Custom measuring systems and special applications
Measuring solutions when standard equipment is not enough
We develop and manufacture tailor-made measuring systems – from manual measuring stations to fully automatic inline solutions. Precise, reliable and perfectly matched to your measuring task.
Custom solutions
Tailor-made measuring systems for your specific task.
One source
From the idea to commissioning – one contact, full responsibility.
Maximum precision
Modern measuring technology and careful design for reliable results.
Statistical analysis
Measured-value visualization, SPC, Cp/Cpk and complete documentation.
Long-standing experience
More than 60 years of expertise in custom machine and system construction.
Custom measuring systems for individual measuring tasks
Ballbach develops and implements custom measuring systems for demanding production and quality-assurance tasks. Our range extends from manual measuring stations and automatic systems to inline measurement with external robot loading. Engineering, mechanics, electrical design, PLC programming, C#/.NET software, control cabinet construction, assembly and commissioning are available from one source.
A complete project path
From planning to commissioning
- 1
Analysis
Measurement task and conditions
- 2
Concept
Solution design and project planning
- 3
3D engineering
Mechanics and fixtures
- 4
Electrical design
Circuit diagrams and components
- 5
Software & PLC
Control, interfaces and data
- 6
Assembly
Mechanical and electrical installation
- 7
Control cabinet
Wiring and inspection
- 8
Commissioning
Testing, handover and documentation
Interdisciplinary expertise
Scope of services
Planning & engineering
- Requirements analysis
- Feasibility studies
- 3D engineering (CAD)
- Mechanical design
- Documentation
Electrical engineering & control cabinets
- Electrical design
- Component selection
- Control cabinet construction
- Wiring & inspection
- Safety & standards compliance
- CE documentation
C#/.NET software & PLC programming
- C# user interfaces & operation
- PLC programming, e.g. Beckhoff/TwinCAT
- Sequence control & interlocks
- Databases & recipe management
- Interfaces & communication
- Service & remote maintenance
Measurement data, statistics & documentation
- Data acquisition & visualization
- Tolerance evaluation & SPC
- Inspection reports & export
- User & rights management
- Long-term archiving
Software, PLC and statistical analysis
Measured-value visualization
Clear display of measured values and features.
Tolerance evaluation & SPC
Automatic evaluation and SPC analyses.
Process capability Cp/Cpk
Calculation and display of capability indices.
Trend analyses
Long-term monitoring and early trend detection.
Reports & export
PDF and CSV export with flexible reporting.
Operator guidance
Intuitive operation and rights management.
Recipe management
Fast switching between measuring programs.
Control technology and integration into your production
Electrical engineering and control cabinets
We plan and implement the complete electrical system – from component selection and electrical drawings to the finished control cabinet. All cabinets are built and inspected to current standards.
- Component selection
- Wiring & inspection
- Safety technology
PLC programming and system integration
With TwinCAT we develop powerful controls for measurement and automation tasks. We integrate robots, peripherals and measuring systems and connect the system to higher-level platforms.
- TwinCAT / Beckhoff
- I/O and axis control
- Communication & interfaces
- Robot integration
- MES / ERP connection
Flexible fields of use
Typical applications and requirements
Custom measuring systems
Individual solutions for complex geometries and special tasks.
Manual measuring systems
Ergonomic stations for production and inspection.
Automatic measuring systems
Fully automated systems for high volumes and short cycles.
Inline measurement
100% inspection directly in the production line.
Robot integration
External robot loading for flexible and fully automated processes.
Multi-point measurement
Simultaneous inspection of multiple features for maximum efficiency.
FAQ
Frequently asked questions
When is a custom measuring system worthwhile?
When standard measuring equipment cannot economically cover the required features, cycle times, automation or process integration.
Can existing production systems be connected?
Yes. Depending on the project, interfaces to PLCs, robots, databases, MES, ERP and other higher-level systems can be implemented.
Does Ballbach also provide software and control cabinet construction?
Yes. Mechanics, electrical engineering, control cabinets, C#/.NET software, PLC programming, assembly and commissioning can be supplied from one source.
Are statistical analyses and process capability evaluations possible?
Yes. SPC functions, Cp/Cpk analyses, trends, control charts, histograms and inspection reports can be integrated as required.
Do you have a special measuring task?
Talk to us about your requirements – we develop the right solution.