The Factory Automation Magazine 0 2 2 0 1 2 Sensing your Needs Ultrasonic sensors are in tune with your needs Page 2-3 Weathering the storm Page 8
0 2 SENSING YOUR NEEDS EDITORIAL Dear Reader, As the market and technological leader in the field of ultrasonic sensor technology, we have over the last few years focused increasingly on developing an extensive portfolio for the widest range of applications. Our many years of experience and the independent development and production of ultrasonic transducers allow us to satisfy specific market requirements. Today, we are already working on solutions for tomorrow. technology Ultrasonic sensors a Place your trust in 20 years of experien We offer a comprehensive portfolio of small, compact sensors that incorporate different technologies and are designed especially for the highly integrated mechanical engineering sector. There is even a clear trend towards compact designs among ultrasonic sensors, a trend that we have satisfied with our smallest ultrasonic sensors the F77 Series. Our sensors and systems not only ensure safe operation in the factory automation industry, but also in process plants and hazardous areas. The latest highlight is the extremely robust F31K2 inductive double sensor for valve position feedback, which is suitable for outdoor use. See the following pages for more information or visit us at one of the upcoming exhibitions. We look forward to seeing you. Ultrasonic sensors from Pepperl+Fuchs have been used in a wide variety of applications for more than 20 years. Fill level measurement in silos, leveling in road construction applications, or double sheet detection in the printing industry to name just a few examples. All these applications benefit from the power of ultrasonic technology. The transducer is the heart Regardless of color and reflection characteristics, objects can be detected with millimeter precision. The transmission properties are evaluated in order to detect different layers of material and double sheets. Wolfgang Helm Manager Business Unit Sensors
02/2012 0 3 re in tune with your needs ce with ultrasonic sensors Regardless of color and reflection characteristics, objects can be detected with millimeter precision Independent ultrasonic transducer production ensures consistently high sensor quality Benefit from the unique ultrasonic expertise of Pepperl+Fuchs. The degree of vertical integration of our independently developed and produced transducers guarantees a high level of quality and makes us independent of suppliers. Even the coupling layer is manufactured independently. The first ultrasonic sensors were adjusted using a plug-in jumper, but today precision adjustments are made via a Teach-In function, pushbutton, or potentiometer. IO-Link has established itself as the process and parameterization interface among the latest sensors. Powerful microprocessors allow the digital filtering of received signals in addition to the precision measurement of the object distance. Interference in the immediate vicinity is suppressed effectively. The heart of this robust yet accurate measurement process is the ultrasonic transducer. Essentially, a transducer consists of a combination of piezo ceramics for generating a mechanical vibration and an acoustic coupling layer. The transducer largely determines the properties of the ultrasonic sensor, such as the minimum near range, narrow projection cone, and highest IP class. We are working on tomorrow s solutions Over the past two decades, ultrasonic technology has developed into a sensor technology that is easy to use in almost every application. Our large engineering development team is working to develop the solutions of tomorrow and looks forward to finding the perfect solution for your application. Franz-Josef Heimerl Manager Product Management Ultrasonic Sensors n WEB INFO www.pepperl-fuchs.com/ultrasonics
0 4 SENSING YOUR NEEDS PRODUcT Intensive development bears fruit Ultrasonics a technology as diverse as its applications Level control in a water tank is one of the classic applications for ultrasonic sensors. A cylindrical sensor in M30 design can handle heights of four or six meters without any problems. If the pump is controlled with a PLC, sensor installation is limited to mounting and wiring the sensor to the control. The measured value is transmitted via IO-Link or analog output and processed further in the controller. With stand-alone solutions, a few additional steps are required to parameterize the sensor. Empty or full threshold, hysteresis for activating the pump, and averaging system for providing a more accurate measured value during filling all settings can be adjusted easily using parameterization software. The sound cone width can be easily reduced and interfering objects such as a ladder can be suppressed. Intuitive parameterization software allows you to adapt the sensor to specific tasks. Ultrasonics simple application Alternatively, there are simple tasks that ultrasonic sensors can perform with great reliability. One example is the detection of PCBs in a mounting machine. The sensor has the task of accurately detecting the edge of an approaching PCB. Recesses in the PCB and different colored or shiny surfaces do not pose a problem for ultrasonic sensors in F77 miniature design. The flat projection cone of the sensor ignores recesses and reliably detects the edge. Just teaching in the PCB position is sufficient for adjustment of the sensor. Level control with ultrasonic sensors Intensive development pays dividends Two years of intensive development bear fruit: Ultrasonic technology from Pepperl+Fuchs is easy to install and can be used in a wide variety of applications. On the one hand, ultrasonic sensors can be adapted precisely to specific tasks and conditions using intuitive parameterizing tools. And on the other hand, you can select a simple, cost-effective ultrasonic sensor for classic applications. The working distance is adjusted using a simple Teach-In function. Franz-Josef heimerl Manager Product Management Ultrasonic Sensors PCB detection using ultrasonic sensors
02/2012 0 5 PRODUcT Sensing by Ranging Mission 2-D Universal application options for the R2000 laser scanner The innovative R2000 laser scanner was presented for the first time at this year s Hannover Exhibition and was voted into the TOP 5 of the prestigious international technological prize, the Hermes Award. With a measurement angle of 360, a maximum scanning frequency of 50 Hz, and a unique interactive display in the light-emitting surface, the 2-D laser scanner raises the bar in its performance class. Intuitive operation and parameterization The basic device has now been expanded to include additional functions that make it even more suitable for factory automation applications. For example, several monitoring fields can be defined in the sensor. A DTM (Device Type Manager) is available for parameterizing fields and basic functions. The DTM is integrated in an FDT framework application such as PACTware so that the device can be parameterized and operated intuitively. The current scan performed by the device is displayed graphically for the user. The monitoring field can be edited directly in this kind of display. The measured result is output via digital signals. Configurable switching outputs are available for this purpose. In addition to userfriendly operation, a meaningful diagnosis for the relevant application can be performed based on the DTM. Universal application Potential applications for the device include many different types of object detection such as overhang control, distance monitoring, or quality control in the picking process. In combination with reflectors and due to their large measuring range, more applications are possible, such as monitoring large areas. In particular, the measuring angle of 360 means that surface extensions up to 100 m² pose no problems for the R2000. Thorsten Schroeder Product Manager Innovative Photoelectric Sensors The innovative 2-D laser scanner for quality control in the picking process. The R2000 was among the TOP 5 at the Hermes Award 2012
0 6 SENSING YOUR NEEDS Product Small, high-performance sensors for tight spaces The greatest challenges of technology are the limits of physical possibility. The machine builder market is always aiming for more compact, faster machines with higher capacity. In addition to technical excellence, the economic aspect is taking on an increasingly important role. Special packaging machines or machines for manufacturing PCBs are being constantly improved to enhance their overall power density. The mechanical components are becoming smaller and the electronic components that control the systems must be consistently adapted. There is an increasing demand for smaller sensors that offer the performance, speed, and precision of larger sensors. Along with functionality, discrete integration in the machines and simple mounting play an important role. To meet these demanding requirements, Pepperl+Fuchs offers small, compact sensors that incorporate different types of technology: n Inductive technology n Photoelectrics n Ultrasonic technology n AS-Interface Metal detection with inductive functional principle Inductive sensors always detect metals without contact and are therefore wear-free. They are used in numerous applications, such as object detection, counting, and controlling processes. The smallest inductive sensors with fully integrated electronics reliably and accurately detect metallic objects. Whether in cube or cylindrical form, the inductive miniature sensors can fit into the smallest of spaces inside a machine. Advantages of inductive proximity switches include a complete absence of maintenance and outstanding resistance to sources of interference such as dust, dirt, vibration, and moisture. Our inductive miniature sensors are available in a wide range of versions: n Cylindrical housings from only 3 mm in diameter n Smallest cubic housings Works well with any material thanks to ultrasonics Ultrasonic sensors offer a perfect solution in all fields where the reliable detection of objects made from different materials is required. The new ultrasonic generation of the F77 Series with a compact design can accurately detect objects made of the most problematic materials, such as reflective or transparent objects. The narrow projection cone and extremely small blind zone of 10 mm enable the detection of objects through extremely dense clusters of machine components. The F77 Series offers an impressively high degree of immunity to plant noise and can be easily integrated in machines with limited space. The F77 compact series is available in the following versions: n Diffuse mode sensor with background suppression n Retroreflective sensor n Thru-beam sensor with large detection range Inductive technology Ultrasonic technology
02/2012 0 7 Optical precision Photoelectric sensors are ideal for monitoring highly precise positioning processes and sampling rapid events in a machine. Miniature photoelectric sensors fulfill all criteria for user-friendly, time-saving, and universal application in factory automation. The latest development in the miniature housing category is the R2 Series. The special features of the ultra-small series include extreme robustness, user-friendliness, and ease of installation. The extremely small housing with 45 cable outlet allows for space-saving installation in the plant. Due to the flat, scratchproof glass front, the R2 can be mounted close to the moving object. The small light spot and wide selection of functions open up a whole new range of solutions. Our photoelectric miniature sensors are available in different versions: n Smallest cubic standard housings such as the ML6, ML7, and ML100 Series n Application-specific housings such as the ML8 and ML10 Series as well as various fiber optics n Miniature GL5 photoelectric slot sensors Perfectly interlinked with AS-Interface AS-Interface is the standard solution for the simple and cost-effective interlinking of sensors and actuators in the field. Pepperl+Fuchs developed the ultra-compact G10 Series, which is the smallest AS-Interface module worldwide in IP68/69K. These one-piece modules fit in any cable duct and are notable for simple mounting just insert the flat cable, snap shut, and tighten the screw. The unique swivel mechanism ensures a reliable contact. These compact AS-Interface modules can control motors intelligently and help save energy. Sensors and DC motors are connected directly. This innovative, energy-efficient concept from Pepperl+Fuchs won this year s German industry prize Automation with AS-Interface as a Contribution to Climate Protection. New in the ultra-compact G10 Series: n Digital module now available with two outputs n Smallest safety module worldwide with IP67 n A large variety of junction blocks n WEB INFO www.pepperl-fuchs.com/small-sensors The small, ultra-compact sensors from Pepperl+Fuchs offer the performance, speed, and precision of larger sensors Photoelectrics AS-Interface
0 8 SENSING YOUR NEEDS PRODUCT Weathering the storm Valve position sensing in harsh environments The F31K2 dual inductive sensor is the ruggedized and weather-proof solution for valve position sensing Valve position sensor solutions for standard pneumatic actuators are typically used in process automation applications, such as chemical, petrochemical, offshore, oil and gas industries. Traditionally, limit switch boxes with mechanical, magnetic, or inductive contacts are used to detect the position of the valve in valve actuators. However, open solutions becoming more and more popular in the market due to their compact design and easy installation. Designed for today s valve automation Pepperl+Fuchs new F31K2 valve position sensor completes the family of the most contemporary direct-mount, open solution products for valve position sensing. Our sensor product portfolio includes the F25 Series for manual valves and small-sized pneumatic actuators, the F31/F31K Series for small and medium-sized actuators with a wide range of electrical versions available, and the new F31K2. The F31K2 is the most flexible, ruggedized, and weather-proofed model yet. An extended temperature range of -40 C to 75 C along with numerous options for electrical connections are just some of the features inherent in a sensor designed for today s valve automation and communication requirements. Well protected The F31K2 s unique double housing construction provides double mechanical protection and impermeability for unlimited outdoor use. Typical areas of use include outdoor applications in standard and hazardous areas. The sensor electronics and highly visible LEDs are integrated in the inner housing and the terminal compartment is located in the outer housing. The translucent, impact-resistant housing requires no additional sealing. The construction materials provide high UV protection, extended temperature range and corrosion resistance. These features combined with the highly visible valve position indicator turn the F31K2 into the ultimate outdoor sensor for valve position feedback. Thomas Wirth Product Manager Sensors n WEB INFO www.pepperl-fuchs.com/f31k2
02/2012 0 9 APPLIcATIOn Safety in the coupling station The RFID solution for hazardous areas In chemical, pharmaceutical, and aseptic plants, different materials must be transported and combined safely. Errors that occur when fluids are filled or mixed in process plants can result in significant damage and incidental costs. Reliable checks for the right hose connection and monitoring of the correct flow volume are decisive economic factors for plant operators. Protected processes The scope of applications of the RFID system includes food technology. Pipes for food products are purged regularly with cleaning solutions. The different materials for food production and cleaning pipes must always remain separate. RFID is used to check and reliably control processes such as pre-purging, cleaning, and rinsing. The correct hose connection assignment is important when filling tanks with pressure monitoring for final shutdown. If the pressure sensor for the adjacent tank is connected inadvertently, there may be a danger of the tank bursting due to overfilling. The new RFID solution for explosion Zone 1 and 21 (2G/2D) now allows the automated monitoring of hose connections in hazardous areas and safeguards the process sequence as a result. Dr. Konrad Kern Product Manager Systems The RFID solution for explosion Zone 1 and 21 ensures safe process monitoring in the coupling station The correct hose RFID technology is used in the coupling interfaces of the hose connections to avoid line failures and process interruptions. The new RFID system for Zone 1 and 21 (2G/2D) automatically detects whether the hose and coupling are assigned correctly. If the connection is incorrect, the valve does not open and an error message is issued. The RFID tag is attached to the hose and the reader to the coupling. The tag and reader can be inserted fully into metal. The entire RFID system is extremely mechanically robust because the installation is protected. A large selection of LF and HF read/write tags are available to the user.
1 0 SENSING YOUR NEEDS IMPRInT Publisher: Pepperl+Fuchs GmbH Lilienthalstrasse 200 68307 Mannheim, Germany Phone: +49 621 776-4411 E-Mail: fa-info@pepperl-fuchs.com Editorship: Diana Weissenfeld E-Mail: dweissenfeld@de.pepperl-fuchs.com PRODUcT Unmatched versatility in hazardous areas Rotary encoder certified according to ATEX and IECEx Whether for positioning or speed feedback explosion-protected rotary encoders from Pepperl+Fuchs are the perfect match for applications in hazardous areas in oil or gas extraction and in the chemical industry. to flameproof enclosure ignition protection class (Ex d) and meets the international ATEX and IECEx requirements for gases according to Zones 1 and 2 and dust according to Zones 21 and 22. As a result, the rotary encoders are suitable for global use. Editorial staff: Irmtraud Schmitt, Katja Hilkert, Susanne Gajewski graphic design and layout: Paolo Dell Orto E-Mail: pdellorto@it.pepperl-fuchs.com Edition: 40,600 Year of publication: 2012 Frequency of publication: semi-yearly Place of publication: Mannheim, Germany Printed by: Trassini Printing S.r.l. Via Marzabotto, 27 20871 Vimercate (MB) Italy Pepperl+Fuchs GmbH. The robustness and flexibility of the recently developed 78E rotary encoder series are impressive during operation. The absolute rotary encoders output a uniquely coded numerical value at each shaft position, even over several rotations. The output data is transmitted to the controller via an SSI interface or PROFIBUS, CANopen, or DeviceNet fieldbus. Approved for worldwide use The compact housings are 78 mm in diameter and available in anodized aluminum or stainless steel. For the mechanical connection, users can select between a clamp and synchro flange. With a maximum speed of 3000 rpm, the rotary encoders are designed for a temperature range of -40 C to +70 C and correspond to temperature class 5 or a maximum permitted surface temperature of 100 C. The 78E Series corresponds Modular design A special feature of the 78E rotary encoder is the modular design with removable connection cover. The connection covers are supplied either with a cable or with only a certified cable gland. This provides the option of customized cabling. In addition to simple installation, the modularity facilitates maintenance, as the rotary encoders can be replaced independently of the cable. For fieldbus versions, bus coding takes place in the connection cover. This means that the user can program the relevant address on site and set the terminator if required. Stefan horvatic Product Manager Rotary Encoders All rights reserved. No part of this newsletter may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, whithout the written permission of the publisher. Part No. ENU200237 Rotary encoders from the 78E Series are robust and flexible in oil and gas production applications
02/2012 1 1 PRODUcT Vision goes Fieldbus Positioning systems with fieldbus interfaces for industrial applications In factory automation, industrial vision positioning systems are a component of technological progress. Vision sensors ensure the automatic, highly accurate positioning of stock feeders, predominantly in material handling applications. As a result, goods are loaded and unloaded from the rack fully automatically. The PHA vision sensor requires only a single hole in the rack for rack fine positioning The PCV Data Matrix positioning system uses a Data Matrix code tape routed in the longitudinal direction on the drive unit and vertically on the lifting unit, in order to detect the exact position in the X- and Y-direction at any time. The stock feeder uses the absolute position to locate the correct lanes and determine the rack height. At this point, the PHA vision sensor is used for rack fine positioning. Only a single hole in the rack structure is required to precisely position the stock feeder and load or unload the goods accurately. However, the bundle only becomes really interesting when the PHA and PCV communicate via fieldbus interfaces such as PROFIBUS or PROFINET and are operated using internal switches, e.g., in a linear topology. Both vision sensors then demonstrate their full performance capability. Simple wiring saves costs and saves time during commissioning. You benefit from the full diagnostic capabilities during operation. In the future, put your trust in vision sensors with a fieldbus. Armin hornberger Product Manager Industrial Vision Components PRODUcT The all-purpose performer in optical object detection MLV41 Series now equipped with IO-Link throughout The MLV41 Series is an all-purpose performer in optical object detection. It offers the right sensor technology for every application and is equipped with standardized IO-Link communication interfaces throughout. The standardized parameterization and operation of Pepperl+Fuchs IO-Link sensors across all products considerably simplifies commissioning, diagnostics, and maintenance of the devices. Not only do you save time, but also costs in the long term. The newest member of the MLV41 family is the flexible quick-change artist MLV41-8-H-IO. The sensing by ranging sensor with integrated measuring principle detects the presence of an object based on the distance to the sensor, thereby guaranteeing accurate object detection in comparison with pure sampling methods. Parameterization options for the measuring principle via IO-Link allow the devices to be perfectly tailored to the requirements of different applications. The MLV41 Series with IO-Link interface offers advantages on every level This technology is packed into a robust metal housing with a corrosion-resistant Delta Seal coating that ensures that the sensor will function even under harsh ambient conditions. holger Unger Product Manager Photoelectric Sensors n WEB InFO www.pepperl-fuchs.com/io-link
1 2 SENSING YOUR NEEDS 02/2012 APPLIcATIOn high-tech fruit harvesting Sensors for mobile harvesters Between August and November, more than 1,000,000 tons of apples are harvested in the largest apple-growing region of the EU in South Tyrol, Italy. In dealing with these enormous quantities, the South Tyroleans have long since dispensed with traditional fruit-growing accessories. Ultrasonic sensors mounted on the side at the front of the chassis allow automatic driving and steering between the rows of trees. Trees on the left and right of the vehicle act as sound reflectors. The machine is thus kept in the alley automatically without the need for steering movements by the EVENTS SPS/IPc/Drives, nuremberg/germany 27-29 november 2012 Valve World Expo, Duesseldorf/germany 27-29 november 2012 BAU, Munich/germany 14-19 January 2013 LogiMAT, Stuttgart/germany 19-21 February 2013 CONTACT Please address suggestions and questions regarding this newsletter to: Pepperl+Fuchs gmbh Lilienthalstrasse 200 68307 Mannheim Tel. +49 (0) 621 776-4411 Fax +49 (0) 621 776-27-4411 E-mail: fa-info@pepperl-fuchs.com www.pepperl-fuchs.com Harvesting systems with fully automatic controls are used instead. The South Tyrolean company BerMarTEC is one of the leading manufacturers of modern harvesting and multipurpose machines that guarantee efficiency, quality, and the greatest possible degree of occupational safety. The sometimes extremely steep South Tyrolean slopes pose a particular challenge here, which BerMarTEC meets with a wide range of sensors from Pepperl+Fuchs. Inclination sensors from the F99 Series allow noncontact measurement of inclination angles. The measured values provide for automatic leveling of the work platform. As soon as the inclination exceeds a permissible value, an audible signal sounds. The machine stops and can be lowered safely. Mobile equipment sensors ensure a high degree of safety when harvesting in fruit plantations harvesting personnel. Ultrasonic sensors also detect obstacles in the path and stop the machine in order to avoid collisions. With its automatic steering function, the PMI F90 inductive positioning system monitors the steering angle and allows safe turning maneuvers in the tightest of spaces. The high degree of accuracy and robustness of mobile equipment sensors from Pepperl+Fuchs meet the highest demands for quality and safety. Harvesting machines from BerMarTEC travel at controlled speeds through the tree rows and lift fruit pickers safely to the tree tops. Thomas hensler Product Manager Sensors Worldwide headquarters Pepperl+Fuchs GmbH Mannheim Germany E-mail: fa-info@pepperl-fuchs.com USA headquarters Pepperl+Fuchs Inc. Twinsburg, OH USA E-mail: fa-info@us.pepperl-fuchs.com Asia Pacific Headquarters Pepperl+Fuchs Pte Ltd Singapore Company registration number: 199003130E E-mail: fa-info@sg.pepperl-fuchs.com www.pepperl-fuchs.com Copyright Pepperl+Fuchs ENU Part No. 200237