application reports success stories from the real world 2016

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APPLICATION REPORTS Success stories from the real world

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Page 1: Application Reports Success stories from the real world 2016

APPLICATIONR

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Success stories from the real world

Page 2: Application Reports Success stories from the real world 2016

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Kusch+Co: Precise photoelectric sensors for perfect edges 4 - 5

Hassia Mineralquellen: Permanent vibration diagnostics 6 - 9

Gustav Eirich GmbH & Co KG: Worldwide access to the sensor 10 - 13

KLN Ultraschall: Ultrasonic cleaner completely wired with AS-i 14 - 17

Zwettler Beer: Fit for the future 18 - 21

Chocolate museum: Only ensured by the exact temperature 22 - 23

Wessel-Werk: RFID meets AS-i 24 - 25

Gritzke – Automatic levelling system for graders 26 - 29

Gritzke – Depth control system for hydraulic excavators 30 - 31

NOBA Verbandmittel: Efficient, new power supplies 32 - 33

Romfil: Process monitoring for water filtration 34 - 36

Automation in agriculture – windrow recognition 38 - 40

Automation in the real worldEveryday, millions of ifm sensors are used in a variety of plants and machines worldwide. Our communication and control systems are the basis for a problem-free process flow. This brochure shows examples from different industries. Learn how and where our customers use ifm systems and what “success

stories” they tell. And above all, get inspired and find out how you can automate your plants easily and reliably with our solutions. Enjoy reading!

Andreas BiniaschEditor

Contact: [email protected]

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Application report Kusch+Co

High-performance diffuse reflection sensorsare used for contour detection during theprocessing of veneer top surfaces thus en-suring highest quality during the sandingprocess.

The medium-sized enterprise Kusch+Co from Hallenberg,Sauerland, is a manufacturer of design-oriented seatingand tables for furnishings. The furniture can be found innumerous international architectural objects worldwide.In the field of airport seating Kusch+Co is one of theworldwide leaders furnishing waiting areas in more than200 international airports.One of the numerous processing steps during the manu-facture of furniture is smoothing and levelling of veneersurfaces. A sanding machine from the company Heese-mann optimised by Kusch+Co is used for large furniturepanels such as table tops for conference tables.The challenge during the sanding process: The edges ofboth the outer ends and the cut-outs of the high-qualityveneer must not be rounded by sanding. Therefore no

pressure must be applied by the sanding shoe segmentswhere there is no veneer underneath. For this reason thecontour and cut-outs of the workpiece, if any, are detectedduring each cycle and transferred to the controller.

53 lowerable pressure shoe segments adapt to the surface ofthe workpiece geometry during sanding. That avoids undesiredrounded sanding edges.

Precise photoelectric sensorsfor perfect edges

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n Sensor replaces mechanicsThe problem of this longitudinal sanding machine used tobe the scanning of table tops because this scanning waseffected by mechanical switches. The table top was de-tected via levers with rollers and evaluated by an old PLC.The PLC inputs only require a small current of approx. 1 mA. There used to be problems with the switching con-tacts of the mechanical switches since they did not switchreliably when the contacts were worn away in the courseof time. Another big problem was the detection by therollers. The sanding dust took its toll on the rollers’ bear -ings thus causing the rollers to fail more and more often.The rollers caused stress marks on the veneer so that thetable top could no longer be used. So they were lookingfor a solution using non-contact detection without mechanical switches. The technical service at Kusch+Cofound it from their long-standing supplier, ifm electronic.The company ifm provided its diffuse reflection sensors ofthe O6 design free of charge and after tests such as thereaction of the diffuse reflection sensors to dust and to the different colours of the veneers, showed that thesensor met all required criteria. In this context the PLC was also completely updated andthe sensing of the diffuse reflection sensors was visual isedon a 19" display to show any wrong detection at an earlystage.

n Optical contour detectionNow 51 compact ifm diffuse reflection sensors of the O6design detect the contour and cut-outs of the furniturepanel from the front and another 51 from the back, bothwhen the panel is moved forward and backwards under -neath the sanding belt. Depending on the workpiecegeometry and the individual cut-outs they control the upand down movements of the individual pressure shoesegments via a PLC. This avoids excessive pressure on theedges caused by the neighbouring pressure shoe seg-ments. The result are precise, right-angled edges.The requirements on the photoelectric sensors that arealigned like a scanner strip are high: Different veneerswith light, dark, matt or glossy top surfaces have to be

reliably verified without the sensors having to be read-justed. Simultaneously the background, i.e. the contactarea, has to be suppressed. Depending on the thicknessof the furniture panel this means a range of a few millimetres. Therefore sensors with precise backgroundsuppression are required.

n Small photoelectric sensors with high performance

The sensor specialist from Essen supplies the suitable sen-sors – its diffuse reflection sensors of the O6 design. TheO6H201diffuse reflection sensors feature an adjustablerange from 2 to 200 mm. The maximum range is colour-independent. It applies, for example, both to white surfaces with 90% remission and black surfaces with just6% remission. Readjustment for surfaces of different reflectivity is not necessary for these ifm sensors.The diffuse reflection sensors suppress background inter -ference effectively. Depending on the distance and thedegree of remission of the object surface distances ofonly a few millimetres can be reliably differentiated. Inaddition the background suppression is extremely inter-ference immune: Even highly reflective backgrounds suchas stainless steel or reflections caused by moving machineparts do not influence the detection. The clearly limited round light spot of only 8 mm diameter(at maximum range) provides a homogeneous light distribution in the light cone. Scattered light around thelight spot potentially disturbing other photoelectric sen-sors due to reflections is avoided. This ensures additionalreliability in particular in this application where the sensorsare mounted closely to each other.

n ConclusionThe high-performance photoelectric sensors of the O6 design ensure optimum sanding results – a perfectexample of two leaders on the worldwide market com-bining their competences.

O6 miniature photoelectric sensors with high-performance. Setting of ranges via potentiometer and a rotary switch is intuitive and simple (light-on / dark-on selection).

The controller receives an image of the workpiece from thesensors and controls the lowering of the individual sandingsegments.

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these stress points add up – via hundreds of bottles –to strong irregular vibration at the drive. Therefore thebearings on the gear and motor have to be monitored topredict the wear limit in time so that maintenance canbe carried out.

To avoid unplanned machine downtimesHassia Mineralquellen rely on permanentelectronic vibration diagnostics in bottle filling. The investment already paid off inthe pilot phase: Imminent damage to adrive was detected in time and eliminated. Unplanned downtime could thus be pre-vented.With an annual output of about 765 million litres theHassia group is one of Germany’s largest mineral springsoffering mineral waters and non-alcohol beverages in theupper price classes with various subsidiaries and brands.In the parent plant in Bad Vilbel, Hesse, alone there aresix filling stations parallel in three-shift operation. High-performance drives transport the bottles across several hundreds of metres through the individual stations – from rinser, filler, capper, labelling to packagingand dispatch. When the bottles pass from one conveyor belt to the nextand when bottles touch the guide rail and each other,

Application report Hassia Mineralquellen

Sensors detect in time that the wear limit on the motor and gearbox has been reached.

Permanent vibration diagnosticsin mineral water botteling

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n Manual detection of soundsA common method to monitor vibration characteristicsis the manual, acoustic detection of sounds using a stethoscope. Gerhard Simon, Maintenance Manager at Hassia Mineral-quellen, says: “In the past we used to monitor manually.A person was sent to the machine to listen to the soundof its motor. That was, however, a rather subjective feeling. Three people listening to the drive, motor or gearfeel completely different things. This manual listening hasone decisive disadvantage: There are never the same operating states when listening three times. I must listento the machine when it is rotating, but I cannot do it during the filling process, e.g. filler / rinser areas, for microbiological reasons: You cannot enter this cleanroom during filling. That means you can only do it at theweekend when there is no filling. During idling opera-tion there is, however, a different vibration characteristic.And then there are areas, for example at the labelling machine, where drive shafts are running, where the motors and gears are very close to each other. You can‘tget in there when it’s running.”

n Electronic vibration diagnosticsThere was urgent need for another solution for machinediagnostics. The automation and sensor specialist ifm offers vibration diagnostic systems under the name“efector 800”. Quickly a meeting was agreed.Gerhard Simon: “We have decided to make first testswith the electronic vibration diagnostics on one of ourreturnable PET bottle plants. Some machines such as Spiragrip, the machine cleaning machine, de-labellingmachine, decapper and the filler-rinser area were equippedwith the sensors.”

The system consists of type VSA001 vibration sensors andtype VSE100 evaluation units.The cylindrical sensors are screwed directly into the motoror gearbox via bore holes. They continuously detect vibration on non-rotating machine surfaces.

They operate according to the capacitive measuring principle and are free from saturation and tribo-electricalnoise interference thanks to their special microelectro-mechanical design (MEMS). An integrated self-test pro-vides additional protection.The type VSE evaluation unit monitors up to 32 acceler -ometers (objects) on up to 4 different measurementpoints where a type VSA vibration pick-up is installed.

Vibration sensors on the drives detect even smallest vibrations.

The VSE100 evaluation unit evaluates the signals from up tofour vibration sensors.

Sensors allow vibration diagnostics in places that you couldnever access during operation for safety reasons.

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Application report Hassia Mineralquellen

The pre-alarm and main alarm are provided via switchingoutputs and, as is the case at Hassia, via light indicators.The evaluation unit communicates for example with the machine controller or the process control level viaEthernet TCP/IP.Gerhard Simon: “Here I have a value-free system whereI can define my own limits and say “OK that is my level,I do not want to exceed it, there I must intervene andmake some mechanical improvement, for example by lubrication or replacement of components”. Before thiswas not possible.”

n Crucial test passedShortly after installation the vibration diagnostics was already successful in a major challenge.

“After just a few weeks we had first successes when animminent plant downtime was detected by the vibrationdiagnostics on the basis of a mechanical disturbancevalue. We could make a repair in time thus preventing aplant failure. The yellow light indicators signalled a pre-alarm. Then the machine was thoroughly inspected at

The vibration characteristics can be visualised on the PC in thecontrol room; furthermore the operator can set limits (yellowand red lines for pre-alarm and main alarm).

the weekend and it was found that a bearing had increased tolerances at a transfer starwheel where thebottles are transferred from the rinser to the filler andalso a shaft that drives the rinser and the capper blockwas off-centre causing vibration in the entire system. Wecould repair these sources of interference thus prevent -ing an unplanned stop in the middle of production whichwould have had fatal consequences in a 3-shift opera-tion and meant immense cost.” said Gerhard Simon.

n Full protectionBesides local display of the vibration status by indicatorlights the evaluation unit can also be networked with thecontrol desk via Ethernet TCP/IP.

Here Hassia plan a further extension of their plant. Maintenance Manager Simon: “At the moment only onesingle line is networked through to a staff working station. We will gradually extend this. The other threelines are at present monitored by operators who informthe maintenance staff about a yellow pre-alarm or a redmain alarm displayed on the lindicator lights. Then we can react in time. But the system is being gradually extended. The goal is that we in maintenance can per-manently monitor the live state of our systems. So farwe have been monitoring four machines in our pilotplant.In the future we want to monitor the entire plant bymeans of vibration diagnostics and to document whathad to be replaced in what kind of damage event so thatthe plant can be further optimised, if necessary. We alsowant to record the cost to prove that the investment intothe diagnostic system has paid off. I have many moreideas for the system: We have numer ous pumps in such

Gerhard Simon, Maintenance Manager at Hassia Mineralquellenin Bad Vilbel.

Visual status monitoring on site: The light indicators for “pre-alarm” and “main alarm”.

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plants that should be monitored and very many subsy-stems and auxiliary drive systems that could be monito-red to be able to intervene any time before a standstill isabout to occur.”

n Pioneer praisedThe decision to secure process reliability by means of permanent vibration diagnostics was particularly pointedout at the annual IFS (International Featured Standards)audit, a certification common in the food industry. Gerhard Simon: “In the beverage industry we are probably the first bottling plant that has started to work with the ifm vibration diagnostics. The final reportparticularly mentioned that in maintenance we are starting with monitoring such systems in the plant whichlogically has effects on the product safety. Because if they have a standstill in their plant this plant has to beemptied. This emptying process is necessary to avoidgerms in cleaned bottles that are standing on the belts incase of repair or germs in the clean room should workbe carried out there. This means that a repair that onlytakes 30 minutes can cause a standstill of up to 2 hours.This would entail unnecessary costs.”

n ConclusionThe wear of machine parts cannot be prevented. Per-manent vibration diagnostics, however, ensures that suchdamage is reliably detected in time. Maintenance cannow be planned. Expensive plant downtime can be prevented with comparably little investment which in theend has positive effects on the product quality.

Different machines in filling are monitored by means of vibration diagnostics.

Page 9: Application Reports Success stories from the real world 2016

The company Maschinenfabrik Gustav EirichGmbH & Co. KG uses IO-Link for networkingof their systems on sensor level. This allows highly granular process moni -tor ing down to each individual sensor andactuator. Parameter setting and diagnosisare carried out centrally. Even worldwide access to each individualsensor is possible. This gives maximum trans-parency to the plant operator in processmonitoring and remote maintenance.

Maschinenfabrik Gustav Eirich, a family-owned companywith 150 years of history and a worldwide presence, is atechnology leader in the field of material preparation and,among others, produces mixing systems for different industries. One current example is a highly-complex mixingsystem for the production of lead paste for car batterieson the basis of exothermic reactions under vacuum. Sophisticated process technology regulates the pressureconditions, temperatures, moisture and fluid supply.

The condenser is an important process element, situatedon a platform above the actual mixer. It cools the warmair extracted from the mixer and feeds the condensedmoisture back into the process.

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Application report Gustav Eirich GmbH & Co. KG

Sophisticated process technology: In the condenser above theactual mixing system, different sensors and actuators monitorand control the process.

Worldwide access to the sensorCommunication of the plant control down to the sensor via IO-Link

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Flow and temperature sensors from ifm are positioned inthe supply and return of the cooling circuit of the con-denser, precisely monitoring the flow. Features of theseifm sensors: they are equipped with IO-Link.

n Interface for the “last metre”IO-Link is a point-to-point interface for the connection of any sensors and actuators to a control system. In com-bination with other bus systems and network levels, it enables for the first time a consistent vertical commu-nication from the process control level down to each individual sensor.

Networking with IO-Link: The ifm flow meter SM9000 is posi-tioned in the cooling circuit of the condenser. Process values,parameter values and diagnostic information are exchangedbetween sensor and controller via IO-Link.

Interface for the last metre: IO-Link is a manufacturer indepen-dent point-to-point interface for the connection of any sensorsand actuators on field level. Using IO-Link, parameter setting ofsensors, diagnosis of plant states and loss-free transmission ofmeasured values on all communication levels are possible.

IO-Link is not another bus system, but an add-on for theconnection of the “last metre” to the sensor or actuator.In contrast to conventional fieldbus systems, there is nobus wiring but parallel wiring.IO-Link is suitable for binary and analogue sensors. Thefeature of IO-Link sensors is the extension of the switching status channel by a communication mode. It isconnected to the same pin as the switching output ofconventional sensors (pin 4 for M12 connectors). The signal level is at standardised 24 V DC. So all existingconnection cables can still be used for IO-Link units. IO-Link sensors are 100 % downward compatible withconventional sensors.

n CommunicationIO-Link sensors command three types of communication:• Switching status

(operating principle like conventional sensors).• Cyclic process data

(e.g. digital transmission of measured values).• Transmission of device parameters and diagnostic data

(e.g.: “fault in sensor electronics”, “device temperaturetoo high” or “photoelectric sensor contaminated”).

The connection of the “last metre” is done via an unscreened 3-wire M12 standard cable up to a length of20 m. Process data, e.g. measured values, is transmitteddigitally. This reduces D/A and A/D conversion losses to a minimum. This ensures, for example, that the con-troller can process the high accuracy of a pressure measuring cell without any loss. In the communication mode, e.g. 16 bits of process dataare transmitted per cycle. With a baud rate of 38.4 kbaudthe cycle time is 2.3 ms. Per cycle, up to 32 bytes of pro-cess data can be transmitted in both directions (input /output).

n Simple replacement of unitsParameter setting of sensors and actuators can be done“by the press of a button” on the control level, or evenautomatically. Complex parameter setting of each sensoron site, e.g. if recipes or tools are changed, is a matter ofthe past. Data storage in the IO-Link master enables a simple and reliable replacement of units. The IO-Linkmaster immediately detects when a faulty unit is replacedby a new identical one and writes the saved parametersof the replaced unit into the new device. As an alternative to parameter setting via the controller,ifm offers the LINERECORDER SENSOR software. It allows parameter setting of IO-Link sensors on the PCvia a USB adapter. Further functions are the recordingand distribution of parameter sets (duplication), the detection and evaluation of sensor values over a longerperiod as well as the reset of sensor parameters to factorysettings. By importing sensor libraries (IODDs), IO-Link sensors of other manufacturers can also be managed using LINERECORDER SENSOR.

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Another trump card for parameter setting via IO-Link. The replacement of sensors is particularly safe thanks toIO-Link, because the parameters are automatically trans-mitted from the controller to the replacement unit. So, wrong sensor settings by the installer are virtually excluded. In addition, the device identification checkswhether the intended unit is connected to the port.

In addition to parameter setting, process monitoring playsa decisive role. On the dispaly in the control room, thesensors are visualised and evaluated with all parametersand measured values. “By using IO-Link, we can see rightdown onto the field level in our process control system”,says Blatz. “We can set device parameters, we obtaindiagnostic information about the units and can gain a fair amount of profit in our systems on the basis of condition monitoring.” Because by linking and evaluating measured values anddiagnostic data, critical plant conditions such as wear orharmful deposits can be detected and remedied at anearly stage. So, unplanned machine downtimes can belargely avoided.

Another option for “data backup” for IO-Link sensors isthe memory plug. This compact component allows easycopying and saving of sensor parameters. When a dataset is stored on the memory plug it is copied from theplug's memory to a new sensor as soon as a sensor ofthe same type is connected. The memory plug can be temporarily plugged onto thesensor for simple parameter setting. As an alternative, itcan remain permanently connected between sensor andconnection cable without any adverse effect on thefunction or output signals of the sensor during opera-tion.All of this saves time and prevents parameter settingfaults during setup or replacement of units.

n Why IO-Link?Hendrik Blatz, in charge of sensors at EIRICH, explainswhy the company decided to entirely equip the mixingsystems with IO-Link: “The process technology behind our systems is very com-plex, therefore a lot of process measurement technologyis spread in the field. Due to the parameter setting ofthese instruments, the setup is often relatively complexand time-consuming. Therefore we needed a solution for centralised parameter setting and diagnosis of theseinstruments.”At EIRICH, remote parameter setting of the sensors in thecontrol room is possible thanks to IO-Link. This is of particular advantage because the sensors in big systemsare often widely spread in the field, e.g. on top of a siloor down in the basement. In small, compact systems ormachines however, sensors are often very close to eachother and therefore hardly accessible.

Application report Gustav Eirich GmbH & Co. KG

Keeping track of all details: From the control room, the operator has access to each individual sensor and actuator in the system. This facilitatessimple diagnosis.

Detailed visualisation: This is the visualisation of the flow meterin the control room: Thanks to IO-Link, not only the currentflow rate, but also the medium temperature and total quantityare transmitted.

Easiest data storage for IO-Link sensors: The memory plug is aplug with storage medium. When the memory plug is used incombination with IO-Link sensors it reads the data and param -eters automatically and saves them.

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n Manufacturer-independent standardAnother argument for EIRICH is that IO-Link is manufac-turer-independent. “We sell our machines and systems to many different in-dustries all over the world and we need to comply withthe national regulations. Therefore, it is important for usto use a very open standard", Hendrik Blatz says. Usingcorresponding modules, IO-Link can communicate withthe controller via common bus systems, such as AS-i orProfibus.” Due to the changing requirements, it is particularly important for us that the standard we use is fieldbus-independent and also independent of the higher-levelcontrol system." The specifications of the manufacturer-independent andfieldbus-independent system have been submitted to andadopted by IEC as 61139 (CiD). ifm as a sensor manufac-turer is a member of the IO-Link consortium and has beendecisively involved in the implementation of the specifi-cation.

Maximum transparency: With IO-Link, all sensor parameters can be displayed, set, read and stored in the plant controller.

n ConclusionSensors with IO-Link ensure greatest possible transpar -ency in the plant. In addition to central parameter setting, extensive diagnosis is a big plus for plant main-tenance and fault diagnosis. Hendrik Blatz‘s summary: “We can access the plant remotely via our VPN tunnel, for example: What are thesensor settings? Is there a problem? In short: Worldwideaccess down to the sensor. This is really great.”

Page 13: Application Reports Success stories from the real world 2016

particles or other deposits for further processing or finishing. One example is the removal of the fine abrasivedust in glass processing, for example when optical lensesare made. Ultrasonic cleaning is also used for cleaningequipment itself. The system shown here serves to cleanmicroscopically small nozzles which are used to make plastic fibres. The range of equipment is as wide as the area of appli-cations: from small, standardised compact devices to in-dividual equipment as big as a garage. The cleaning equipment is often an integral part of a pro-duction process. A failure would stop the whole process.Therefore, maximum reliability is needed. And in case ofa problem quick fault location should be possible. Besidesreliable sensors and actuators wiring is also important forreliability and diagnostic capabilities.Here, the fieldbus system AS-Interface (actuator sensorinterface, in short AS-i) shows its strength. Instead of

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Water set to 30,000 pulses per second removes even microscopically small dirt particlesfrom surfaces or very thin gaps by means of ultra-fine cavitation explosions. And this atlocations which are inaccessible from the outside, for example, with a water jet.

KLN Ultraschall from Heppenheim is a specialist for building such equipment for useworldwide. The design of the plant's control system is as clean a job as the cleaned parts.Instead of complex cable harnesses the slim bus system AS-Interface is used.

Application report KLN Ultraschall

All sensors are connected to the bus system AS-Interface (AS-i)using modules.

A clean jobUltrasonic cleaner completely wired with AS-i

In numerous production areas ultrasonic cleaning is used.Often after mechanical machining processes to ensurethat the part is absolutely free, for example, of abrasive

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complex and confusing cable harnesses communicationis carried out at sensor level using a flat two-wire AS-ibus cable. Dieter Bickelhaupt, Manager Cleaning Technology atKLN: “For us size, flexibility and very quick decentralisedinstallation at any location of the plant are major advantages of AS-i”.As with the sensors, KLN also relies on solutions of ifm for fieldbus communication. The automation specialistsupplies all components for a comprehensive communi-cation solution with AS-Interface from insulation displace -ment connectors, I/O modules to master gateways. “At the time we were one of ifm’s first customers whoused AS-i with resounding success. ifm’s product range isideal for our applications,” said Dieter Bickelhaupt.

n Manufacturer-independent standardAS-i is a manufacturer-independent standard for con-nection of actuators and sensors of the first field level. Itis the only wiring system which is accepted worldwideand based on the IEC 62026-2 standard. With over 15 million installed slaves it proved a low-cost and robustfield bus system for all industrial controllers. Thanks to the standardised system, little wiring and the toolless quick-connection technology AS-i ensuressimple “plug & play” for installation and set-up. Anotheradvantage which is not to be underestimated: Fewer terminals lead to much less documentation.Dieter Bickelhaupt: “In the past we wired conven -tionally, i.e. using a terminal box system and directly viathe inputs and outputs of the PLC. Wiring was complexand needed much space in the plant and control cabinet.”With AS-i, however, data and energy for the connectedsensors / actuators are transmitted via a two-wire flatcable. The keyed insulation displacement connectiontechnology helps avoid installation errors. The modulardesign and the freely selectable network structuresmoothly fit to the plant structure and provide a maxi-mum of flexibility to the plant developer.

n Everything via a yellow cableFor the process control different sensors and actuatorsare installed in the cleaning facility: For example, induc-tive and photoelectric sensors are used to monitor theposition of the trolleys where the parts to be cleaned areinserted and then brought to the cleaning facility. Process sensors monitor the temperature and level of theliquids in the cleaning stations. Binary switching signalsand analogue process values, for example, temperaturevalues, are transmitted to the controller via the AS-i bus. An example of sensors with combined actuators are thesafe AS-i door switches with guard locking. If they receive an “enable signal” from the controller viaAS-i, locking is released and the pull-out can be opened.This prevents the user from unintentionally removing thepull-out from the facility while cleaning or placement ofthe clean parts is in process.

n On the safe side with AS-iThe system also integrates safety-related devices. Besidesthe door switches with locking actuators these are mainlye-stops and fail-safe inductive sensors for position detection.

After cleaning the user can remove the clean parts from these pull-outs.

Thanks to these safety-related AS-i door switches with guardlocking the pull-outs cannot be opened unintentionally whilecleaning is in process.

“Safety at Work”: This fail-safe inductive sensor for positionmonitoring is connected to the controller via AS-i.

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Here AS-i plays another trump card: Thanks to the extended AS-i standard “Safety at Work”, safety-relatedsignals can also be transmitted via the yellow flat cable.A separate cable for safety-related signals is not needed.Special safety modules monitor the communication onthe bus. Safety components up to the highest control category 4 to EN 954-1, SIL 3 to IEC 61508 and EN ISO 13849-1 / PL e can be connected via AS-i.

n From the sensor to the plant controller The sensors and actuators are connected via the input /output modules, also called slave in the AS-i network.Normally these modules are installed at a decentralisedlocation near to the sensors. They connect sensors / actuators to the AS-i bus via standardised M12 connections. The bus is inserted intothe module lower part in the form of a yellow two-wireflat cable.The insulation displacement technology ensures a reliableconnection. The advantage of this installation: The modules can be connected to the bus cable at any location, also at a later point in time. Thanks to AS-i additional sensors and actuators can be installed in theplant simply, quickly and at low cost. ifm offers different modules for control cabinets, field installation or as PCB solution. They are available with different configurations on digital inputs and outputs,analogue inputs / outputs or special connections such asfor Pt-100 temperature sensors.ifm also offers “intelligent” sensors and actuators withintegrated AS-i bus connection, e.g. pneumatic valves,inductive AS-i sensors or the e-stops used here. Theyneed no special AS-i module and can be directly connec-ted to the AS-i cable as a slave via a flat cable insulationdisplacement connector.

n Master / gatewayThe heart of each AS-i network is the master. This is astand-alone controller which manages the “bus traffic”.At the same time, it offers a powerful PLC functionalityand can be programmed by the user to process sensorand actuator signals, thus operating as a stand-alone decentralised controller. Also, the master often integrates a gateway functionalityto communicate with the higher-level controller or control level via Profinet or Profibus.Depending on the version one or two AS-i cables withup to 248 binary sensors and 186 actuators can be connected to these masters.

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Application report KLN Ultraschall

Safe AS-i input modules can be used in control cabinets or localboxes for the connection of conventional safety sensors, e.g. e-stops or door switches. All status indications are displayed via LEDs on the front panel.

Different AS-i modules for normal (orange) and safety-related(yellow) communication.

Passive flat cable insulation displacement connectors for theconnection of intelligent AS-i sensors / actuators to the yellowflat cable.

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n ConclusionIt’s the end result that matters: Thanks to AS-i wiring, documentation and set-up times are considerably re-duced. The decentralisation of the AS-i participants leadsto smaller and less expensive control cabinets. Confusing cable trays are avoided. Simple diagnosis anda clear plant set-up lead to high machine uptime, reduc -ing cost for installation and diagnosis.Dieter Bickelhaupt: “The connection of the switches and valves with pre wiredcables saves much time and prevents error sources. Thecost saved with AS-i cannot be determined exactly. But Ithink that all things considered, i.e. also the size of thecontrol cabinet, the space needed in the plant, decentralised installation and flexibility as well as inte-gration of ifm’s safety system plus the good creation ofthe documents 10 to 15 %. Plus less working time duringinstallation, documentation and troubleshooting!”

The heart: Dual AS-i master for two AS-i lines with Profinet gateway. For energy supply ifm offers suitable AS-i power supplies.

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The private brewery Zwettl invested about15 million euros to expand and modernisetheir facility in the town of the same namein Lower Austria.

So they are uniquely positioned in the European market for highly flexible andautomatic brewing of high-quality beers.

The new energy-saving installations help reduce the needfor resources, enabling the brewery to operate in an evenmore environmentally sound way. Many sensors ensureprocess feedback and diagnostic data for the brewingequipment up to the control level.Detailed engineering was implemented by M&L Con-sulting from St. Gallen and the company Corosys fromHofheim with an individual construction and the complete automation equipment. As leading OEMs for the brewery and beverage industrythe companies M&L Consulting and Corosys rely on thewide product portfolio of sensors and control systemsfrom ifm, guaranteeing maximum process reliability andmachine uptime.This is important to comply with the required standardsand directives. In particular in the food industry high temperature, cleaning resistance and protection rating IP 68 / 69K are required.

n Sensors in the cold areaThe process chain in the brewery is roughly divided intothree areas: brewhouse, cold area and filling. From thepoint of view of process sensors the cold area is the mostinteresting part. Countless pressure, flow and tempera-ture sensors are installed on the tanks and pipes. All valves are equipped with inductive sensors for positiondetection.

The examples below show how Corosys has solved theapplication in the Zwettl brewery by means of ifm sensors.

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Application report Zwettl Brewery

Temperatures, pressures or levels: Different sensors monitor the process.

Zwettler beer Fit for the future

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n Electronic manometer in the diatomaceous earth filter

Following the fermentation and storage process the un-filtered beer reaches the diatomaceous earth filter. Herethe yeast cells and sediment are filtered out.The condition of the filter is monitored via differencepressure measurement. The fully electronic PG2894 contact manometer is used for this process. It combinesthe advantages of an electronic pressure sensor and a highly visible manometer display. The pressure pick-up has a hygienic flush design, optio-nally with conical G1 thread or Aseptoflex Vario processconnection. This process connection also allows hygienicflush installation using the available adapters.In combination with the ecolink socket of the EVT seriesin M12 design protection rating IP 68 / IP 69K ensureshighest ingress resistance in the wet area. Thanks to its temperature resistance the fully electronic contact manometer is also perfectly suited for CIP (cleaning inplace) / SIP (sterilisation in place) processes.The large pointer display, the integrated digital processvalue display and the LED bar graph for switch point andtrend display provide the operator with user-friendly readout. With its high total accuracy of 0.2 % the devicecan also be used for sensitive processes.

n Temperature monitoring during the production of mixed beverages

In addition to the pure beer Zwettl also produces mixedbeverages such as the popular “Radler” – beer with lemonade. At the mixing station additives from varioustanks are mixed. To ensure an optimum process, definedmedium temperatures are required.At the tanks, temperature transmitters of type TA34transmit the temperature value to the plant controller viaan analogue signal (4...20 mA). The hygienic G 1/2 process connection and the high-grade stainless steel (316L /1.4404) housing materialmean that direct contact with the medium is no problemat all. The high-precision Pt1000 measuring elements of

accuracy class A provide precise measurement results.Temperature probes of type TM4501 with hygienic G 1/2 process connection are integrated in the pipes. Thesensor signal is evaluated and transmitted by the separateTP3231 temperature plug. It is very compact and has two standardised M12 connections for both the connection of the sensor andthe output. This reduces the installation complexity as compared to a common head / DIN rail transmitter to a minimum.

n Self-monitoring temperature sensor in flash pasteuriser

To kill microorganisms and to preserve the beer, it is heatedto a defined temperature by means of flash pasteurisa-tion. High precision is of highest priority.A special sensor is used for this purpose: The ifm TAD991temperature transmitter uses two different sensor elements monitoring each other in the process. This self-monitoring system ensures that an occurring drift of thesensor is detected at once and reliably diagnosed. The deterioration of the sensor accuracy is known as drift.Drift is caused by thermal stress. Especially in the food industry the regular cleaning processes (CIP, SIP) createextreme temperature shocks that stress the sensor andtherefore inevitably cause a drift. To detect occurring temperature drift the off-set with thereference has to be automated. This exactly is the approach with the calibration-free TAD temperature sensor.

2 in 1: The fully electronic PG contact manometer combines a pressure sensor and manometer display in one unit.

Small, compact, cost-effective: The TP temperature plug converts the sensor signal into a standardised analogue signal (4…20 mA).

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Standard temperature sensors have a resistance measur -ing element which in the food or pharmaceutical industryvery often complies with the accuracy class A to DIN EN 60751. A resistance measuring element (Pt1000) is integrated into the TAD temperature sensor. This resis-tance element is specially measured and preselected bythe manufacturer and its accuracy is therefore higher byabout factor 4 than class A which is normally used. To have a signal to compare, the probe of the TAD addi-tionally has an NTC measuring element with long-termstability which is matched with the characteristics of thePt element in the production process of the sensor. Bythis you understand the matching of two components orcharacteristics.So in normal operation the TAD temperature sensorworks with two different measuring elements. As a result of this, the process can be finished safely withthe second measuring element (backup function) if oneelement fails. The electronics of the TAD temperature sensor calculatesthe mean average of the measured temperatures andprovides a temperature-proportional 4...20 mA analogueoutput. During operation the difference between the twotemperatures is compared with two adjustable thresholdvalues. The first threshold value is called drift warninglimit, the second one drift alarm limit. To guarantee wire break monitoring there is a 24 V sig-nal on the diagnostic output in normal operation. If thedrift warning limit is exceeded, the diagnostic outputclocks at a frequency of 2 Hz. Via a timer the signal canbe evaluated in any controller. If the drift alarm limit isalso exceeded, the diagnostic output switches and a 0 Vsignal is continuously provided.

Advantage: Compared with the common temperaturesensors that are cyclically calibrated the use of the TADtemperature sensor increases process reliability. With cyclical calibration an occurring drift is detected, how-ever a drift-prone sensor had already been used for anuncertain period of time in the production. Since the TADgenerates a signal the moment the set drift thresholdsare exceeded and you do not have to wait for the end ofthe calibration interval, process reliability and conse-quently product quality are considerably improved duringthe demanding flash pasteurisation process.

n Level monitoring on tanksTanks are used in many places in the brewery: For examplein the bright beer cellar as a buffer between filtration andfilling, in water purification or in the central CIP installa-tion. The exact level of these tanks is needed for plantcontrol; furthermore the permissible min. and max. levelsshould be detected and signalled.Pressure sensors of the PI28 series are installed on thetank bottom for hydrostatic level measurement. The exacttank level can be derived from the measured hydrostaticpressure.The housing of these sensors is completely made of high-grade stainless steel (316L /1.4404). Together with thehigh protection rating IP 68 / IP 69K and the process-oriented design this series is particularly suited for hygienicapplications.The new G1 process connection Aseptoflex Vario madeof high-grade stainless steel (316L/1.4435) provides fourreliable sealing options. The metal-to-metal as well as thenew PEEK seals are maintenance-free and thus cost-saving during their life time. The latter is distinguished byhigh resistance to chemicals and temperature. Elastomer O-rings are another hygienic sealing option(EPDM / FKM). Different process adapters (such as clamp,DIN11851 pipe fittings, etc.) are available as accessories,and are of course also made of high-grade stainless steel(316L/1.4435). Depending on the sensor type, their pressure range is between 100 mbar and 25 bar. High-purity ceramicmeasuring cell as well as easy handling via the integratedpushbuttons and the LED display are other features.Electrically the sensor can be connected as a 2, 3 or 4-wire unit. This makes it easier to exchange units in existing installations. Furthermore the sensors of the PI28 series are distinguished by a high overall accuracy(0.2 %) and electronic temperature compensation. Dueto their high temperature resistance they are also ideallysuited for CIP and SIP processes.The second sensor system on the tank is the LMT pointlevel sensor that reliably monitors the maximum and min-imum level. As opposed to other solutions such as mechan-ical tuning fork probes it does not need any mechanicalcomponents thus operating without wear. Special feature: It is insensitive to foam and other deposits whichit reliably suppresses. Besides the factory preset the LMTcan be set to different media and deposits via IO-Link.

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Application report Zwettl Brewery

Maximum process reliability: The self-monitoring TAD temperature transmitter for especially sensitive processes.

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This also ensures reliable limit level detection even withdifficult media.A variety of adapters allows various installation options.The sensor operates independently of the installation position. High-quality housing materials such as high-grade stain-less steel (316L/1.4404) and the sensor tip of food-gradePEEK meet all hygienic requirements. A lasered type labelfor durable legibility as well as the high protection ratingIP 68 / IP 69K for cleaning processes are natural.

n Applications in pipesThe point level sensors of the LMT series are also used inpipes. They detect if the pipes are full or empty and aretherefore used as run-dry protection for pumps. Its com-pact sensor tip allows integration of the LMT even insmall DN25 pipes.To monitor the conveying pressure in pipes the above-described PI28 pressure sensor is used. It transmits themeasured value as an analogue signal to the controller.

n Inductive sensors monitor valve manifoldTo guide the medium valves on manifolds of differentsizes are used in different places in the brewery. Electro-mechanical rising stem valves ensure an open or closedpipe thus allowing the controlled distribution of themedia. Inductive sensors are used for position detectionsince they detect if the valve is open or closed by meansof the position of the valve stem. The type IFT203 sensorsused feature high-quality housing material (high-gradestainless steel, PEEK) and the high protection rating IP 68 / IP 69K so that they withstand regular high-pressurecleaning processes without being damaged.

n Manway and cover monitoringAnother application for inductive sensors is position mon-itoring of manways or covers, for example on tanks. Thesensors of type IIT212 provide sufficient sensing range(15 mm) to signal the status “cover open” or “cover closed„ to the controller even in the event of mechanicaltolerance.

n ConclusionThanks to the know-how of many years the sensor specialist ifm offers a comprehensive product portfolio toreliably automate the brewing process and to ensure con-tinuously high beer quality. Due to similar requirementsthe example application solutions can be transferred toother areas in the beverage and food industries to makethem fit for the future.

Typical tank monitoring: LMT point level sensor and hydrostati-cally measuring PI pressure sensor on the tank bottom.

Perfect pump protection: The LMT point level sensor (top) determines if the pipe is full or empty. The PI pressure sensor (bottom) monitors the conveying pressure.

Position feedback: The IFT203 inductive sensor monitors thevalve stem and signals to the controller if the valve is open.

Cover closed? An inductive sensor monitors the tank cover.

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In Cologne within the sight of the cathedral, situated ona small island at the banks of the river Rhine, the well-known chocolate museum demonstrates this creationprocess as a realistic experience. The highlight is the completely automated production ina mini production line from the cocoa bean to the ready-to-enjoy chocolate bar. Every day 80,000 little bars areproduced 6 days a week while curious streams of visitorsare watching. An interruption of this automated processwould have serious consequences. Since July 2006 ifm electronic from Essen has been supporting this exceptional museum with state-of-the-art technology. Besides temperature sensors vibration, cylinder and pressure sensors from ifm support this extremely sensitive process.

n It is all about the right temperatureAfter preprocessing such as roasting and grinding thebrown chocolate mass is temporarily stored in a 3-wallstorage tank. Via a dual-wall piping system equippedwith a trace heating the liquid chocolate mass is pumped towards further processing. The temperature inthe hot water cycle of the trace heating guaranteeing

the optimum flow must be constantly at 50-51 °C. If tempering is not precise, the chocolate mass will crystallise and clog the pipes.

Then the entire production has to be stopped and the affected part of the system must be completely cleaned.Quite considerable costs arise because this process is extremely complex and time-consuming. The TN-typetemperature sensors from ifm are of great help. They pre-cisely monitor the temperature of the heating cycle.

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Everybody knows it, everybody loves it – chocolate. The mere mention of this word has amouth-watering effect on many people. The fewest, however, know something aboutthe sensitive production process from the cocoa bean to the ready-to-eat bars usuallywrapped in flavour-conserving aluminium foil and colourful packaging.

Application report Chocolate museum

Delicious chocolateOnly ensured by the exact temperature

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n Reliable temperature sensorsThe temperature sensors from ifm are based on a PT100or Pt 1000 resistor. The measured temperature value corresponds to a change in resistance and is convertedinto an electrical analogue signal. A microprocessor con-trols the evaluation of the electrical signal. The current system temperature is displayed directly onthe evaluation unit via LEDs. Both the microprocessor andthe display make process adjustment much easier. Theuser can set the values for the switch points, hysteresisand measuring range by means of the programming buttons even without the system temperature being applied. This facilitates installation and set-up.

n The tempering machineThe chocolate mass is pumped from the storage tanks tothe tempering machine. A tempering machine consists of several heating chambers.The chocolate is pumped from the bottom to the top viathese chambers. They experience a precisely defined tem-perature curve. The temperature depends on the recipeand is controlled to a tenth of a degree by the temperingmachine. Tempering ensures that the finished chocolatehas a glossy shine and a firm break after processing. Thisprecise temperature is monitored by an ifm TN2531 andgives an alarm when it deviates by 0.5 degrees.

n First hot, then cold – moulding and packing

The next production step is moulding the liquid, aromat-ically smelling chocolate into the respective bar moulds. The mass in the moulds is cooled down to 6-9 °C usingcooling water.

This temperature is necessary to ensure that the moul-ded bars can be removed from their moulds by rhythmicshaking. The TN2531 temperature sensor used here hasan installation length of 45 mm and a diameter of 8.2 mm. It is extremely robust and distinguished by a veryhigh pressure rating of up to 300 bar. The measuring

range is -40…150 °C. There are countersunk setting buttons underneath the local display. That means that anaccidental serious change is almost excluded. Then follows packaging. Here again certain temperatures haveto be kept because there is only a narrow time window.This is constantly getting shorter, the higher the outsidetemperature increases. The critical air temperature is 22-23 °C. When the ambient temperature in the production area that is protected by perspex panels exceeds this limit – e.g. by streams of visitors becauseevery person radiates heat – an alarm is triggered and a horn is sounded. A TN-type temperature sensor fromifm performs reliably also in this situation.

All detected temperatures are not only displayed locallybut also centrally in a control cabinet for controlling purposes so that the operators can react at once in thissensitive production process. Bottom line: The alpha and omega of the manufacture ofquality chocolate is the permanent, precise temperaturemonitoring both in the hot and the cold area. The complete manufacture is to be handled sensitively so that the sensitive human taste buds can enjoy delicious and aromatic chocolate.

The TN2531 temperature sensor from ifm is monitoring the cooling temperature.

Exact temperature monitoring during the packaging process.

The finished chocolate bars are stored at a constant tempera-ture of 18 °C.

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The constant increase of the degree of automation in modern production plants is moreand more often supported by identification systems. Their tasks include, for example, the control or release of production steps or the assignment of information about eachproduct. This is particularly easy to achieve if the RFID components communicate via theAS-Interface fieldbus.

Application report Wessel-Werk

When it comes to assembly technology, the worldwideleader in the development and production of vacuumcleaner nozzles, Wessel-Werk, counts on solutions fromifm electronic who is a global player for automation technology and the first supplier of AS-i based RFID systems worldwide. The result is lean and transparent installation monitoring of the nozzle production.

n High-quality vacuum cleaner nozzlesA high-quality vacuum cleaner nozzle consists of at least a dozen different components. The world market leader develop and build the assemblymachines themselves, in order to be able to promptly andflexibly implement innovative technologies. Inside thesemachines, workpiece carriers pass several assembly

RFID meets AS-iTransparent installation monitoring

Assembly machine for the production of vacuum cleaner nozzles.

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The ID tag is available in different versions and offers flexible mounting options for workpiece carriers, tanks,etc. Using simple insulation displacement technology, the AS-imodule can be connected with the yellow AS-i flat cable.To do so, the cable can be laid transversely or lengthwisethrough the module. The AS-i module is mounted withouttools – for removing it you only need a screwdriver.Not only RFID read/write heads but other sensors, such as light barriers or inductive sensors can be connected viaAS-i modules with the controller. This reduces even morewiring.Being the head-end, the AS-i master collects all data forall common superior fieldbuses. Because of the integratedPLC functionality it can pre-process the data, supportingthe plant controller.

n ConclusionGerhard Feyerabend, control engineer at Wessel-Werkon the simplicity of the AS-i RFID system: “Setting up thesystem is much simpler than expected because the readheads immediately send the data to the PLC after in-stallation and addressing. A further configuration is notnecessary!”For ifm, RFID in combination with AS-i is ideal for identi-fication tasks in assembly technology which are easy toimplement.

stations. On these carriers, different vacuum cleaner nozz-les are assembled from chassis, brush strips, rollers andother parts.Wessel Werk produces flexible lots of different types inmixed operation. Conveyors transport workpiece carriersto different processing stations. Depending on the nozzletype, different assembly steps and conveying routes are required. Each workpiece carrier can be clearly identified via a special RFID code. The code is read at each processing station and sent to the controller via AS-Interface. Depen-ding on the nozzle type, the corresponding processing stepis carried out and the distribution gates on the conveyorpath are set. The clear identification reliably prevents processing failures in mixed operation.

n RFID with AS-iThe industrially compatible DTS125 RFID system from ifmis used for a problem-free process flow. It is a compact andeasy alternative for applications where, for example, optical identification cannot be used due to the ambientconditions. It is also the first RF identification system for AS-Interfaceworldwide. It allows reading and writing of code carriers(ID tags), benefiting from the advantages of AS-Interface.It can be easily integrated into existing AS-i networks andis immediately ready for operation. The highlight of the AS-i solution is the easy wiring. Up to31 write / read heads can be connected to 100 metres of AS-i cable. The cable can be branched as you like andlaid according to the layout of the production line. It isespecially suited for modular structures since both data andenergy run over only one cable. For reading, the RF identification system uses the commonAS-i analogue protocol 7.4 for data transfer. Special software modules are not required. The read / write headstores transmission errors which can be retrieved for a targeted fault analysis. Antenna, electronics and AS-i interface are integrated in a compact housing. The voltage is supplied via the AS-inetwork via a rotatable M12 connector. No additional operating voltage is needed. This facilitates mounting andminimises wiring.

Fully automatic assembly of a vacuum cleaner nozzle at several stations.

The ID tag chip is installed at the bottom of the workpiece carrier. The chip can store up to 224 bits.

Sensors can be connected to any spot of the AS-i cable via a flat cable insulation displacement connector.

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Application report Gritzke – Automatic levelling system for graders

In no other industry, competitive stress is assevere as in the construction industry. To maintain a position on the market, economic efficiency needs to be constantlyimproved. In other words: More efficiencythrough increased working speed and improved quality.

The unique GRi-P1 Gritzke automatic levelling system for graders increases theflexibility and productivity of the machinessignificantly. This helps save material costsfor earth moving and fine grading. The system can be equipped with severalsensors; it combines easy handling with a self-explanatory user interface.

Each millimetre counts when, for example, miles of roadsections under construction need to be graded to thesame level. A grading that is only one millimetre higherthan required can easily cause several truckloads of additional material.

n Laser levellingLevelling long stretches with millimetre precision is onlypossible by applying efficient modern technology. Here,laser-based systems have proved to be particularly accu-rate, cost-efficient and reliable. Function principle: A laserfixed to a tripod rotates around its own axis to create alaser level. This level can be adjusted in parallel to the required surface. A vertical photoelectric receptor cellmounted to the grader blade receives the laser beam. An intelligent controller tracks the laser receptor and thegrader blade to make sure they are always at the exactheight with the laser projection level. So the driver canfocus on the horizontal movements of the grader whilethe blade is automatically kept with millimetre precisionat reference height.To level sloped surfaces, the laser can simply be adjustedin parallel to the required slope. Depending on whetherthe grader movements are longitudinal, transverse or diagonal to the slope, different lateral blade inclinationsare required. With laser-based systems, the blade inclination can be controlled automatically. For this purpose, a second laser receiver is installed on one side of

Automatic at a high levelGRi-P1 automatic levelling system for graders

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the grader blade. Alternatively, an inclination sensor and / or an ultrasonic sensor is used on the blade. GritzkeLasertechnik OHG is based in Lemgo, Eastern West-phalia. They are specialised in the development, produc-tion and distribution of construction machine control andpositioning systems. Their customers benefit from the excellent quality and reliability of the systems and thecompany's service standards.A central credo: Circumventing the product monopolyconstraints of the market leaders, i.e.: The Gritzke systems can be installed on any machine, even if it is already pre-equipped with cables.To distinguish themselves from common systems, Gritzkehas considered the advantages and disadvantages of allsystems while putting their own ideas into practice.

n A new flexible system was neededIn the past, Gritzke used programmed controllers fromdifferent manufacturers to control the levelling systems.Disadvantage: Gritzke could not carry out customer and

machine-specific adjustments or software modificationsas the system integrator. The hardware manufacturershad the ownership of the software. Individual adjust-ments or modifications were very time-consuming andcost-intensive or were refused.Dipl.-Ing. Rolf Oschatz, managing director at Gritzke:“About 2 years ago, I decided that we would develop our own laser-based levelling system for construction machines. The aim was to offer our customers a combi-nation of special user-friendliness, high accuracy andbest-possible competitive price. With our developmentwe basically did not reinvent the wheel, but combinedall advantages of the competitive systems with our ideasand requirements.”

n ifm as partnerApplication know-how is one thing, but when it came tothe heart of the system, the controller and its software,Gritzke found their present partner, the ifm group ofcompanies, more or less by accident. Dipl.-Ing. Rolf Oschatz: “The development togetherwith the earlier hardware suppliers was rather slow. The initially promised support was very hesitant and consisted of target figures rather than technical support.In April 2013, at ifm stand at BAUMA (the world’s largest trade fair for construction machine, editorial comment) I was asked in an informative conversation if we needed help. Mutual interest arose quickly. Whatimpressed me in particular: They did not ask about possible quantities but promised comprehensive projectsupport.”This was the beginning of the close partnership betweenGritzke and ifm.In cooperation with the automation specialist ifm (hardware), Gritzke Lasertechnik developed, built andsold the first German CANbus-based GRi-P1 levelling system for graders.

Working surface with following setting options: “Mast installa-tion” e.g. “search laser” or “park mast”, automatic mode forthe right or the left mast “on / off”, "mast adjustment on bothsides” as well as current height indication in 1/10 mm

Gritzke developed andbuilt the marketablesystem in cooperationwith ifm.

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Application report Gritzke – Automatic levelling system for graders

n ImplementationThe following months were characterised by intensive cooperation. Dipl.-Ing. Dennis Blume, sales specialist for control technology at ifm, had the lion’s share in supporting theproject. This was done in close cooperation with Gritzkebecause one important requirement on the new systemwas to have Gritzke’s in-house software know-how. Theheart of the installation is the CR0033 CAN-compatibleifm controller for mobile applications. ifm's CR1084 display with graphics capabilities is used as the operatingunit.Dipl.-Ing. Rolf Oschatz: “The cooperation with ifm waspassionate and successful. Often we tested the softwareand hardware outdoors on the machines till late at night.Many thanks in this respect to the company Stork Tongruben und Transportunternehmen in Hiddenhausenwho provided us with a caterpillar (Cat D6T) and the site,a clay pit, for thorough testing. And it paid off: After 18 months we could implement the system until it wasready for the market. Without Mr Blume’s exceptionalpersonal commitment we would never have achieved thisin such a short time.”

n Flexible in the applicationThe levelling system is the first of its kind to be de-veloped, programmed and built by only one supplier. The customer benefits from the fact that adaptations,special customer requests or improvements can be implemented rapidly. Due to its modular concept the GRi-P1 Gritzke systemcan be used for any kind of laser-based height monitoringand control for different applications as well as for construction machines.That means that it can also beused on excavators for depth monitoring, on height and/ or pivoting angle limitation, on wheel loader levelling

systems, on piling and drilling rigs, on agricultural ma-chines or on container lifts. Advantage: The customerdoes not need expensive software updates since the different applications are already stored and selectable inone software program. The controller can also be used ondifferent machines, if required. The customer saves thepurchase of double components such as operating unit,central processing unit or sensors. By integrating selectable application programs in a modular device the development and hardware costswere reduced to a minimum. The result: The Gritzke system costs about one third less than the common systems.

n High speed – thanks to CANbusIt is the first system to use the CANbus interfaces for datatransfer. The data can be transmitted up to five times faster from the laser receiver or from the inclination sensor / ultrasonic sensor to the controller. This fast datatransmission and processing in the controller is necessaryto ensure a fast signal chain from the laser receivers to the controller to the valve control of the caterpillarblade. This is the only way to enable work with millime-tre precision, even at high speeds.Also the joysticks, switches and buttons of the construc-tion machine are polled and transmitted via CANbus to the process control. If necessary, the user can manually alter the automaticzero adjustment on the graphic operating unit. Switching – for example to inclination sensor or ultra-sonic sensor (for grading according to a ground refer -ence, e.g. kerb) – can easily be done on the operatingunit.

Dipl.-Ing. Dennis Blumefrom ifm on site: Thecontroller was testedon the machine andthe programming adjusted again andagain on site. The customers only getproducts guaranteeingflawless functioning.

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n The heart: the controllerIt has up to 16 multifunctional inputs and outputs as wellas 4 CAN interfaces. The heart of the controller is a modern and fast 32-bit processor integrated into a compact IP 67 metal housing. Its monitoring and protec-tive functions enable reliable operation even under extreme operating conditions. The high number of multifunctional inputs and outputs allows easy and precise adjustment to the respective application using application software (IEC 61131-3 with CODESYS). Depending on the type of input, a configuration as digital, frequency or analogue input with diagnosticfunction or as input for resistance measurement is possible.The 4 CAN interfaces to ISO 11898 support all importantbus protocols and different baud rates as well as thetransparent or preprocessed data exchange. The newcontrollers were specially designed for robust applica tionsin vehicles and for mobile automation and can carry outcomplex and proportional functions reliably.

n Graphical operating unitThanks to the closed diecast aluminium housing with theprotection rating IP 67 the PDM360 NG dialogue modulecan be used outside and inside the cabin – by means ofsurface or panel mounting.The scratch-resistant 7" TFT colour display with a resolu-tion of 800 x 480 pixels and a colour depth of 18 bitsprovides brilliant graphical representation. For operationthe PDM360 NG has 9 backlit function keys with tactile

feedback. In addition, an encoder with pushbutton or anavigation key is available depending on the model.The powerful 32-bit controller is programmable with CODESYS according to IEC 61131-3. In addition to theinternal 1 GB memory the user can connect externalmedia to the integrated USB 2.0 port. Four CAN interfaces to ISO 11898 support the CANopen,SAE J1939 or a free protocol. Together with a 100 MbitEthernet interface and the Linux operating system, a universal platform for networking and communicationwith other vehicle components is formed. Connection ismade via robust and safe M12 connections.

n ConclusionThe project benefits from the application know-how ofmany years, powerful hardware and, above all, the will tobring about something special together. Once again,“Made in Germany” has set new standards.

The CR1084 dialogue monitor from ifmfor visualisation and data entry.

The heart of the system is a 32-bit controller from ifm for mobile applications.

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Application report Gritzke – Depth control system for hydraulic excavators

Gritzke Lasertechnik from Lemgo specialises in diggingdepth control systems. Together with ifm electronic, oneof the leading manufacturers of sensors and automationsolutions for mobile applications, an innovative solutionfor exact relative height determination of the excavator’sbucket blade was developed. Precise inclination sensors, a compact BasicController anda programmable dialogue display together with the software developed for this purpose combine into an efficient system and give the excavator operator absolutecontrol over his tasks.First of all the reference height is levelled by means of therotation laser and the laser receiver on the adjustableboom of the excavator. Then the planned heights can bedetermined at any position of the earthworks.

Systematic excavationEasily retrofittable digging depth control system for hydraulic excavators

The height of the excavator shovel edge at a glance to the nearest centimetre – this enables the excavator’s digging depth control system from the company Gritzke. The special feature: It can be retrofitted to any hydraulic excavator without having to tamperwith its controller. This is made possible by ifm’s high-precision inclination sensors on theindividual excavator arms and the shovel.

The BasicController helps calculate the reference height.

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The signals are processed and the complex calculationsare made in the dialogue module which contains the dis-play, the operating keys and a powerful controller. Thedisplay graphically shows the excavator operator the ex-cavator bucket and the current height of the cuttingedge. A clearly visible traffic light also signals the exca-vator operator if the required depth has been reached.

Setting height markings, angle meters and direct visualcontact are no longer required. This makes it possible towork at night or if vision is obscured.Dipl.-Ing. Rolf Oschatz, managing director at GritzkeLasertechnik: “What is special about our solution is thatit can be easily adapted to different excavators from different manufacturers by easy modifications of the parameters.”

n For robust applicationsFurther benefits of the system: The outdoors sensors aredesigned for a broad temperature spectrum (-40…85 °C).Active temperature compensation ensures exact valuesmeasured by JN – irrespective of the ambient tempera-ture. They have a precise measurement accuracy of 0.1 °across the whole measuring range of 0…360 degrees without annoying jump characteristics. They are connectedvia a vibration-resistant and sealed M12 connector.The dialogue module with operating keys and graphicdisplay provides the excavator operator with an overviewof the most important settings at any time. The relevantsettings such as the required relative depth can be madeconveniently and accurately via pushbuttons, touch display and control dials. The change to the basic coor-dinate system (perpendicular / Euler / gimbal angle) ispossible by pressing a pushbutton.

n ConclusionExperience of long years with construction machine controllers and first-hand automation know-how: The customers benefit from the excellent quality and reliability of the unique digging depth control. In short:When competences complement each other, earth canbe moved correctly!

n Exact inclination anglesSix ifm inclination sensors of type JN – spread across theexcavator boom, in the upper structure and on the tiltbucket – precisely measure the angle of inclination in thex and y direction.

The intelligent software calculates the height position ofthe bucket blade to the centimetre from the measuredresults of all six inclination sensors and the known ex-cavator arm length.Of particular relevance is the three-dimensional straightline between the left and right bucket edges that allowsexact flat levels and any angle for earthworks by meansof the inclination sensor on the bucket.

One inclination sensor determines the exact angle per excavator arm.

The lateral inclination of the excavator bucket is also taken into consideration for the calculation.

ifm’s dialogue module (CR1082) serves as the display and dataentry. Furthermore, the integrated PLC calculates the height.

A traffic light within the sight of the excavator operator indicates if the shovel is too high or too low.

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Application report NOBA Verbandmittel

The company NOBA Verbandmittel in Wetter on the Ruhr makes all types of bandages and dressings for hospitals, doctors’ offices and pharmacies worldwide.Maximum hygiene is given top priority inthe clean room when dressings for medicalpurposes are produced, packed and thensterilised.

In order to eliminate bacteria and fungi, environmentalparameters such as the number of particles in air, ambient temperature and air humidity are strictly controlled.The optimum ambient temperature in the clean room is21 °C. If the temperature is too high, it is cooled downusing chillers.To keep energy costs for air-conditioning low, the com-pany plans and builds their production equipment so thatthe components used in the clean room give off as littleheat as possible.

Michael Rohe, Technical Manager at NOBA: “It is par-ticularly important to use low-loss devices in the cleanroom because heat in the clean room must be cooleddown again with chillers to keep the temperature constant, which is very expensive. Furthermore, low-lossdevices in control cabinets usually eliminate the need tocool control cabinets using ventilators, so there is no turbulence any more in the clean room caused by controlcabinet ventilators or such like.”

n Heat in the control cabinet is expensive!In control cabinets the power supplies are the main heatproducers. Conventional electronic switched-modepower supplies are very efficient compared to the trans-former power supplies used in the past. However, theywill never reach the ideal degree of efficiency of 100 percent. The difference between the actual degree of efficiency and the ideal 100 per cent is converted intoheat energy which heats up the control cabinet.In many industrial installations heat in the control cabinetmay be of minor importance. In defined clean room con-ditions as with NOBA, however, heat loss costs twice as

Cool and slimEfficient, new power supplies in the control cabinet

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much: On the one hand, energy costs incur, on the otherhand heat loss must be compensated for by means ofenergy-intensive air conditioners.

n Low temperature = long lifetimeTherefore NOBA relies on the new power supplies fromifm. They are distinguished by a very high degree of effi-ciency of up to 94 per cent. This degree is one to two percent higher than that of comparable modern switched-mode power supplies of other manufacturers. At first sight, this does not seem to be very much. Butcalculations show that this 1 or 2 per cent adds up to noticeable energy costs over the year. Particularly in thisapplication with the extra cost for the compensating air-conditioning.In practice, this heat loss may result in an additional tem-perature increase of 10 degrees in the control cabinet.But for some electronic components, e.g. electrolytic capacitors, this temperature difference of 10 degrees results in halving the lifetime. The machine controller is often installed directly besidethe power supplies. So the higher degree of efficiencyparticularly impacts the lifetime of the PLC installed in thecontrol cabinet. In short: The lower the temperature inthe control cabinet, the higher the lifetime of the plantcontroller.

n New power supplies from ifmIn 2013 ifm redesigned their family of power supplies.The new generation includes 24 V DC switched-modepower supplies with output currents of 3.3 to 20 A aswell as AS-i power supplies of 2.8 to 8 A. All these de-vices integrate components and circuits rated for maxi-mum efficiency, longevity and powerful performance.The heart of the devices is a highly efficient compact cir-cuit design. So ifm's power supplies are much slimmerand require less space in the control cabinet than devicesfrom other manufacturers with equal power rating. Withthis, ifm makes an important contribution in the machinebuilding industry which requires ever smaller control cabinets.

One could think that this compactness would be at theexpense of component dimensioning and a reducedfunctionality. But developers managed to prove the opposite: The components are dimensioned so that thepower supplies can be operated permanently at theupper limit of the specifications. They provide the speci-fied nominal power almost over the whole temperaturerange. Therefore, the usual “overdimensioning” ofpower supplies to provide a reserve for a longer lifetimeis not necessary for ifm power supplies. This saves spaceand money. The excellent MTBF value of 0.89 to 1.4 mil-lion hours (depending on the variant), which correspondsto a lifetime of 100 to 160 years, confirms this. A minorderating (reduced power) only occurs from an ambienttemperature of 60 °C.

n Strong extra featuresThanks to ifm‘s application know-how of many years weexactly know the requirements for energy supply in auto-mation technology. Therefore many extra features wereintegrated, ensuring a reliable function in all operatingphases.Instead of an inrush current limitation with a simple NTCresistor, charging the capacitors of the new switched-mode power supplies from ifm is microprocessor-controlled. This “soft” start of the voltage supply ensures that the fuses upstream of the power supply donot have to be dimensioned for a higher inrush current.This creates additional safety on the primary side of thepower supply.Additional power reserves on the secondary side ensurethat the power supply still provides enough current to reliably trigger the downstream circuit breakers in caseof a short circuit. The ifm power supplies feature an additional power reserve of 20 % which allows the installation to be expanded at a later point of time.The power supplies compensate short voltage dips caused, for example, by switching operations in the supply network for several milliseconds.

n ConclusionWhat is often hardly noticed in data sheets may have aconsiderable impact on lifetime and reliability of theequipment. NOBA realised the advantages of the newifm power supplies. Thus they save operating costs andcreate ideal climatic conditions to reliably meet the highproduction requirements.

Really cool: Thanks to the high degree of efficiency the new generation of power supplies from ifm does not heat up the control cabinet.

A small but useful detail: All 24 V switched-mode powersupplies are equippedwith double terminals.

This simplifies wiringand provides more clarity in the control cabinet.

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34

Application report Romfil

Water purification is increasingly becomingan important production factor. Modernfluid sensors ensure efficient and energy-saving processes.

The crossflow filter system Aquacross W675 from RomfilGmbH filters up to 300 cubic metres of water per hour –this corresponds to about the volume of a 100 m² flat. It produces drinking water from pre-treated but still con-taminated water. The principle of crossfiltration is particularly efficient:Waste water is pressed into a circuit through thin, porouscapillary tubes. Only pure water can penetrate this mem-brane. Water which is infiltrated with pollutants continuesto circulate until it is also purified progressively. Hundreds of such capillaries are combined in a filter module of a height of approx. 1.5 m. That results in a filtration area of 75 square metres. Depending on the

requested throughput several modules operate in parallel.This system is equipped with two lines of 9 modules eachwhich corresponds to a filter area of 1,350 square metres.It enables to clean 300,000 litres of waste water per hour. Modern sensors help to monitor various processes of theinstallation and to operate them in an optimum range.This is the only way to achieve the maximum filter per-formance with a minimum of energy input. For their installation Romfil fully rely on sensors from ifm whichhave proved to be particularly reliable.

n Inflow monitoringExact pressure values are needed to let the waste watercirculate through the filters so that the filter capillariesreach their optimum degree of efficiency. Therefore, an ifm pressure sensor type PF2654 is installedin the inflow line to the filter elements. The flush-mountsensor is rated for a measuring range of -0.5 to 10 bar

Sensors for clean waterProcess monitoring for water filtration

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and features very high precision of 0.6 per cent. In combination with the O-ring-free sealing concept theoverload-protected and drift-free ceramic measuring cell ensures maintenance-free long-term operation. The pressure sensor has two switching outputs. The second output can also be configured as analogue out-put (4…20 mA or 0…10 V). The alphanumeric LED display helps with parameter setting and also serves asdisplay of measured values.Apart from pressure, the system temperature is also mon-itored in the inflow line. The TA3437 unit is a universal temperature transmitterwith a 4...20 mA analogue current output. A high levelof accuracy is achieved using a class A accuracy Pt sensorelement and in-house calibration. Furthermore, the tried-and-tested ifm film technology ensures excellent response times of T05 = 1 s and T09 = 3 s. In addition tothe protection rating IP 69 K, the completely sealed andwelded stainless steel housing also ensures high mechan-ical stability. The housing design reduces build-up of dirtand can be cleaned all around.

n Level in the filterAn LMT100 point level sensor from ifm is mounted at thebase of the first filter module. It monitors whether thefilters actually contain water for filtration.The particularity of the LMT series is its insensitivity to de-posits. The extremely smooth surface characteristics of the PEEKtip of the sensor is Ra < 0.8 μ. Adherence of dirt and

residues of media is hardly possible. The level is reliablydetected even with foam or viscous media.Set-up is also easy. Media adjustment is not necessarysince the sensor is preset in the factory. The level is detected independently of the orientation. Its compactsensor tip allows integration of the LMT even in smallDN25 pipes.The sensor with its high-quality housing materials suchas high-grade stainless steel (316L / 1.4404) and PEEKmeets all requirements for hygienic areas This also in-cludes a lasered type label and the high protection ratingIP 68 / IP 69K.

Feed flow monitoring: temperature transmitter and pressure sensor in the inflow line.

Level monitoring in the filter module: Even in case of depositsor foam the LMT100 reliably monitors the limit level.

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Application report Romfil

n EmptyingOccasionally, the complete installation must be emptied,e.g. before or after cleaning operations. A pressure trans-mitter monitors this emptying process using compressedair.The PP7554 sensor is distinguished by a high total accu-racy of 0.5 %, a compact stainless steel housing and a switch point accuracy of 0.5 %.The pressure sensing principle using a ceramic-capacitivemeasuring cell ensures reliable and long-term stable measured values. The user can choose between two switching outputs or one switching output and one diag-nostic output. The sensor also has IO-Link capabilities.That ensures not only digital process data transmissionbut also parameter setting or diagnostics from a controlleror a PC.

n Flow monitoring of the detergentsThe filter membrane must be cleaned regularly to ensurea long life. This is done using different detergents whichare exactly dosed. During the automatic cleaning processan ifm flow sensor is used for flow monitoring. The SI5000 sensor operates to the calorimetric principleand therefore needs no mechanical moving parts. Thisguarantees reliable monitoring even in cases of difficultmedia over a long period of time. Using microprocessortechnology the units are easy to handle. Flow and switchpoints are simply set via pushbuttons. A multi-colour LEDbargraph displays measured values and switch points. Various adapters available as accessories ensure fast andreliable process connection.

n Monitoring the pneumatic systemAll valves of the installation are operated pneumatically.The necessary system pressure of 6 bar for valve controlis monitored using an ifm PQ3834 pressure sensor which

is installed in a control cabinet. The piezo-resistive siliconcell measures between -1 and 10 bar. It is insensitive toliquids (e.g. condensed water) and deposits that mightoccur in the system. Furthermore, it guarantees very highaccuracy. The display colour is selectable: red or green. For exam-ple: In the acceptable range, the measured value is displayed in green, it turns red when a selectable switchpoint is exceeded or not reached. This provides optimumoverview. Two programmable switching outputs or oneswitching output and one diagnostic output provide flexible adaption options.

n ConclusionNumerous process parameters are important for waterfiltration. For these applications ifm offers a completerange of sensors. The precise and maintenance-free sensors with long-term stability enable an efficient andreliable operation of the plant. Therefore, Romfil havebeen using ifm sensors for a long time.

A pressure transmitter monitors the emptying process of the installation using compressed air

A flow sensor monitors the feed flow of detergents downstream of the pumps.

Page 36: Application Reports Success stories from the real world 2016
Page 37: Application Reports Success stories from the real world 2016

Automation technology plays an increas -ingly important role also in agricultural machinery. Suitable sensors and controllershelp automate many functions; the strainon machine operators is reduced; produc-tivity and efficiency are increasing.

A typical example is windrow recognitionfor tractors during the grain or hay harvest.The 3D sensor system from ifm is used here.

Industry, agriculture and the service sector are the supporting pillars of a modern economy. Ever since theindustrial revolution where the machines continuously rationalised the originally typical manual production, industrial production has become more and more efficient thanks to technical progress. Today everybody is talking about “Industry 4.0”. The useof electronics, information technology and communica-tion is expected to lead to a fourth industrial revolutionin production. In general, the development in agricultureseems to be of less interest for the media and the public.

However, there are remarkable possibilities by using electronics and IT. The purposes do not differ greatly fromthose in industry: productivity, efficiency and quality needto increase.

n Automation in agricultureIn agriculture there is also a constant price pressure thatforces the farmers to produce at lower and lower prices.On the other hand the quality requirements are increasing – and environmental protection is playing amore and more important role. The approach is similarto industrial production: Machines have to assume moreand more tasks; preferably without the intervention ofan operator. Productivity is increasing and personnel cost

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Application report automation in agriculture – windrow recognition

3D sensor on a tractor On the way to agriculture 4.0

Like a motorway “lane assist” in modern cars, the automation technology ensures that the tractor keeps

the baler in line – that it exactly follows the windrow.

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is decreasing. Quality of agriculture can also increase. Intelligent systems can, for example, optimise the use offertilisers so that depending on the soil only the amountthat is actually necessary is used. Such applications are summed up by the term “precisionfarming”. The systems and components used are similarto those in industrial applications. Sensors play an im-portant role in this context: They detect measured valuesthat are further processed by a controller and convertedinto commands for the actuators. It is particularly important that all components and systems can communicate with each other without anyinterruptions. This requirement is also known from in-dustrial applications. There are, however, also importantdifferences from industrial applications. The componentsused must resist the harsh environments in agriculturalmachinery.

n Keeping in line during harvesting A typical application is harvesting grass or cereals. Themowed grass or the straw that remains after the harvestis raked to form windrow lines in the field. Then the material can be further processed in a baler. The tractor baler has to be moved as exactly and continuously as possible over the windrow. The line guidance is a typical task that can be automated. Like amotorway “lane assist” in modern cars, the automationtechnology ensures that the tractor keeps the baler inline – that it exactly follows the windrow. In this application the sensor technology is decisive. Here,a 3D sensor system from ifm is used. Using the PMDtechnology it creates a three-dimensional image of theenvironment.

n Time-of-flight PMD technology The most important element of ifm’s 3D sensor system is a photonic mixer device (PMD) whose function is basedon the time-of-flight principle. A modulated light source illuminates the detection zonewith invisible infrared light. The PMD sensor that is coupled with the modulation source receives the re-flected light and measures the phase shift between thetransmitted and received signals. This allows the precisedetermination of the time-of-flight of the light and thusthe distance to the object. The PMD sensor has an integrated active extraneous light suppression and operates extremely reliably even in bright sunlight.Distances can be determined exactly with a resolution of 64 x 16 pixels. With this 3D sensor system there arecompletely new possibilities for environment and objectdetection. In the example above very good windrow recognition can be implemented where the baler is always pulled exactly over the windrow. At the sametime the speed of the tractor can be optimised. Balers have an optimum working range for the quantityflow. If it is too small at low speed – if not enough material is fed – the productivity in the harvest time

window suffers. If the speed is too high, the baler is overloaded and there are delays up to machinedowntime. To measure the quantity flow the 3D sensorsystem determines the size of the windrow. This infor-mation can therefore be used for optimising the speed.

n Image processing directly in the sensorBased on the large number of pixels and the high measuring frequency of up to 50 Hz there is a large datavolume. To implement applications as easily as possible,the sensor system processes the 3D data internally. To do so,two powerful 32-bit processors are directly integrated inthe sensor to provide some high-performance functions.

The compact and robust sensor systems can be easily installedon the tractor.

The 3D sensor system from ifm detects objects in the field of view reliably and fast.

Page 39: Application Reports Success stories from the real world 2016

Highly-developed algorithms from the automotive in-dustry are used which enable, for example, reliable objectrecognition of up to 20 objects simultaneously. Easy taskssuch as distance measurement or area surveillance are already implemented in the sensor. Typical functions suchas minimum, maximum and average distance are avail -able. This preprocessed data is communicated to a higher-level controller via CANopen or SAE J1939. Alternatively,the sensor system can also transfer the complete 3D data.An additional interface for Fast Ethernet UDP is availablewhich transfers the complete distance information for allpixels up to 50 times per second. The controller can evaluate this data as required. To configure the sensor system ifm provides a user-friendly software. Live moni-toring of the 3D data is also possible via the ifm Vision Assistant.

n Optimised for mobile machinesApplications in mobile machines have high demands onthe components used. They have to withstand environ-mental influences such as vibration, shock, dust and tem-perature fluctuations. Since the 3D system does not haveany moving parts, the sensor is particularly resistant toshock and vibration and virtually wear-free. Thanks to thehigh protection ratings IP67 and IP69K and the ambienttemperature range of -40 °C to 85 °C, the system is anexcellent choice for use on mobile machines. In addition,the system has the e1 approval that is important for vehicles. Both the sensor system and the associated infrared illumination are compact and can be installed onalmost any agricultural machine.

n FazitIn agriculture and other sectors in which mobile machi-nes are used it is possible to implement automated so-lutions with the 3D sensor system from ifm. Besides thewindrow recognition described above, many otherfunctions are possible. Instead of the subjective feelingof the machine operator, reliable data ensures optimummachine control. Productivity and efficiency depend lesson the routine and the know-how of the staff. Precisionfarming which is required in modern agriculture is thusmade considerably easier.

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Application report automation in agriculture – windrow recognition

A tractor pulls the baler over the windrow. Using the 3D sensor system, line tracking can be

automated and the speed can be optimised.

Page 40: Application Reports Success stories from the real world 2016

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