmorning startup after overnight poweroff, eliminating homing and improving production uptime.

Cuidado: Dairyplant washdown is confined to fillingarea wet zones. Never locate sensor near cleaning stations. Cleaningagent vapour and mist will cause shortcircuit failure.

Case 5: Lifting Discharge Gate for Ingredient Silos for Extrudedsnack / Feed Production (Dry Powderprocessing Workshop)

Condição Operacional: Grainandextrudedsnack ingredient workshop. Vertical discharge gate stroke ≤1200 mm. Gate opening continuously regulated to control powderfeed flow rate. Drydustprone workshop with no washdown operations.

Sistema: 010 V analog signal for closedloop gateaperture control; multiple recipebased openingdegree parameters supported.

Requisito de proteção: Fully enclosed metal guard mandatory to prevent grain and snack dust entering drawwire housing. Dust accumulation may jam drawwire movement. Perform dryair purging each shift.

⚠️ Mandatory Usage Restrictions for Foodindustry Deployment (Armadilhas de seleção)

1. ❌ Forbidden applications: Bottle washers, máquinas de enchimento, cooking equipment, CIP washinplace stations, highpressure washdown zones, frostprone coldstorage interiors, steamsplashing stations. IP50 provides no defence against moisture and cleaning fluids; premature failure is highly likely.
2. ✅ Permitted scenarios: Downstream packaging, palletizing, depalletizing and cooling dry zones in food plants. Independent metal protective enclosure is required for dust and moisture isolation.
3. Drawwire is V4A stainless steel with PA coating. Visually inspect drawwire surface regularly; foodresidue adhesion accelerates wear.
4. No EHEDG or FDA hygienic certification. Direct contact with food is prohibited.

Alternative Selection for Foodplant Wetzone Conditions

If moisture or washdown cannot be avoided onsite, do not use the BCG05 series. Choose SICK BTFseries drawwire encoders (IP67) for splashresistant and washdowncapable operation.