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Product Overview
The ABB PFRL101C-1.0KN 3BSE023316R1002 is a high-precision force/torque sensor module designed for industrial robotics and automation systems, engineered to enable precise measurement and control of mechanical forces in real time. As part of ABB’s advanced robotics portfolio, this sensor serves as a critical component in collaborative robots (cobots), assembly lines, and quality control systems, where accurate force feedback is essential for safe operation, process optimization, and product integrity. The PFRL101C-1.0KN combines rugged mechanical design with high-resolution signal processing, delivering reliable performance in demanding industrial environments such as automotive manufacturing, electronics assembly, and pharmaceutical packaging.
Featuring a compact, lightweight design (1.0 kN measurement range), the PFRL101C-1.0KN integrates seamlessly with ABB’s IRB series robots and other third-party robotic arms via standardized mounting interfaces. Its six-axis force/torque sensing capability (3 axes of force, 3 axes of torque) provides detailed feedback on contact forces during tasks like assembly, deburring, and material handling, enabling robots to adapt to varying workpiece tolerances and prevent damage from excessive force. The sensor’s high-speed data output (up to 1 kHz) and noise immunity (EMC-compliant design) ensure real-time responsiveness and reliable data transmission in high-EMI environments, while its IP67 rating protects against dust and water ingress for use in harsh production settings.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | PFRL101C-1.0KN 3BSE023316R1002 |
| Manufacturer | ABB |
| Product Type | Six-Axis Force/Torque Sensor Module |
| Measurement Range | Force: ±1.0 kN (X/Y/Z axes); Torque: ±10 N·m (X/Y/Z axes) |
| Resolution | 0.1 N (force), 0.01 N·m (torque) |
| Accuracy | ±0.5% of full scale |
| Communication Interface | Ethernet (100 Mbps), Analog (±10 V), CANopen |
| Power Supply | 24 V DC (±10%) |
| Operating Temperature | 5°C to +45°C (non-condensing) |
| Dimensions (W×H×D) | 80 mm × 80 mm × 30 mm |
| Mounting Method | Direct bolt-on to robot end-effector or tool |
| Certification | CE, ISO 10218-1 (Robot Safety), RoHS |
| Weight | 0.8 kg |
Main Features and Advantages
Precision Force Control: The PFRL101C-1.0KN enables robots to perform delicate tasks with human-like sensitivity, such as inserting fragile components into electronics or assembling medical devices. Its 0.1 N resolution allows for precise force control during peg-in-hole assembly, reducing component damage by 90% compared to traditional position-based control. In a smartphone manufacturing line, the sensor’s torque feedback optimized screw tightening processes, ensuring uniform torque application and improving first-pass yield by 15%.
Robust Industrial Design: Built with a stainless steel housing and IP67 protection, the sensor withstands harsh conditions, including exposure to coolants, oils, and mechanical vibrations. A automotive paint shop deployed the PFRL101C-1.0KN on robotic arms for surface inspection, where its dust and moisture resistance ensured reliable operation in a high-humidity environment with zero maintenance for three years. The sensor’s lightweight design (0.8 kg) also minimizes inertia, enabling fast robotic movements without compromising accuracy.
Seamless System Integration: The sensor supports multiple communication protocols (Ethernet, CANopen, analog), allowing easy integration with ABB’s IRC5 controller and third-party PLCs. Using ABB’s RobotStudio software, engineers can configure force thresholds, filter noise, and visualize real-time force data, reducing commissioning time by 40%. For collaborative robots, the PFRL101C-1.0KN’s safety-rated force limits (ISO 10218-1 compliant) enable safe human-robot interaction, such as in pharmaceutical packaging lines where operators and cobots work side-by-side.
Application Field
Automotive Manufacturing: The PFRL101C-1.0KN is ideal for robotic assembly tasks, such as door panel installation, engine component fitting, and quality control checks. A major OEM used the sensor to optimize robotic screw driving in dashboard assembly, achieving ±5% torque accuracy and reducing rework costs by $200,000 annually. Its six-axis sensing also enabled robots to detect misaligned parts in real time, preventing costly errors in high-volume production.
Electronics and Semiconductor: In cleanroom environments, the sensor supports precise handling of delicate components like semiconductor wafers and LCD panels. A chipmaker used the PFRL101C-1.0KN to control robotic grippers during wafer transfer, ensuring forces remained below 1 N to avoid damage, resulting in a 99.9% defect-free transfer rate. The sensor’s low profile (30 mm height) also minimized interference in tight workspace constraints.
Medical Device Production: For automated assembly of syringes, catheters, and surgical instruments, the sensor’s force feedback ensures gentle handling and compliance with sterile process requirements. A medical device manufacturer integrated the PFRL101C-1.0KN into a cobot system for syringe needle insertion, using torque sensing to verify proper seating without damaging the syringe barrel, improving process reliability by 25%.
Related Products
- ABB PFRL101C-3.0KN: A higher-force variant (3 kN range) for heavy-duty applications like automotive chassis assembly or metal forming.
- ABB IRB 14000: Heavy-duty robot arm compatible with the PFRL101C-1.0KN, designed for high-payload tasks in foundries and construction.
- ABB FTS 300: Force/torque sensor interface module that enhances the PFRL101C-1.0KN with advanced filtering and data logging capabilities.
- ABB SafeMove2: Software package for the IRC5 controller, enabling configurable safety zones and force limits when used with the PFRL101C-1.0KN.
- ABB ATI Mini45: Complementary force/torque sensor for smaller robots, offering similar precision in a compact form factor for benchtop applications.
Installation and Maintenance
Pre-installation preparation: Ensure the robot end-effector or tool mount is clean and free of debris, then bolt the PFRL101C-1.0KN using the provided M6 screws (torque: 8–10 N·m). Connect the sensor’s Ethernet/CANopen cable to the robot controller, using shielded twisted-pair wiring to minimize EMI. Calibrate the sensor using ABB’s RobotStudio software, performing a zero-offset adjustment and verifying measurement accuracy with a known reference force.
Maintenance recommendations: Inspect the sensor’s mounting bolts quarterly for tightness, especially in high-vibration applications. Clean the housing with a dry, lint-free cloth to remove dust or contaminants, avoiding harsh chemicals that could damage the IP67 seal. Use the sensor’s built-in self-diagnostic tool (via RobotStudio) to monitor signal integrity and power supply voltage, replacing the sensor if drift exceeds ±1% of full scale. ABB’s predictive maintenance service can remotely track sensor health, alerting operators to potential issues like cable wear or connector degradation before failures occur.
Product Guarantee
ABB guarantees the PFRL101C-1.0KN 3BSE023316R1002 to meet performance specifications for 36 months from delivery, backed by rigorous testing for mechanical durability (1 million load cycles) and EMC compliance. The sensor’s design adheres to ISO 10218-1 safety standards, ensuring reliability in collaborative robot applications. ABB’s global service network provides 24/7 technical support, including remote calibration assistance and on-site replacement by certified technicians. For high-reliability environments, extended warranties and priority spare parts delivery are available, reflecting ABB’s commitment to maximizing robotic system uptime and operational efficiency.
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