Distance Measurement with Inductive Sensors

When we think about inductive sensors we automatically refer to discrete output offerings that detect the presence of ferrous materials. This can be a production part or an integrated part of the machine to simply determine position. Inductive sensors have been around for a long time, and there will always be a need for them in automated assembly lines, weld cells and stamping presses.

We often come across applications where we need an analog output at short range that needs to detect ferrous materials. This is an ideal application for an analog inductive proximity sensor that can offer an analog voltage or analog current output. This can reliably measure or error proof different product features such as varying shapes and sizes. Analog inductive sensors are pure analog devices that maintain a very good resolution with a high repeat accuracy. Similar to standard inductive sensors, they deal very well with vibration, commonly found in robust applications. Analog inductive proximity sensors are also offered in many form factors from M12-M30 tubular housings, rectangular block style and flat housings. They can also be selected to have flush or non-flush mounting features to accommodate specific operating distances needed in various applications.

Application Examples:

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For more specific information on analog inductive sensors visit www.balluff.com.

Back to the Basics – Object Detection

In the last post about the Basics of Automation, we discussed how humans act as a paradigm for automation. Now, let’s take a closer look at how objects can be detected, collected and positioned with the help of sensors.

Sensors can detect various materials such as metals, non-metals, solids and liquids, all completely without contact. You can use magnetic fields, light and sound to do this. The type of material you are trying to detect will determine the type of sensor technology that you will use.

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Types of Sensors

  • Inductive sensors for detecting any metallic object at close range
  • Capacitive sensors for detecting the presence of level of almost any material and liquid at close range
  • Photoelectric sensors such as diffuse, retro-reflective or through-beam detect virtually any object over greater distances
  • Ultrasonic sensors for detecting virtually any object over greater distances

Different Sensors for Different Applications

The different types of sensors used will depend on the type of application. For example, you will use different sensors for metal detection, non-metal detection, magnet detection, and level detection.

Detecting Metals

If a workpiece or similar metallic objects Object Detection 2should be detected, then an inductive sensor is the best solution. Inductive sensors easily detect workpiece carriers at close range. If a workpiece is missing it will be reliably detected. Photoelectric sensors detect small objects, for example, steel springs as they are brought in for processing. Thus ensures a correct installation and assists in process continuity. These sensors also stand out with their long ranges.

Detecting Non-Metals

If you are trying to detect non-metal objects, for example, the height of paper stacks, Object Detection 3then capacitive sensors are the right choice. They will ensure that the printing process runs smoothly and they prevent transport backups. If you are checking the presence of photovoltaic cells or similar objects as they are brought in for processing, then photoelectic sensors would be the correct choice for the application.

Detecting Magnets

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To make sure that blister packs are exactly positioned in boxes or that improperly packaged matches are sorted out, a magnetic field sensor is needed which is integrated into the slot. It detects the opening condition of a gripper, or the position of a pneumatic ejector.

 

Level Detection

What if you need to detect the level of granulate in containers? Then the solution is to use capacitive sensors. To accomplish this, two sensors are attached in the containers, offset from each other. A signal is generated when the minimum or maximum level is exceeded. This prevents over-filling or the level falling below a set amount. However, if you would like to detect the precise fill height of a tank without contact, then the solution would be to use an ultrasonic sensor.

Stay tuned for future posts that will cover the essentials of automation. To learn more about the Basics of Automation in the meantime, visit www.balluff.com.

Smart IO-Link Sensors for Smart Factories

Digitizing the production world in the age of Industry 4.0 increases the need for information between the various levels of the automation pyramid from the sensor/actuator level up to the enterprise management level. Sensors are the eyes and ears of automation technology, without which there would be no data for such a cross-level flow of information. They are at the scene of the action in the system and provide valuable information as the basis for implementing modern production processes. This in turn allows smart maintenance or repair concepts to be realized, preventing production scrap and increasing system uptime.

This digitizing begins with the sensor itself. Digitizing requires intelligent sensors to enrich equipment models with real data and to gain clarity over equipment and production status. For this, the “eyes and ears” of automation provide additional information beyond their primary function. In addition to data for service life, load level and damage detection environmental information such as temperature, contamination or quality of the alignment with the target object is required.

One Sensor – Multiple Functions

This photoelectric sensor offers these benefits. Along with the switching signal, it also uses IO-Link to provide valuable information about the sensor status or the current ambient conditions. This versatile sensor uses red light and lets you choose from among four sensor modes: background suppression, energetic diffuse, retroreflective or through-beam sensor. These four sensing principles are the most common in use all over the world in photoelectric sensors and have proven themselves in countless industrial applications. In production this gives you additional flexibility, since the sensor principles can be changed at any time, even on-the-fly. Very different objects can always be reliably detected in changing operating conditions. Inventory is also simplified. Instead of four different devices, only one needs to be stocked. Sensor replacement is easy and uncomplicated, since the parameter sets can be updated and loaded via IO-Link at any time. Intelligent sensors are ideal for use with IO-Link and uses data retention to eliminate cumbersome manual setting. All the sensor functions can be configured over IO-Link, so that a remote teach-in can be initiated by the controller.

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Diagnostics – Smart and Effective

New diagnostics functions also represent a key feature of an intelligent sensor. The additional sensor data generated here lets you realize intelligent maintenance concepts to significantly improve system uptime. An operating hours counter is often built in as an important aid for predictive maintenance.

The light emission values are extremely helpful in many applications, for example, when the ambient conditions result in increased sensor contamination. These values are made available over IO-Link as raw data to be used for trend analyses. A good example of this is the production of automobile tires. If the transport line of freshly vulcanized tires suddenly stops due to a dirty sensor, the tires will bump into each other, resulting in expensive scrap as the still-soft tires are deformed. This also results in a production downtime until the transport line has been cleared, and in the worst case the promised delivery quantities will not be met. Smart sensors, which provide corresponding diagnostic possibilities, quickly pay for themselves in such cases. The light remission values let the plant operator know the degree of sensor contamination so he can initiate a cleaning measure before it comes to a costly production stop.

In the same way, the light remission value BOS21M_ADCAP_Produktbild.png allows you to continuously monitor the quality of the sensor signal. Sooner or later equipment will be subject to vibration or other external influences which result in gradual mechanical misalignment. Over time, the signal quality is degraded as a result and with it the reliability and precision of the object detection. Until now there was no way to recognize this creeping degradation or to evaluate it. Sensors with a preset threshold do let you know when the received amount of light is insufficient, but they are not able to derive a trend from the raw data and perform a quantitative and qualitative evaluation of the detection certainty.

When it comes to operating security, intelligent sensors offer even more. Photoelectric sensors have the possibility to directly monitor the output of the emitter LED. This allows critical operating conditions caused by aging of the LED to be recognized and responded to early. In a similar way, the sensors interior temperature and the supply voltage are monitored as well. Both parameters give you solid information about the load condition of the sensor and with it the failure risk.

Flexible and Clever

Increasing automation is resulting in more and more sensors and devices in plant systems. Along with this, the quantity of transported data that has to be managed by fieldbus nodes and controllers is rising as well. Here intelligent sensors offer great potential for relieving the host controller while at the same time reducing data traffic on the fieldbus. Pre-processing the detection signals right in the sensor represents a noticeable improvement.  A freely configurable count function offers several counting and reset options for a wide variety of applications. The count pulses are evaluated directly in the sensor – without having to pass the pulses themselves on to the controller. Instead, the sensor provides status signals, e.g. when one of the previously configured limit values has been reached. This all happens directly in the sensor, and ensures fast-running processes regardless of the IO-Link data transmission speed.

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Industry 4.0 Benefits

In the age of Industry 4.0 and IoT, the significance of intelligent sensors is increasing. There is a high demand from end users for these sensors since these functions enable them to use their equipment and machines with far greater flexibility than ever before. At the same time they are also the ones who have the greatest advantage when it comes to preventing downtimes and production scrap. Intelligent sensors make it possible to implement intelligent production systems, and the data which they provide enables intelligent control of these systems. In interaction with all intelligent components this enables more efficient utilization of all the machines in a plant and ensures better use of the existing resources. With the increasing spread of Industry 4.0 and IoT solutions, the demand for intelligent sensors as data providers will also continue to grow. In the future, intelligent sensors will be a permanent and necessary component of modern and self-regulating systems, and will therefore have a firm place in every sensor portfolio.

To learn more about these smart sensors, visit www.balluff.com.

When to Use Hygienic Design vs. Washdown

Both washdown and hygienic design are common terms used in the food and beverage industry, and are increasingly being used in the packaging industry. These terms are used in different scenarios and easily confused with each other. What exactly are the differences between them, and in what applications are each used?

Why are hygienic design and washdown needed?

The consumer, and more specifically, the health of the consumer is the core concern of the food and beverage industry. Contaminated food can pose a danger to life and limb. A product recall damages the image of a company, costs a lot of money and as a worst case scenario can lead to the complete closing of the company. To prevent such scenarios, a producers primary objective is to make sure that the food is safe and risk-free for the consumer.image 1

In food manufacturing and packaging plants, a differentiation is made between the food area (in direct contact with the product), the spray area (product-related) and the non-food area. The requirements of the machine components are different depending on which area they are in.

The Food Area

In the food area the food is unpacked, or partially unpacked, and particularly susceptible to contamination. All components and parts that may come in contact with the food must not adversely affect this, e.g. in terms of taste and tolerability.

The following needs to be considered to avoid contamination:

  • Hygiene in production
  • Use of food contact materials
  • Food-grade equipment in Hygienic Design

These requirements result in the need for components that follow the hygienic design rules. If the component supplier fulfills these rules, the machine manufacturer can use the components and the producer can use the machines without hesitation.

Hygienic Design

Many component suppliers offer different solutions for hygienic design and each supplier interprets the design differently. So what does hygienic design mean? What must be included and which certifications are the right ones?

  • The material used must be FoodContact Material (FCM). This means that the material is non-corrosive, non-absorbent and non-contaminating, disinfectable, pasteurisable and sterilizable.
  • Seals must be present to prevent the ingress of microorganisms.
  • The risk of part loss must be minimized.
  • Smooth surfaces with a radius of < 0.8 μm are permitted.
  • There must be no defects, folds, breaks, cracks, crevices, injection-molded seams, or joints, even with material transitions.
  • There must be no holes or depressions and no corners of 90°.
  • The minimum radius should be 3 mm.

Supporting institutions and related certifications

There are different institutions which confirm and verify the fulfillment of these rules. They also support the companies during the development process.

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EHEDG – The European Hygienic Engineering and Design Group offers machine builders and component suppliers the possibility to evaluate and certify their products according to Hygienic Design requirements.

image33A – 3-A Sanitary Standards, Inc. (3-A SSI) is an independent, non-profit corporation in the U.S. for the purpose of improving hygiene design in the food, beverage and pharmaceutical industries. The 3-A guidelines are intended for the design, manufacture and cleaning of the daily food           accessories used in handling, manufacturing and packaging of edible products with high hygiene requirements.

image4FDA – The Food and Drug Administration is a federal agency of the United States Department of Health and Human Services, one of the United States federal executive departments. Among other things, the FDA is responsible for food safety.

What does a hygienic design product look like?

Below is an example of a hygienic design product.

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  • Stainless steel housing VA 1.4404
  • Laser marking
  • Protection class IP69K (IEC 60529)
  • Active surface made of PEEK
  • EHEDG conform
  • FDA conform

Since the product contacting area is associated with high costs for the plant manufacturer and the operator, it’s beneficial to keep it as small as possible.

The Spray Area

In the spray area, there are different requirements than in the food area.
Depending on the type of food that is processed, a further distinction is made between dry and wet areas.

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Areas in the food and beverage production

Here we are talking about the washdown area. Washdown capable areas are designed for the special environmental conditions and the corresponding cleaning processes.

Washdown

Components which fulfill washdown requirements usually have the following features:

  • Cleaning agent/corrosion resistant materials (often even food compliant, but this is not a must)
  • High protection class (usually IP 67 and IP 69K)
  • Resistant to cleaning agents
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Photoelectric sensor for washdown requirements

Ecolab and Diversey are two well-known companies whose cleaning agents are used for appropriate tests:

Ecolab Inc. and Diversey Inc. are US based manufacturers of cleaning agents for the food and beverage industry. Both companies offer certification of equipment’s resistance to cleaning agents. These certificates are not prescribed by law and are frequently used in the segments as proof of stability.

The washdown component must also be easy and safe to clean. However, unlike the hygienic design, fixing holes, edges and threads are permitted here.

For basic information on IP69K see also this previous blog post.

To learn more about solutions for washdown and hygienic design click here.

 

The Perfect Photoelectric Sensor – Imagine No More

In my last blog, Imagine the Perfect Photoelectric Sensor, I discussed the possibilities of a single part number that could be configured for any of the basic sensing modes: through-beam, retroreflective, background suppression and diffuse. This perfect sensor would also have the ability to change the sensing mode on the fly and download the required parameters for a changing process or format change.  Additionally, it would have the ability to teach the sensing switch points on the fly, change the hysteresis, and have variable counter and time delays.

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Tomorrow is here today! There is no need to imagine any longer, technology has taken another giant leap forward in the photoelectric world.  Imagine the possibilities!

Below are just some of the features of this leading edge technology sensor. OEM’s now have the opportunity to have one sensor solve multiple applications.  End users can now reduce their spare inventory.

To learn more visit www.balluff.com.

 

Top 5 Automation Insights Posts from 2017

Kick off the New Year by taking a look at the top 5 Automation Insight blog posts from last year.

#5. Make sure your RFID system is future-proof by answering 3 questions

With the recent widespread adoption of RFID technology in manufacturing plants I have encountered quite a number of customers who feel like they have been “trapped” by the technology. The most common issue is their current system cannot handle the increase in the requirements of the production line. In a nutshell, their system isn’t scalable.5

Dealing with these issues after the fact is a nightmare that no plant manager wants to be a part of. Can you imagine installing an entire data collection system then having to remove it and replace it with a more capable system in 3 years or even less? It’s actually a pretty common problem in the world of technology. However, an RFID system should be viable for much longer if a few simple questions can be answered up front. Read more>>

#4. IO-Link Hydraulic Cylinder Position Feedback

Ready for a better mousetrap?  Read on…..

Some time ago here on Sensortech, we discussed considerations for choosing the right in-cylinder position feedback sensor.  In that article, we said:

“…….Analog 0-10 Vdc or 4-20 mA interfaces probably make up 70-80% of all in-cylinder feedback in use…..”

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And while that 70-80% analog figure is still not too far off, we’re starting to see those numbers decline, in favor a of newer, more capable interface for linear position feedback:  IO-Link.  Much has been written, here on Sensortech and elsewhere, about the advantages offered by IO-Link.  But until now, those advantages couldn’t necessarily be realized in the world of hydraulic cylinder position feedback.  That has all changed with the availability of in-cylinder, rod-style magnetostrictive linear position sensors.  Compared to more traditional analog interfaces, IO-Link offers some significant, tangible advantages for absolute position feedback in hydraulic cylinders. Read More>>

#3. External Position Feedback for Hydraulic Cylinders

The classic linear position feedback solution for hydraulic cylinders is the rod-style magnetostrictive sensor installed from the back end of the cylinder. The cylinder rod is gun-drilled to accept the length of the sensor probe, and a target magnet is installed on the face of the piston. A hydraulic port on the end cap provides installation access to thread-in the pressure-rated sensor tube. This type of installation carries several advantages but also some potential disadvantages depending on the application. Read More>>

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#2. 3 Smart Applications for Process Visualization

Stack lights used in today’s industrial automation haven’t changed their form or purpose for ages: to visually show the state (not status) of the work-cell. Since the introduction of SmartLight, I have seen customers give new2 meaning to the term “process visualization”. Almost every month I hear about yet another innovative use of the SmartLight. I thought capturing a few of the use-cases of the SmartLight here may help others to enhance their processes – hopefully in most cost effective manner.

The SmartLight may appear just like another stack-light.  The neat thing about it is that it is an IO-Link device and uses simply 3-wire smart communication on the same prox cable that is used for sensors in the field. Being an IO-Link device it can be programmed through the PLC or the controller for change of operation modes on demand, or change of colors, intensity, and beeping sounds as needed. What that means is it can definitely be used as a stack light but has additional modes that can be applied for all sorts of different operation/ process visualization tasks. Read More>>

#1. What is a Capacitive Sensor?

Capacitive proximity sensors are non-contact devices that can detect the presence or absence of virtually any object regardless of material.  1They utilize the electrical property of capacitance and the change of capacitance based on a change in the electrical field around the active face of the sensor.

A capacitive sensor acts like a simple capacitor.  A metal plate in the sensing face of the sensor is electrically connected to an internal oscillator circuit and the target to be sensed acts as the second plate of the capacitor.  Unlike an inductive sensor that produces an electromagnetic field a capacitive sensor produces an electrostatic field. Read More>>

Where Did You Find That Sensor?

I recently visited a customer that has a large amount of assembly lines where they have several machine builders manufacturing assembly process lines to their specification. This assembly plant has three different business units and unfortunately, they do not communicate very well with each other. Digging deeper into their error proofing solutions, we found an enormous amount of sensors and cables that could perform the same function, however they mandated different part numbers. This situation was making it very difficult for maintenance employees and machine operators to select the best sensor for the application at hand due to redundancy with their sensor inventory.

The customer had four different types of M08 Inductive Proximity sensors that all had the same operating specifications with different mechanical specifications. For example, one sensor had a 2mm shorter housing than one of the others in inventory. These 2mm would hardly have an effect when installed into an application 99% of the time. The customer also had other business units using NPN output polarity VS PNP polarity making it even more difficult to select the correct sensor and in some situations adding even more downtime when the employee tried to replace an NPN sensor where a PNP offering was needed. As we all know, the NPN sensor looks identical to the PNP offering just by looking at it. One would have to really understand the part number breakdown when selecting the sensor, and when a machine is down this sometimes can be overlooked. This is why it is so important to standardize on sensor selection when possible. This will result in more organized inventory by reducing part numbers, reducing efforts from purchasing and more importantly offering less confusion for the maintenance personel that keep production running.

Below are five examples of M08 Inductive sensors that all have the same operating specifications. You will notice the difference in housing lengths and connection types. You can see that there can be some confusion when selecting the best one for a broad range of application areas. For example, the housing lengths are just a few millimeters different. You can clearly see that one or two of these offerings could be installed into 99% of the application areas where M08 sensors are needed for machine or part position or simply error proofing a process.

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For more information on standardizing your sensor selection visit www.balluff.com

 

Imagine the Perfect Photoelectric Sensor

Photoelectric sensors have been around for a long time and have made huge advancements in technology since the 1970’s.  We have gone from incandescent bulbs to modulated LED’s in red light, infrared and laser outputs.  Today we have multiple sensing modes like through-beam, diffuse, background suppression, retroreflective, luminescence, distance measuring and the list goes on and on.  The outputs of the sensors have made leaps from relays to PNP, NPN, PNP/NPN, analog, push/pull, triac, to having timers and counters and now they can communicate on networks.

The ability of the sensor to communicate on a network such as IO-Link is now enabling sensors to be smarter and provide more and more information.  The information provided can tell us the health of the sensor, for example, whether it needs re-alignment to provide us better diagnostics information to make troubleshooting faster thus reducing downtimes.  In addition, we can now distribute I/O over longer distances and configure just the right amount of IO in the required space on the machine reducing installation time.

IO-Link networks enable quick error free replacement of sensors that have failed or have been damaged.  If a sensor fails, the network has the ability to download the operating parameters to the sensor without the need of a programming device.

With all of these advancements in sensor technology why do we still have different sensors for each sensing mode?  Why can’t we have one sensor with one part number that would be completely configurable?

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Just think of the possibilities of a single part number that could be configured for any of the basic sensing modes of through-beam, retroreflective, background suppression and diffuse. To be able to go from 30 or more part numbers to one part would save OEM’s end users a tremendous amount of money in spares. To be able to change the sensing mode on the fly and download the required parameters for a changing process or format change.  Even the ability to teach the sensing switch points on the fly, change the hysteresis, have variable counter and time delays.  Just imagine the ability to get more advanced diagnostics like stress level (I would like that myself), lifetime, operating hours, LED power and so much more.

Obviously we could not have one sensor part number with all of the different light sources but to have a sensor with a light source that could be completely configurable would be phenomenal.  Just think of the applications.  Just think outside the box.  Just imagine the possibilities.  Let us know what your thoughts are.

To learn more about photoelectric sensors, visit www.balluff.com.

The Evolving Technology of Capacitive Sensors

In my last blog post, Sensing Types of Capacitive Sensors, I discussed the basic types of capacitive sensors; flush versions for object detection and non-flush for level detection of liquids or bulk materials.  In this blog post, I would like to discuss how the technology for capacitive sensors has changed over the past few years.

The basic technology of most capacitive sensors on the market was discussed in the blog post “What is a Capacitive Sensor”.  The sensors determine the presence of an object based on the dielectric constant of the object being detected.  If you are trying to detect a hidden object, then the hidden object must have a higher dielectric constant than what you are trying to “see through”.

Conductive targets present an interesting challenge to capacitive sensors as these targets have a greater capacitance and a targets dielectric constant is immaterial.  Conductive targets include metal, water, blood, acids, bases, and salt water.  Any capacitive sensor will detect the presence of these targets. However, the challenge is for the sensor to turn off once the conductive material is no longer present.  This is especially true when dealing with acids or liquids, such as blood, that adheres to the container wall as the level drops below the sensor face.

Today, enhanced sensing technology helps the sensors effectively distinguish between true liquid levels and possible interference caused by condensation, material build-up, or foaming fluids.  While ignoring these interferences, the sensors would still detect the relative change in capacitance caused by the target object, but use additional factors to evaluate the validity of the measurement taken before changing state.

These sensors are fundamentally insensitive to any non-conductive material like plastic or glass, which allows them to be utilized in level applications.  The only limitation of enhanced capacitive sensors is they require electrically conductive fluid materials with a dipole characteristic, such as water, to operate properly.

Enhanced or hybrid technology capacitive sensors work with a high-frequency oscillator whose amplitude is directly correlated with the capacitance change between the two independently acting sensing electrodes.  Each electrode independently tries to force itself into a balanced state.  That is the reason why the sensor independently measures  the capacitance of the container wall without ground reference and the capacitance of the conductivity of the liquid with ground reference (contrary to standard capacitive sensors).

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Up to this point, capacitive sensors have only been able to provide a discrete output, or if used in level applications for a point level indication.  Another innovative change to capacitive sensor technology is the ability to use a remote amplifier.  Not only does this configuration allow for capacitive sensors to be smaller, for instance 4mm in diameter, since the electronics are remote, they can provide additional functionality.

The remote sensor heads are available in a number of configurations including versions image2that can withstand temperature ranges of -180°C up to 250°C.  The amplifiers can now provide the ability to not only have discrete outputs but communicate over an IO-Link network or provide an analog output.  Now imagine the ability to have an adhesive strip sensor that can provide an analog output based on a non-metallic tanks level.

For additional information on the industry’s leading portfolio of capacitive products visit www.balluff.com.

Solve Difficult Sensing Applications with Ultrasonic Technology

When reviewing or approaching an application, we all know that the correct sensor technology plays a key role in reliable detection of production parts or even machine positioning. In many cases, application engineers choose photoelectric sensors Image1as their go-to solution, as they seem more common and familiar. Photoelectric sensors are solid performers in a variety of applications, but they can run into limitations under certain conditions. In these circumstances, considering an ultrasonic sensor could provide a solid solution.

An ultrasonic sensor operates by emitting ultra-high-frequency sound waves. The sensor monitors the distance to the target by measuring the elapsed time between the emitted and returned sound waves.

Ultrasonic sensors are not affected by color, like photoelectric sensors sometimes are. Therefore, if the target is black in color or transparent, the ultrasonic sensor can still provide a reliable detection output where the photoelectric sensor may not. I was recently approached with an application where a Image2customer needed to detect a few features on a metal angle iron. The customer was using a laser photoelectric sensor with analog feedback measurement, however the results were not consistent or repeatable as the laser would simply pick up every imperfection that was present on the angle iron. This is where the ultrasonic sensors came in, providing a larger detection range that was unaffected by surface characteristics of the irregular target. This provided a much more stable output signal, allowing the customer to reliably detect and error-proof the angle iron application. With the customer switching to ultrasonic sensors in this particular application, they now have better quality control and reduced downtime.
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So when approaching any application, keep in mind that there is a variety of sensor technologies available, and some will provide better results than others in a given situation. Ultrasonic sensors are indeed an excellent choice when applied correctly. They can measure fill level, stack height, web sag, or simply monitor the presence of a target or object. They can also perform reliably in foggy or dusty areas where optical-based technologies sometimes fall short.

For more information on ultrasonic and photoelectric sensors visit www.balluff.com.