Always correctly and precisely positioned: Metallux sensors in track control systems of the BST

Demo of a track running regulation in the BST showroom in Bielefeld. (Copyright: elexis AG)

Actuator of a track guidance control with sensor inside. (Copyright: elexis AG)

Assembly of the sensors into the actuator. (Copyright: elexis AG)

Nicol Otterbach (BST), Ingo Ellerbrock (BST), and Bernd Rath (Metallux) in conversation (from right to left). (Copyright: elexis AG)

Metallux sensors during assembly at BST. (Copyright: elexis AG)

Standard foil sensor MMP by Metallux. (Copyright: elexis AG)

The company BST GmbH manufactures rail run control systems, inspection, and quality assurance systems for rail-processing industries. For their actuators, the company relies on contactless position sensors from Metallux AG.

The BST GmbH, based in Bielefeld, is a medium-sized manufacturer of systems for rail-processing industries. Founded in 1979, the company with over 300 employees is represented at 11 locations worldwide and is part of elexis AG.

Rail run controls are needed wherever flat material webs are produced, further processed, or refined. A typical application is in the printing industry for paper, packaging, and labels. But they are also indispensable in the manufacture of battery cells, printed electronics, tires, or hygiene products, as well as in conveyor and transport systems.

For example, when a paper web passes through a printing press, it is guided through the machine by numerous rollers. To achieve a perfect final result, the position of the web in the printing press must be defined and always correct. A rail run control ensures the precise guidance of the web and keeps the material on track even at the highest web speeds, so it is always correctly positioned.

Nicol Otterbach, Vice President of Global Marketing at BST, emphasizes that a rail run control is an essential part of the continuous printing process. BST places great importance on comprehensive consulting for its customers and high reliability, combined with simple and intuitive operation of the respective solution. BST also enables extensive process optimizations through the use of inspection and quality assurance systems. Good worldwide service completes the package.

An important component of these rail run controls is the MMP linear sensor from Metallux. The sensor is integrated into the actuator of the rail run control. Its task is to continuously detect the absolute current position of the drive and thus enable highly precise control of the web run.

The absolute measuring, wear-free sensor is hermetically sealed and particularly flat with a height of less than 2 mm. The detection is contactless, using a magnet guided at a distance from the sensor. The MMP is operated in a low-voltage range, typically with a 5 VDC power supply. The output signal can be processed by all common controllers.

The MMP not only offers good resolution, precision, and measurement accuracy. It is robust, wear-free, and has a very high lifespan of up to 50 million cycles. And it is precisely these advantages that make it the ideal sensor for high-quality, fast machines: Accurate and reliable control is made possible only with such a sensor.

However, BST does not use a standard version but a customized solution. The sensor is not mounted on a foil with adhesive coating as usual but integrated directly into the design of the drive. The special shape of this assembly allows for easy installation. The dimensions and cables are also customized. The resistor carrier is made of FR4 instead of polyester. Customer-specific adjustments that meet BST's high standards.

Metallux not only has an extensive standard range but also focuses on consulting and developing customized solutions.

Manufacturing is done exclusively in Germany: from sample quantities to large series of several hundred thousand units. Modern, automated production processes are used. A cleanroom is part of the equipment, as are high-quality testing and inspection facilities.

Metallux has been supplying BST for over 10 years. Ingo Ellerbrock, Product Manager at BST, praises the quality of the product and customer orientation. "Metallux's ability to understand our complex technical requirements and translate them into reliable products, as well as to communicate clearly and effectively with our team, has significantly contributed to the success of our products. I look forward to continuing our collaboration."

And this ensures that not only the material web controlled by BST but also Metallux is always positioned correctly and precisely.