Smart Cylinder Position Sensors - Teach position. Track performance
Know where your piston is. Know how your cylinder is performing.
Smart Cylinder Position Sensors combine precise piston-position monitoring with intelligent condition and performance data. Digital teach-in makes it quick and simple to define the required piston end position, while integrated cycle counting and temperature monitoring provide valuable insight into cylinder operation over time.
Designed for demanding hydraulic and pneumatic applications, our Smart Cylinder Sensor solutions bring position sensing, diagnostics and connectivity together in one extremely robust sensor.
Teach position
Accurate piston-position detection starts with simple setup.
Instead of relying on complex mechanical adjustment, the required piston end position can be digitally taught. This enables fast commissioning and repeatable switching-point configuration while helping maintain consistent process control.
Once taught, the Smart Cylinder Sensor reliably monitors the piston position and provides the switching information needed by the machine or control system.
Measure the piston position. Digitally teach the end position. Monitor it reliably.
Track performance
Smart Cylinder Position Sensors do more than detect piston position. Integrated diagnostic functions provide additional information about how the cylinder is operating.
A built-in cycle counter tracks switching cycles and can generate an alarm when a defined cycle threshold is reached. The sensor can also monitor temperature and report over-temperature events.
This additional condition data can support predictive and preventive maintenance strategies, helping maintenance teams identify operating trends and plan service activities before they result in unexpected downtime.
With a Smart Cylinder Position Sensor, you can monitor:
- Piston position – reliable detection of the taught piston end position
- Switching cycles – integrated cycle counting with alarm functionality
- Temperature – monitoring and reporting of over-temperature events
- Sensor and process data – accessible through IO-Link for connected automation systems
Built for demanding hydraulic and pneumatic cylinders
Industrial cylinder applications can expose sensors to pressure, temperature changes, vibration and demanding operating conditions. Smart Cylinder Position Sensors
are engineered specifically with these environments in mind.
Their extremely robust construction supports operating pressures of up to 500 bar and peak pressures of up to 1,000 bar, making them suitable for demanding cylinder applications where reliable sensing and long-term durability are essential.
Whether used with hydraulic or pneumatic systems, the sensor provides both the piston-position information required for machine control and the diagnostic data needed for greater visibility into cylinder performance.
Easy configuration. Intelligent connectivity.
Smart functionality should make commissioning easier, not more complicated.
Smart Cylinder Position Sensors are designed for straightforward configuration, including digital teach-in of the required end position. Configuration and access to sensor information are supported through PocketCodr and IO-Link.
IO-Link enables sensor and diagnostic data to be integrated into modern automation architectures, providing access to information such as switching status, cycle counts and temperature data.
This makes the sensor more than a simple switching device: it becomes an intelligent source of cylinder data.
From piston-position sensing to predictive maintenance Traditional cylinder sensing answers an important question:
Has the piston reached the required position?
Smart Cylinder Position Sensors add another:
How is the cylinder performing over time?
Combining position detection with cycle and temperature information creates additional visibility into the operation of the cylinder. Maintenance teams can use this information to support condition-based and predictive maintenance approaches.
For example, cycle-count information can help identify when a cylinder or associated component is approaching a planned service interval. Temperature information can highlight over-temperature events that may indicate abnormal operating conditions.
The result is better information for maintenance planning, troubleshooting and machine optimisation.
One sensor. More insight.
Teach position. Track performance.
Smart Cylinder Position Sensors combine the functions needed for reliable cylinder monitoring in demanding industrial environments:
Precise piston-position measurement
Know when the piston reaches the required position.
Digital end-position teach
Teach the required switching position quickly and intuitively.
Cycle counter with alarm
Track switching cycles and trigger an alarm at a defined threshold.
Temperature monitoring
Detect and report over-temperature events.
Extreme robustness
Designed for demanding industrial environments and high-pressure applications.
Up to 500 bar operating pressure
Engineered for high-pressure cylinder applications, with peak pressures up to 1,000 bar.
IO-Link connectivity
Integrate switching and diagnostic information into connected automation systems.
Easy configuration with PocketCodr
Simplify sensor setup, configuration and access to intelligent sensor functions.
Why use a Smart Cylinder Sensor?
A Smart Cylinder Sensor brings together piston-position sensing and cylinder performance monitoring in a single solution.
For machine builders, it provides reliable position information and simple commissioning. For operators, it delivers consistent process monitoring. For maintenance teams, cycle and temperature information provides additional insight that can support planned maintenance and help reduce unexpected machine downtime.
Instead of simply detecting a piston position, the sensor helps turn the cylinder into a source of useful machine data.
Smart Cylinder Position Sensors FAQs
What does “Teach position. Track performance.” mean?
Teach position refers to digitally teaching the sensor the required piston end position or switching point.
Track performance refers to monitoring additional operating information, including switching cycles and temperature. Together, these functions provide both position information for machine control and diagnostic data for maintenance and performance monitoring.
Can the sensor count cylinder cycles?
Yes. The Smart Cylinder Sensor includes an integrated cycle counter with alarm functionality. This allows switching cycles to be tracked and can support preventive or predictive maintenance based on actual machine operation.
Can a Smart Cylinder Sensor monitor temperature?
Yes. Temperature monitoring is integrated into the sensor, including the ability to report over-temperature events. This provides additional information about cylinder operating conditions.
What pressure can a Smart Cylinder Position Sensors withstand?
The Smart Cylinder Sensor is designed for demanding high-pressure applications, supporting operating pressures up to 500 bar and peak pressures up to 1,000 bar.
Does the Smart Cylinder Position Sensors support IO-Link?
Yes. IO-Link connectivity enables configuration and communication of sensor and diagnostic information with compatible automation systems.
How is the piston end position configured?
The piston end position can be set using digital teach-in, simplifying commissioning and allowing the required position to be configured without complex mechanical adjustment. Configuration is also supported through PocketCodr and IO-Link.
Can Smart Cylinder Position Sensors support predictive maintenance?
The sensor provides data that can support predictive and preventive maintenance strategies. Cycle counts can indicate usage and approaching service intervals, while temperature monitoring can identify over-temperature events. How this data is used for maintenance decisions depends on the application and machine requirements.
Are Smart Cylinder Position Sensors suitable for hydraulic cylinders?
Yes. Their robust design and high-pressure capability make Smart Cylinder Position Sensors particularly suitable for demanding hydraulic cylinder applications.
Are they suitable for pneumatic cylinders?
Yes. Smart Cylinder Sensor solutions can also be used for compatible pneumatic cylinder applications where precise piston-position detection and additional operating information are required.
Teach position. Track performance.
Move beyond simple cylinder switching.
Teach the piston position. Monitor every switching cycle. Track temperature. Connect through IO-Link.
Smart Cylinder Position Sensors give machines the position information they need and maintenance teams the performance information they can use.
Teach position. Track performance.
