Schwer und Kopka GmbH - effiziente Prozess- und  Werkzeugüberwachung Ihrer Produktionsmaschinen

Each process monitoring system depends on the quality of the measuring signal and thus on a suitable sensor type and the selected measuring point. We develop, produce and sell a wide range of analogue and binary sensors for the most diverse areas of industrial sensing for the measurement of forces, pressure, strain, acoustic emission, vibrations, power consumption of electric motors, travels, angles of rotation, temperatures, etc.

For electrical processing of the sensor signals, we produce a program of highly dynamic signal amplifiers. All sensors together with the appropriate amplifiers are designed to connect easily to our process monitoring systems.

The following selection shows some typical and commonly used embodiments. Depending on the application, we use the sensor type which is best suited according to our experience. We are happy to advise you on the selection of the right sensor for your measuring and monitoring task.

Our replacement for the piezo-electric sensing probe Superflex for measuring strains and forces in machine components. The sensor is installed in 8 mm bores, which run perpendicular to the direction of the force (perpendicular measuring probe). The 8 mm sensor bore has established itself as the standard in many industries and is provided ex works by most machine manufacturers for new machines. The sensor can also be fitted in a recessed way in deeper bores.

Protective covers are available for the mechanical protection of the sensor and the cable exit.



Axflex and Mini-Axflex sensors are piezo-based measuring dowels that measure forces in the axial or longitudinal direction. The sensors are usually installed into bores which run in the direction of the force to be measured. A special clamping nut fixes the sensor in its bore.

The Axflex sensor is often installed inside screws that are used, for example, for fixing stressed machine parts, fastening tools and tool holders or adjusting tool positions.

Dimensions: diameter 7 mm, length 10 mm (Mini-Axflex) or 15 mm (Axflex), clamping thread M8 x 0.75


Screw-on, piezo-electric sensor for measuring force and acoustic emission signals on the surface of machine or tool components. The sensor responds to strain, compression, bending, twisting and vibration. The installation of the compact sensor is carried out easily via four M5 screws on appropriately prepared surfaces on the machine parts.

Dimensions: 43 L x 20 W x 10 H (mm) without cable connection

For special applications, the sensor is also available in other dimensions and designs.


Piezo-electric sensor in flat disc shape for measuring force and/or acoustic emission signals in machine components or tools. The sensor can easily be installed by gluing it to the surface of the machine components or by cementing it into prepared cutouts or pockets. The sensors are available in different diameters from 10 to 27 mm.

A special adhesive kit with assembly aids (SK EASY-mix) is available for the correct bonding and cementing of the sensors.

Diskflex EN


Existing screws for fastening machine and/or tool parts or for adjusting tool positions are typically suitable for the integration of force measuring elements. Such screws often record machining forces that are of interest for process monitoring purposes, offering signals which generate from very close to the process.

We can fit screws of any size down to M6 / M8 with piezo-electric measuring elements. The cable outlet can be fixed or pluggable.

Calibratable force sensors for measuring absolute forces, for example, in force fitting, riveting, clinching, mounting and other applications. The sensors are installed directly in the power flow and usually record the respective machining forces completely and provide readouts in absolutes values auch as kilo Newton (kN).

The sensors are available in a wide range of dimensions and structural shapes for different installation conditions and load ranges.

We never say no! Fitting piezo-electric or strain gage sensors on various machine or tool parts to record mechanical loads (force, strain, etc.) is our daily business.

These machine parts include, for example, stripper plates in stamping tools, adjusting wedges and filler pieces in cold forming presses, tool holders and slides of cutting machines and much more.

We also equip screws for fastening tools or adjusting tool components with integrated force sensors.

Sensor for detecting the power consumption or real power of electric drive motors for example as overload protection, detection of tool breakage of drills or tappers, etc. The connection is made simply by passing one of the power supply lines of the motor through the measuring coils of the sensor.

The analog 0 - 10 VDC output of the Powerflex sensor goes directly into the monitoring system. The signals are monitored with the proven envelope technology or via minimum/maximum limits.

Unwanted signal phases such as start-up or switching transients of the motor can be easily faded out with our envelope technology.

Bolt-on strain sensor based on strain gauge technology with integrated amplifier, high measuring sensitivity and good long-term stability. The X-Flex sensor is used, for example, for press force measurement by bolting with 2 M8 screws on the machine body or press frame. With the machine running, the sensor detects the elongation or strain of the machine body under load, which is directly proportional to the forces actually occurring.

The sensor is suitable for the calibrated measurement of absolute forces. In any case, a reference calibration of the machines must be made.

The X-Flex sensor can be used for a wide range of load applications thanks to the 4 pre-calibrated measuring ranges (62,5με, 125με, 250με or 500με). In addition, there is no re-calibration required if a sensor exchange should become necessary.

Dimensions: 96L x 25W x 15H (mm) without cable connection

Power supply: 10 - 30 VDC

Sensors for a precise determination of the machine position down to the specific angle, e.g. for mechanical eccentric presses or the exact linear position of machine parts such as tool slides. These sensors are used when it comes to the exact measurement of force vs. position or force vs. crank angle.

When using these sensors, the envelope monitoring remains active even if the speed of the machine changes and thus monitors the sensor signals even when the machine is cranked up after the initial start.

We build and deliver specially designed signal amplifiers that are tailored to the different types of sensors. They are characterized by high dynamics, which precisely adapt to the respective signal strength and ensure that a sufficiently strong signal is available for monitoring the measurements.

Usually, these are charge amplifiers, which convert the electrical charge signals of the piezo-electric sensors into transferable voltage signals. The amplifiers are equipped with up to 8 channels and can be coupled for applications with higher number of sensors.