Product Overview

The SICK HighLine Wire Draw Encoder is a precision measurement solution designed for accurate wire length detection in industrial environments. It measures wire draw lengths from 0 meters to 2 meters with a combined resolution of 0.05 mm, achieved through the integration of a high-precision wire draw mechanism and encoder. The device features a highly flexible stranded steel measuring wire (1.4401 stainless steel V4A) with a diameter of 1.35 mm, ensuring reliable performance under dynamic conditions. Constructed from anodized aluminum housing and nickel-plated die-cast components, the unit offers robust mechanical durability. With IP64 enclosure rating for the housing and IP65 for mounted mechanical parts, it provides excellent protection against dust and moisture. Designed as a standard product not classified as a safety component under the Machinery Directive, it delivers consistent performance in demanding industrial applications.

Key Features and Technology

The HighLine Wire Draw Encoder combines high accuracy with reliable operation through its wire draw + encoder technology. The resolution of 0.05 mm is derived from a mechanical wire draw mechanism and an integrated encoder, calculated based on nominal load conditions at average ambient temperature of 40°C and usage frequency of 8760 hours per year. The measuring wire (1.35 mm diameter) is made of highly flexible stranded steel (1.4401 stainless steel V4A), ensuring minimal deformation during operation. The system offers excellent repeatability of ≤1 mm, specifically for the wire draw mechanism, and supports joint protection for wire rope applications such as BTF/PRF/MRA systems. All electronic failures are considered hazardous, emphasizing the importance of proper installation and environmental control.

Technical Characteristics

The SICK HighLine Wire Draw Encoder has a measurement range from 0 m to 2 m, with a resolution of 0.05 mm (wire draw + encoder combination). The measuring wire diameter is 1.35 mm and weighs 7.1 g/m. The total unit weight is 1.42 kg, while the net unit weight is 1.7 kg. Supply voltage operates within 18 V to 30 V. Communication interface supports IO-Link / IO-Link V1.1 via a male M12, 4-pin universal connector. The housing and wire draw mechanism are made from aluminum (anodized or die-cast with nickel plating). Operating temperature range is –20 °C to +70 °C, with performance tested at ambient temperature of 25 °C. Values are rounded and based on average conditions; actual performance may vary due to environmental factors such as installation location, traversing speed, and acceleration.

Configuration and Integration

The HighLine Wire Draw Encoder integrates seamlessly into industrial automation systems via IO-Link V1.1 communication, enabling real-time data exchange with PLCs or HMIs. The M12, 4-pin male connector ensures universal compatibility across various equipment types. The device is designed for direct mounting and supports joint protection in wire rope applications (BTF/PRF/MRA). All values are based on standard operating conditions at ambient temperature of 25 °C; performance may vary under different environmental or operational loads. The resolution calculation example (based on BTF08 with PROFINET) shows a step resolution of 0.001 mm, derived from 262,144 steps per revolution over a 200 mm wire draw length. This ensures high precision in dynamic measurement scenarios.

Operating Environment

The HighLine Wire Draw Encoder is designed to operate reliably within an ambient temperature range of –20 °C to +70 °C, with optimal performance observed at 25 °C. The device features IP64 protection for the housing and IP65 for mounted mechanical components, providing robust resistance against dust and water ingress. Performance may vary due to environmental conditions such as temperature fluctuations, humidity, or vibration. The measuring range is influenced by traversing speed, acceleration, installation location, and ambient temperature. While the product has been tested under standard conditions at 25 °C, actual performance in field applications may differ depending on operational parameters and environmental exposure.

Industrial Applications

The SICK HighLine Wire Draw Encoder is ideal for use in wire drawing, cable winding, and rope tensioning systems where precise length measurement is critical. It supports joint protection in wire rope applications such as BTF/PRF/MRA configurations, ensuring safe and reliable operation. The encoder’s high resolution (0.05 mm) and repeatability (≤1 mm) make it suitable for monitoring wire draw processes with minimal error. Its robust construction, IP64/IP65 ratings, and IO-Link interface support integration into automated production lines in manufacturing, packaging, and material handling environments. The device is designed as a standard product not classified under the Machinery Directive as a safety component, though electronic failures are considered hazardous. It operates within a service life influenced by load type, environmental conditions, and operational parameters such as speed and acceleration.”}