moreTURCK 1 11 EN

moreTURCK 1 11 EN
Issue 01
2011
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T h e M a g a z i n e f o r C u s t o m e r s o f t h e Tu r c k G r o u p
“Huge Potential”
RFID-tags with integrated
sensors offer many possibilities,
Walter Hein explains Page 12
Fieldbus Replaces 19”
Elantas Beck modernizes
19” interface cards with Turck's
excom remote I/O
Page 32
Control Stand
Somakon controls MP blender
family with HMI/PLC solution,
VT250, from Turck
Page 36
Total Transparency
How the automotive industry benefits from the general use
of RFID technology – from the supplier to the delivery
02 E D I TO R I A L _ C H R I S TO P H
ZÖLLER
Demand and Reality
Let's be honest – how many manufacturers do you know
that present themselves as 'solution providers' – at least
on paper? To offer solutions instead of single components is an honorable thought, but often it is difficult to
realize this challenge during the daily business. Historically grown sales structures and corporate strategy often
differ widely.
However, Turck offers solutions to its customers, such
as in RFID and image processing or with the CoDeSysprogrammable fieldbus gateways and HMI/PLC systems.
The more often these solutions are requested, the more
important it becomes to adapt our processes accordingly; both internally and externally. Much has changed at Turck during
the past few years, and today we are able to provide the support for
the solution business that you rightly expect. Turck's new support
concept provides systematic guidance and project management in
the fields of industrial image processing and RFID.
For complex questions about automation, you will get support from
our newly created regional distribution system. If a challenging project arises, a project management team in Mülheim professionally
coordinates the whole project design and management. If necessary, our system partners with their distinct knowledge ensure the
efficient implementation of the project – especially with identification solutions. In addition to our already existing partnerships, we
added two more partners recently: The Company ISW in Hamburg
for the field of vision and the company AIT Göhner in Stuttgart for
RFID projects.
Already at the Hannover Fair we are going to hold subject related
panels in cooperation with our partners and we would like to invite
you to attend (see page 5). Of course, we also would like to welcome
you at our booth H55 in hall 9.
Sincerely, yours
Christoph Zöller, Director Sales Factory Automation
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CONTENT_1_2011 NEWS
Innovation for automation specialists COVERSTORY
RFID IN THE AUTOMOTIVE INDUSTRY: Total Transparency How the automotive industry benefits from the use of RFID technology –
from the supplier to the delivery
INSIDE
08
12
VISION APPLICATION PARK: Automation to Go At the Vision Application Park, visitors can witness the automatic transformation of their
order into a customized product in a multi-vendor machine
14
RFID IN THE FOOD INDUSTRY: Intelligent Chocolate Production Informational advantage through RFID: Wireless identification of chocolate forms
guarantees transparency during the whole production chain
TECHNOLOGY
20
ENCODERS: The Right Turn Turck expands its sensor portfolio with encoders in different types and designs
24
RFID: Efficiently Stored The Bachofen AG from Switzerland optimizes their logistics system with the wireless
identification system, BL ident, from Turck for automatic guidance
26
RFID: Easy Cutting Tools Turck’s RFID-system, BL ident, creates transparency for the cutting tool management
of the Shenyang Machine Tool Co. Ltd. (SMTCL)
30
FIELDBUS TECHNOLOGY: Cards on the Table Elantas Beck modernizes 19”-Interface cards with the excom remote-I/O-system
from Turck
32
FIELDBUS TECHNOLOGY: The Right Mix Somakon Verfahrenstechnik uses the HMI/PLC solution VT250 from Turck for the
intelligent control and operator guidance of its MP blender family
36
FIELDBUS TECHNOLOGY: Good Listener Ertsoverslagbedrijf Europoort C.V. installed the Ethernet-Profibus-Interface PB-XEPI
from Turck for constant monitoring of the fieldbus communication
38
SENSOR TECHNOLOGY: Preventing Rollovers The American Ferrara Fire Apparatus uses Turck’s inclinometer for tilt testing to make
sure that its fire trucks are stable in the field
40
SERVICE
CONTACT: Your Fastest Way to Turck We show you, how, when and where Turck is there for you
42
CONTACT: Imprint
43
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To offer its customers the ideal sensor solution, Turck
expanded its portfolio with a comprehensive range
of encoders
Page 24
16
POSITION AND ANGLE MEASUREMENT: Fail-Safe Mini Measuring Device Turck presents the first inductive miniature linear displacement sensor for a measuring range
from 50 to 200 mm using the interference-free resonant circuit measuring principle
APPLICATIONS
Source cover image: Volkswagen Sachsen GmbH
04
INTERVIEW: “Savings on Process Costs” Mathis Bayerdörfer, editor in chief of the trade journal A&D, talked to product manager
Walter Hein about RFID data carriers with integrated sensors from Turck
TREND
03
With the PB-XEPI, Ertsoverslagbedrijf C.V. in Rotterdam
is able to identify disturbances of the Profibus-net
centrally via web browser
Page 38
Ferrara Fire Apparatus Inc. in the USA guarantees the
stability of their fire engines with a static tilting test –
inclinometers from Turck measure the angle Page 40
04 N E W S _ I N N O VAT I O N S
Turck at
Interpack
 Turck will exhibit its portfolio for
the food and packaging industry at
booth D77 in hall 13 at the Interpack trade show in Düsseldorf. Visitors can see the BL ident modular
RFID-system with special developments for the food and packaging
industry, such as data carriers (tags)
with on-board sensor tags for use in
autoclaves, as well as read/write heads
with wash-down capable design. Also
on display are factor-1 sensors with
a terminal chamber from the uprox+
wash-down series. Like the sensors,
the terminal chamber is resistant to
cleansing agents and high-pressure
cleansers. The same applies to FBplus
connectors, as well as the completely
metal M25U Ultrasound sensor from
Banner Engineering.
Connector Series
 The new M12x1 “base line“ connector series has been designed by
the connector specialist, Escha, for
classical applications in the fields of
machine-building and automation.
For the time being, male and female
versions are available as 3-, 4-, and
5-pole straight versions with A- or
B-coding. The angled variants will
follow in the second quarter. Two
cable qualities (PVC or PUR halogenfree) are available, through which
base line can be adapted to the
respective application.
Fail-Safe Mini
Displacement Sensor
 Turck developed the
first miniature linear
displacement sensor,
the LI-Q17, especially
for very short measuring ranges between
50 and 200 mm. The
LI-Q17 doesn’t work
with a magnetic locator but with the resonant circuit measuring principle, where
an object’s position
is detected via an
inductive oscillating
system consisting of a
condenser and a coil.
As the only sensor of
its kind, the LI-Q17 is
able to work reliably
where the functionality of a magnetic position device is massively affected by electromagnetic
fields caused by large motors or welding plants. The robust LI-Q17 in an IP67rated housing is available in four different sizes with measuring ranges of 50,
100, 150 and 200 mm, and a temperature range from -40 to +70 °C. The first
models have an analog output (0…10 V, 4…20 mA, 0,5…4,5 V), and a highmore on page 20 

resolution SSI model will be available in the future.
Triangulation Sensors
 Turck extends its portfolio with a series of triangulation laser displacement
sensors for non-contact height or thickness measurement of a wide variety of
materials, made by Turck’s partner Banner Engineering. Sheet metal, wood, ceramic, paper, plastic, rubber, foam and baking dough are just some of the materials
that can be measured for quality assurance. The new LH Series sensors provide
precise measurement of distance, thickness and alignment. Applications include
hot parts, machined parts, semiconductors and PCBs, shiny or reflective parts, and
soft or sticky parts. There
are three models in the
series, with measurement
ranges of 25-35, 60-100
and 100-200 mm. Thickness is measured by two
sensors mounted at either
side of the target that
automatically synchronize
with one another. Up to
32 sensors can be easily combined in a mixed
measurement network of
multi-track displacement
or thickness sensors.
05
Innovation
Forums
 During the fair at Hannover, Turck
offers a number of innovation forums
in cooperation with its system partners.
Interested visitors can attend the free
forums about: „Plagiarism protection through RFID and iDot“, „Manage RFID-projects effectively“ and
„Optimization of quality management and production processes
with parametrizable camera sensors“. Participants will have the oppor-
Flexible Factor-1 Sensor
 The QP08 is the latest member of the ferrite-core-free uprox+ family from Turck.
The compact factor-1 sensor offers a high EMC and magnetic field resistance, as well
as high switching distances for all metals – like all uprox+ sensors. Especially for use
in cramped spaces with little room for the installation – for example in the machine
handling industry or in packaging machines – the non-flush sensor in a plastic housing
provides time and cost savings with regard to installation and service. The new factor-1
sensor reaches up to 300 percent higher switching distances compared to customary
sensors when detecting aluminum, which is often used as target in this industry. Not
only does the sensor have a small and compact housing (32 x 20 x 8 mm, LxWxH), it also
features small metal-free zones, a switching distance of 10 mm and the possibility to
install the sensor directly onto metal. Furthermore, the boreholes are compatible with
all Q08 sensors and similar designs, which allows a fast and uncomplicated replacement
of customary sensor types. Large, curved LEDs display the operational readiness and the
switching state of the QP08.
BL67 Adapter for
Parker Valves
 In cooperation with Parker Hannifin, Turck developed a valve adapter
for its BL67 I/O-system and the valve series Isys Micro and Isys ISO from
Parker. With the new modules, up to 32 valves can be controlled directly with
the BL67. The combination of the IP67 rated I/O system and the valves allows an
easy installation and an uncomplicated connection of electrical and pneumatic components in a minimal space. With its BL67 gateway, the new dreamteam can be integrated easily into the infrastructure of the customer’s devices. The gateway,
also offered as a CoDeSys programmable
version, is available for the established
fieldbuses: DeviceNet, CANopen,
Profibus DP, EtherNet/IP, Profinet IO and
Modbus
TCP.
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tunity to talk with the experts over a
small snack after the presentation. For
further information on the web, visit:
www.turck.de/foren
Identification in
Application Park
 At the Vision Application Park at the
Hannover Messe (booth A12, hall 17),
visitors can order their own special figure of Playmobil and witness the automatic transformation of their order
into a customized product. In a large
multi-vendor-machine, consisting of
ten modular test units and processing
cells, the Park shows a multitude of
optical test procedures. The visitor can
see for himself that there is a solution
for nearly anything. The Park connects
vision, handling and automation
more on page 14 

technology.
6
O PI O N S
06FNI EDWUS _CI NI AN OS VAT
Robust
M40 Connectors
 Turck's
expanded
powerfast series
provides robust connection technology for power
and signal transmissions up to 42
Amps and 600 Volts. Cordsets and
tees are available in 7/8", M16, 1-3/8“,
M23 and M40 and provide a plug and
play solution for wiring power and
signal transmission. To eliminate possible disturbances, Turck offers shielded cables in addition to the standard
lines. A powerlok safety-clip that
protects a connector against accidental disconnection is also available. All
connector sizes are rated to IP67 at
a minimum. The user benefits from
a remarkably short installation time
because of the abandonment of terminal boxes
and the possibility of
prefabrication.
Training
 Turck now offers training courses
about its products, technologies and
systems for interested customers. The
training will teach the customers how
to implement and operate the solutions from Turck fast and reliably. More
information and registration online:
www.turck.de/training

 Webcode
more11110e
Info
You can find more information on the
reports or product presentation in
[email protected] under www.turck.com.
Simply enter the Webcode that you
find at the end of each article in the
search field. The following article page
takes you directly to the product database or you can download or send the
article as a pdf file.
New Range of Encoders
 To offer its customers the ideal sensor solution, Turck completes its portfolio
with a comprehensive range of encoders. The company now offers magnetic and optical encoders in all categories, from incremental over absolute
singleturn, absolute multiturn up to analog. Turck offers the new encoders in
different sizes. In addition to the standard model with 58 mm, there are miniature models of 24 mm
up to 37 mm, as well as
models for large hollow
shafts with up to 100
mm. Thanks to the robust
mechanical construction
and the compact die-cast
housing, the encoders
are insensitive to change
in temperature, jolts and
vibrations. The IP67 rated
devices – special models for offshore use are
IP69k-rated – cover a temperature range of -40 to

+105 °C. more on page 24 
Image Sensor with
Multiple Inspections
 An image sensor offering enhanced recognition, communication and rapid
changeover capabilities has been introduced by Turck and its partner Banner
Engineering. The new iVu Plus TG sensor extends the iVu image sensor platform with capability to save up to
30 inspections. It monitors labels,
parts and packaging for type, size,
orientation, shape and location.
Its color touch-screen display and
on-board memory allow fast and
easy installation and application
setup without connection to a PC.
Ethernet communication assures
compatibility with most industrial systems. In addition to previously available functions, the iVu
Plus TG has a sort sensor that can
recognize up to ten different patterns within the same inspection.
Applications for this new capability include identifying parts on a
production line and ensuring that
all required parts are present in a
package. Other functions included
in the unit is an area sensor to ensure that some features are present on a part,
blemish sensor to detect flaws, such as scratches or color variation and match
sensor to verify that a pattern, shape or part is identical to a reference. Ease
of use is supported by integrated lighting, adjustable focus lenses, automatic
exposure control and high speed processing.
No matter what...
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whenever you need!
.
www.ien.eu
IEN Europe offers a comprehensive information overview for the
industrial professional through an interesting variety of applications,
technical articles, latest product information, news from the industry
and a detailed listing of all relevant shows/events. All are available on
the European market.
www.pcne.eu
PCN Europe has become the reference media covering the latest
industry news, application stories, in-depth technical articles and
product news from and for the processing industries.
www.technische-revue.eu
TR is the indispensable source of information for design engineers/
technical management, mainly in the field of mechanical and electrical
engineering. TR informs on the latest products, trends and
technologies dedicated to the manufacturing industries.
www.pei-france.com
PEI targets key design and engineering management within local and
French-subsidiary companies as the most responsive industrial media
serving France.
www.ien-italia.eu
IEN Italia offers product news information directly to professionals in
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serving the Turkish market.
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08 C O V E R S TO R Y _ R F I D
Author
Walter Hein is the
RFID product
manager at Turck
in Mülheim
Webcode | more11100e
Many automobile
manufacturers are
currently evaluating the
possibilities of continuous identification
I N T H E AU TO M OT I V E I N D U S T R Y
09
Total Transparency
How the automotive industry benefits from the use of RFID
technology – from the supplier to the delivery
A
uto-ID procedures for the automatic identification of components, workpiece carriers or
tools have been used in manufacturing for a
long time. For decades, manufacturers have used optical procedures, like barcodes or data-matrix-codes for
contactless identification, but the focus now lies on
wireless identification technology RFID (radio frequency
identification) .
One of the main advantages of RFID: As opposed
to the optical Auto-ID procedures, the user can read the
authenticity features and also rewrite them to a data
carrier. Data carriers (also known as tags) accompany
the part through the whole production cycle or quality
test; relevant data is written automatically onto the tag
and read at the end of the production cycle. Together,
with the finished product, there is also a quality management protocol available that shows all production
steps of the product, as well as the quality test.
Another benefit of RFID technology is that the
information transfer by electromagnetically radio
waves is less susceptible to environmental influences.
While the externally applied, printed bar codes become
unusable through high temperatures, dirt or moisture,
the special RFID data carriers and robust scanners allow
the use of RFID systems under very rough conditions or
through nontransparent media, for example in painting
plants or kilns.
Turck's modular RFID system, BL ident, can operate interference free HF and
high transmission range UHF combined read/write heads at the same time
Rethinking in the automotive industry
The triumphal procession of RFID for the automobile
production started about 20 years ago. For more than
five years, Turck has been part of it with its modular
RFID-system, BL ident, that was developed in close
cooperation with automobile manufacturers at that
time. One of the first BL-ident data carriers was a high
temperature tag and could resist 210 °C without problems. This tag is attachable to a carriage – so called skid
– that transports a vehicle body through production.
That is how the path of the vehicle can be tracked from
shelling to the final assembly, as long as the transport
system stays the same.
This procedure is a typical example for the previous
use of RFID-technology in the automobile production:
Mostly monorail conveyors, skids or other carriers for
the vehicle body and larger components, like engines
or axles, are identified. Compared to optical measuring,
this procedure increased the performance remarkably,
but with further development of data carriers and combined read/write heads, the potential has increased
even more. Nearly all automobile manufacturers think
about equipping the vehicle bodies or even the single
components with a tag directly instead of equipping
the transport system. This has the additional advanmore @
1_2011
tage that control about the installed components
is possible directly after the assembly. Also, assignment problems because of a change of the transport
system are ruled out.
If a data carrier is firmly connected to the vehicle
body at the beginning of the production process, the
body can be identified safely at any time - from shelling to painting and the final assembly to the delivery.
One of the pioneers in this field is Volvo. The car manufacturer has used vehicle body identification in its plant
in Gent in Belgium for about three years. The RFID-tag
is installed to the front side member of the vehicle at
the beginning of the production process. Through the
whole process, including the painting where tempera-

 Quick read
For more than two decades, the automotive industry has used RFID solutions,
mainly for the identification of their vehicle body transport systems. Thanks to
improved technology and the automotive knowledge of the RFID specialist
Turck, the industry today considers equipping every single vehicle body and
component with data carriers, to benefit from a continuous identification and
quality control through the whole production process.
10 C O V E R S TO R Y _ R F I D
I N T H E AU TO M OT I V E I N D U S T R Y
Vehicle body identification demands
UHF-system
When transport systems are equipped with tags, there
are always defined, relatively small distances between
the data carriers and the combined read/write heads,
so that it is guaranteed that the maximum transmission
range is kept. If the tag is attached to the vehicle body
directly, the range is inevitably larger – it mostly varies
between 30 and 100 cm. For this reason, HF-systems,
which are working within the frequency range of 13.56
MHz, can't be used any longer. This frequency range is
very popular because it guarantees failure free radio
communication and a high read-write speed, so that
the tags can be read very quickly while driving by. Since
the transmission range is limited to 20 cm, another
solution is needed for the vehicle body identification.
The solution is to find within the UHF-range of
865-868 MHz, that allows ranges up to three meters.
Unfortunately, there is also the disadvantage that the
installation is a lot more complex because of the high
range. Through reflections, it can overreach the signals, so that the combined read/write heads read more
than they should. Furthermore, there are often problems when an UHF-tag has to be read while standing
upright, because interferences can lead to zero points
in the transmission field. This is a challenge, because
in the processes where the previously used barcodes
are replaced by RFID, there is a process-related stop
at the reading station because the barcodes can't be
read while driving by. To be able to read UHF-systems
while standing upright, Turck developed combined
read/write heads with two antennas that change their
polarization direction and simulate a moving field. The
staff of Volvo in Gent works with this UHF-technology
without any problems.
From the supplier to the final assembly
The fact that UHF-challenges can be mastered and carry
considerably lower data carrier prices – a temperature
resistant design costs about 50 cent today – convinced
At Volvo in Gent, a
robust plastic tag
is attached to the
side member of the
vehicle body directly
at the beginning of
the shelling
tures up 200 °C can cause problems to the electronics of most data carriers, the tag stays on the vehicle.
Most car manufacturers paint their vehicle bodies
three to five times and expose them correspondingly
frequent to the high temperatures. The electronics
of conventional data carriers often break during this
procedure. With a few technical tricks, Turck is able to
deliver disposable data carriers that are able to resist a
limited amount of high-temperature phases and therefore can stay on the vehicle all the time. Essentially it
is only a question of the durability of the connection
between the ICs and the antenna coil under the influence of high temperature. Classical solder connections
are unsuitable. Instead, technologies like friction welding are used to guarantee a lasting stability. Alternatively, an inductive coupling can be used instead of
the direct connection, although it needs more energy
during the transmission.
At exhibitions, Turck demonstrates the feasibility of gen
11
Until today, usually
the transport systems
are identified by RFID
data carriers, like
in this example the
transport hangers of
the supplier Tower
Automotive
many automobile manufacturers to equip the coming
model ranges with data carriers on the vehicle bodies,
which means that they can be identified throughout
the whole process, from shelling to painting. But this is
not all: In further projects where Turck is involved, the
possibilities are tested to also optimize the delivered
parts of the suppliers with RFID and thereby optimize
the whole production process up to the final assembly
with the wireless identification.
At the moment, the delivered single components
are still identified with barcodes, but they shall be
equipped increasingly with data carriers in the future.
With RFID, these components can be identified without
problems. Furthermore, RFID lessens the risk that wrong
components are installed. An example: The barcode of
an airbag is read before the installation. Afterwards it
can't be read any longer because it is either covered
by the vehicle body or was removed from the component. Based on the bill of materials it becomes apparent
during the final inspection, that the wrong airbag was
installed. Now an expensive rework is necessary. With
RFID it would be possible to install a scanning station
directly after the attachment mounting station. This
scanning station reads the ID of the airbag and alarms
the staff if something is wrong.
Conclusion
eral wireless identification for the automotive industry
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Turck has shown in numerous tests with suppliers
and manufacturers that it makes sense to also equip
the supplier components, like airbags, interior trim,
seats or engines, with the powerful RFID technology
to make them an efficient part of the production process. At innovation forums and events during fairs and
conferences for the automotive industry, the automation specialists will present how the industry is able to
benefit from the general use of RFID technology and
the BL ident system. Most recently, Turck introduced its
concept at the AutoID/RFID Solutions Park at the CeBIT.
The next possibility to gather information about the
benefits of RFID for the automotive industry will be at
the 22. Automobil-Forum in Stuttgart at the 24th and
25th of May 2011, which takes place at the Forum of
the Schlosspark in Ludwigsburg. N
12 I N S I D E _ I N T E R V I E W
For many applications,
sensor data carriers are
a cost-effective transmission solution that
is easy to implement,
Walter Hein asserts
“Savings on Process Costs”
Mathis Bayerdörfer, editor in chief of the German trade journal A&D, talked to product manager
Walter Hein about RFID data carriers with integrated sensors from Turck
At the Hannover fair, Turck will present a RFID data carrier with an integrated temperature sensor. Why this
unusual combination, Mr. Hein?
We often get requests from the industrial
sector where a customer needs a sensor,
but it isn't possible to connect the sensor with a cable. We are talking about very
small distances where a complex wireless
system doesn't make sense. The industrial sector has difficulties with wireless
solutions in general because the process
13
data needs to be transferred flawlessly,
but systems like WLAN or Bluetooth often
interfere with each other. Therefore, the
users often do not trust the safety of the
wireless transfer. With our new solution,
we provide a reliable data transfer, and
establish a solution for a specific range of
applications, which is very cost-effective
compared to wireless-solutions.
What is the difference Turck makes
to provide a safe data transfer?
We rely on established RFID technology; a high frequency solution at 13.56
megahertz. It is standardized, ISO15693
compatible, popular and insensitive to
environmental influences. The possibility
of interferences through other systems
is eliminated from the beginning, especially because the transmission distance
is only a couple of centimeters. Furthermore, the customer isn't bound to a
proprietary system.
How do the sensor data carriers
work exactly?
For the data carrier, also called a tag, we
use a basic-IC that has an integrated
temperature sensor and two interfaces
for additional sensors. The temperature
sensor is permanently attached, but the
other two inputs can be connected to
sensors that are required by the application, such as a proximity switch or a pressure sensor. The tags regularly record a
result and save it to be read. There is also
a data logger that is able to record measuring curves. The tag receives the needed
energy over the high frequency field it is
located in.
Is this new approach able to
improve the reputation of wireless
technology?
If it is in relation to small distances and
data volume, then the answer is yes especially because the system can be
adapted to different applications. The size
of the sensor depends on the transmission
distance, an energy storage device supplies the sensors – coordinated with the
measuring intervals.
Are there already pilot projects for
the new system?
We work with renowned customers from
different industries that have specific
requirements for this technology. The food
industry in particular has a lot of use for this
technology, because it allows processes to
become transparent. Among other things,
temperature cycles can be recorded exactmore @
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ly and adapted precisely, which is essential
for quality management. For example, the
user can retrace how chocolate forms are
exposed to temperature fluctuations and
cleaning liquids during the process, so
that they can be replaced before the forms
get brittle and plastic splinters get into
the chocolate.
What are other possible fields of
application?
There are a lot of applications in the food
industry, such as the continuous monitoring of cold chains and the sterilization
of cans. A lot of food is made durable in
huge pressure cookers, also known as
autoclaves. Through heat, they reduce the
amount of bacteria in the food to a harmless level. The autoclaves are operated by
hand so it is possible for them to be open
longer than intended. That can increase
the bacteria growth, so that the normal
processing time isn't sufficient any longer
– the cans threaten to burst after some
time. That’s why many producers temporarily store their goods for a couple of
weeks for observation. With the new solution, the user can control at what exact
temperature the process in the autoclaves
started – and adjust it, if needed. With this
solution, interim storage isn't necessary
any longer.
Are there other applications beyond
the food industry?
The sensor tags are also suitable for engineering processes at any place where
you can find rotating parts. For example,
in the paper industry all rollers have to
apply a constant, exactly defined pressure onto the paper so that it doesn't rip.
Oftentimes, there is a specific temperature needed too. With the new solution
from Tuck, the user attaches the new sensor tag including the temperature and a
pressure sensor to the rollers and installs a
combined head for analysis. This provides
a cost-efficient transmission solution that
is easy to implement.
What are the costs for the system?
Since the solution is customer-specific,
there is no package price. But in most
cases, the savings on the process costs are
remarkable and the return on investment
can be achieved within days, weeks or a
few months at the latest. With the new
sensor data carriers, Turck offers a solution for numerous problems that either
couldn't be solved in the past at all or that
only could be solved with high financial
and technical effort. “
We work with renowned customers from different industries
that have specific requirements for
this technology. The food industry
in particular has a lot of use for this
technology.
„
Walter Hein
“
In most cases, the savings on the
process costs are remarkable and
the return on investment can be
achieved within days, weeks or a few
months.
„
Walter Hein
Author
Mathis Bayerdörfer is
editor in chief of the
German trade journal A&D
www.aud24.net
Webcode |
more11130e
14 I N S I D E _ V I S I O N
A P P L I C AT I O N PA R K
Automation
to Go
At the Vision Application Park, visitors can witness the automatic transformation
of their order into a customized product in a multi-vendor machine
Author
Markus Bregulla is
the product
manager for optical
and ultrasonic
sensors at Turck
Germany in Mülheim
Webcode | more11131e
In cell number 1,
a palletizer from
Hirata provides
the Playmobil
characters and
circulates them
with the help of
a Hirata robot
Information www.application-park.de
T
he Vision Application Park at the Hannover Messe
tradeshow (booth A12, hall 17), hosted by Vereinigte Fachverlage Mainz that publishes the
trade journals IndustrialVision and MSR Magazine, will
showcase technology from more than 30 associates –
among them Turck – from the fields of vision, material
handling, automation, packaging and labeling technology. In a large multi-vendor machine, the Application
Park shows a multitude of optical test procedures.
The user can see for themselves that there is a
solution for nearly anything. The Application Park connects vision, handling and automation technology and
offers additional information on these subjects. Ten
modular test units and processing cells are connected
to a transfer system within the machine.
Hirata and Turck in cell number1
The visitor can choose one out of four Playmobil characters at the entrance of the Vision Application Park
– a knight, pirate, firefighter or musketeer. The visitor then receives a ticket to get his Playmobil character at the end of the machine. The order information
is imprinted on a work piece carrier with a RFID tag
and inserted into the machine. At the entrance of cell
number 1, the BL ident RFID system from Turck reads
the data and forwards the information via RS232interface to the robotic controls.
The Playmobil characters are kept in a palletizer
from Hirata and are removed with the help of a robotic
arm. A camera observes the 27 positions of the trays
15
At the entrance
of cell number 1,
the BL ident RFID
System from Turck
reads the RFID tag
on the workpiece
that contain the different Playmobil characters. Here,
the PresencePlus Pro Minicam from Turck's partner,
Banner Engineering, comes into operation. The miniature camera is connected to an external controller,
which sends the signal via RS232-interface to the PLC of
the robot. That's how the robot knows which Playmobil figure to choose. Additionally the controller sends
a video-signal to an external screen, so that the visitor
can see a simulcast of the tray.
Cell number 1 is illuminated by two white, linear
LED panel lights from Banner Engineering. To be able
to create a contrast ratio against the normal light in the
exhibition halls, the trays are illuminated by two linear
infrared lamps.
After the Scara-robot has picked the right Playmobil
character, a tag is attached to the back of the figure, which
contains the DataMatrix-Code and the name of the receiver. For control reasons, the Scara-robot places the figure
The DataMatrix/Barcode reader from the iVu family
reads the code from the back of the figure
more @
1_2011

 Quick read
At the Hannover Messe, visitors can experience how image processing and quality management in a multi-vendor machine work at the Vision Application Park,
booth A12, hall 17. From the initial order, through the various test procedures,
to the packaging – the Playmobil characters pass through a realistic test course.
Visitors can take their toy home at the end – individually labeled and packaged.
above a DataMatrix/Barcode reader with an integrated
ring-lights from Banner's iVu-series. The compact reader
is available in two versions, either with a touch screen
at the back or with an external display. Since the reader
had to be installed with the back facing downwards for
this special purpose, the version with the external display
was used here.
Comprehensive diagnostic program
If the Playmobil figure passed all tests in cell number
1, it passes through the other cells. Here the figure
runs through different stations for color recognition
and spectral analysis, the inspection for scratches,
3D-recognition and the creation of an elevation profile or the geometrical measuring. All results of measurement can be viewed by the visitors over monitors at the control stations. At the end of the process,
the accessories and the tested figure are transported
to the packaging station. Finally, a robot hands the
packed figure to the visitor who can take it home as
a souvenir. The Vision Application Park is accompanied by a vision nature trail, where visitors receive
detailed information about the contents and training
opportunities in the image processing industry on
presentation boards.
If you miss the Application Park at the tradeshow
in Hannover, you can see the multi-vendor machine at
three other tradeshows in Germany this year, amongst
others at the Vision in Stuttgart. N
16 T R E N D _ R F I D
IN THE FOOD INDUSTRY
Author
Dr. Bernhard Grimm
is the industry manager for the food and
packaging industry at
Turck in Mülheim
Webcode | more11105e
Intelligent
Chocolate Production
Informational advantage through RFID:
Wireless identification of chocolate forms guarantees
transparency during the whole production chain
D
With an integrated
RFID solution, confectionery manufacturers
are able to identify
every single form
ark chocolate, milk chocolate, white chocolate,
with nuts or praline, shell-shaped or a truffle –
the possible forms of chocolates are as numerous as the preferences of the users. Confectionery
manufacturers usually offer different products, which
means flexible production processes: different casting moulds are needed, new loads need to be
inducted into the manufacturing plants and be
replaced or cleaned during the production
process.
The efficiency of industrial large-scale
production depends on the availability of all components along the
production chain, especially
with flexible production processes. Information about
the production steps is
essential. For the subprocesses involved in
chocolate production,
wireless identification
(Radio Frequency Identification) contains enormous automation potential – and improves plant efficiency and safety at the
same time.
Opposite to
customary autoID procedures,
like bar or datamatrix code,
robust wireless
identification
solutions lik e
the BL ident
RFID system
from Turck offer
an advantage
for confectionery
manufacturers. The
electronic data medium
(tag), as well as the combined read-write heads
that are necessary for the
data transfer, work reliably
under the difficult conditions
of the food production – neither increased temperatures nor
17
From left to right: Bernd Plies, manager electrical- and automation technology of WDS; Harry Imhoff, president & CEO of
Hildebrand Industry; Dr. Bernhard Grimm, industry manager of Turck; Volker Krämer, president & CEO of Agathon
pressure, cleaning supplies or moisture can harm the
components. The contact-free, fully automated data
transfer between the tag, combined read-write head
and controls allows a continuous tracking of the goods
and the forms through all steps of the production process. With an RFID system that is compatible with this
specific process chain, every step of the supply chain
can be monitored, recorded and traced back.
Teamwork for RFID
To meet the specific requirements of the chocolate
manufacturers, Turck cooperates with the industry
giants Winkler and Dünnebier, producer of confectionery machines; Hildebrand, maker of cleaning systems;
and Agathon, the manufacturer of forms. The common
goal: To understand the requirements of the production chain and to offer a trade-specific solution for confectionery manufacturers.
The solution that combines the knowledge of
the different industries has been met with interest
by more and more chocolate manufacturers. Among
other things, the four project partners presented the
results of their cooperation at a workshop at the SPS/
IPC/Drives show. Representatives of known chocolate manufacturers caught up on the practical saving and optimization options a RFID solution offers.
Because of the demand, the partners will offer anothmore @
1_2011
er workshop at the Interpack show in Düsseldorf. For
free registration contact [email protected]
Constant identification
For constant identification of the chocolate forms
throughout the entire process, the producer of the
forms equips them with robust RFID tags. This allows
the different forms for the numerous end products to
be identified easily and anytime – even when stocked.
The data of every single form is available centrally,
so stocking procedures can be carried out without
having to count the stocked forms manually at high
personnel costs.
During the production process, the tags allow the
backtracking of every single form – up to thousands of

 Quick read
Wireless identification via RFID creates an enormous
potential for all production processes. The technology
finds its way into more and more processes. The RFID
solution becomes thoroughly efficient if used during
the whole supply chain of a production process, for
example through the identification of forms during the
production of chocolate.
18 T R E N D _ R F I D
IN THE FOOD INDUSTRY
Efficient process management: Robust data carriers attached to the forms
provide identification and status information of each form at any time
forms can be at one plant. Combined read-write heads
at the loading stations, the casting machines or important checkpoints, record and forward the saved data
to the controls. The operating staff knows at anytime
at which point of the production process the forms are
in and what their current status is; for example, if they
need to be filled, if they have received their content, if
they are cooled down or if they have finished the whole
production process and are ready to start the cycle
once again. This information helps to organize the load
changes more efficiently and avoid plant downtimes –
the whole production cycle is monitored in real time
and disturbances are discovered immediately.
Chocolate forms that are damaged or contaminated are easily identified through RFID and can be
removed from the production process and sent directly
to a connected cleaning plant. The special RFID tags
and combined read-write heads from Turck even
withstand wash-down environments. Thanks to the
modular RFID concept with robust tags (up to IP69K),
combined read-write heads, food and beverage compatible cables, and fieldbus and interface components,
Turck's BL-ident system can be easily integrated into
difficult environmental conditions and preexisting
automation structures.
Identification with additional value
When the sensor detects a contamination, the form is identified immediately and locked out for cleaning
Wireless identification offers more advantages than
the identification of intermediate or end products or
product carriers. The EEPROM or FRAM memories, with
capacities up to multiple kilobytes, record production
dates or cleaning times that are saved with the identification numbers (Unique IDs), so guidelines of hygiene
and quality can be monitored. Also, automated procedures, like the loading of the casting machines or the
precise placement of the products or product carriers
close to handling robots, can be carried out reliably
with a RFID system. Last, but not least, the forms that
have to be replaced because of contamination or material defects can be identified and ejected immediately
before they lead to faulty end products.
Safety creates efficiency
Special read/write heads capture forms in different sizes and shapes when
they are inserted in the cleaning machine
Because all of the relevant data is written onto and
read-out from the RFID tag automatically, the plant
operator doesn't have to enter the data manually
and has the updated data of the production facility. The waiving of manual input and controls doesn't
only minimize the direct operating costs but also the
follow-up costs that are caused through plant downtimes. The automatic data transfer opens up a lot of
new automation potential, because of the applicability
along the whole production chain. It provides a comprehensive and flexible tracing system that is easy to
integrate and upgrades the production safety and the
plant efficiency. Despite the numerous intermediate
products, product carriers and handling processes,
the manufacturers can survey their whole production
with a few mouse clicks – according to EG-Guidelines
for the food industry. N
20 T E C H N O LO G Y _ L I N E A R
DISPLACEMENT AND ANGLE MEASUREMENT
Fail-Safe Mini
Measuring Device
Turck presents the first inductive miniature linear displacement sensor for a measuring
range from 50 to 200 mm using the interference-free resonant circuit measuring principle
T
he biggest challenge posed by distance and
angular measurement is the transmission of the
current position to the measuring system. There
are different measuring systems with specific pros and
cons, but until now there has been no solution that met
all sensing requirements.
The easiest way to detect angular measurement is
through a direct mechanical connection between the
position being detected and the sensor, like a potentiometric solution. Potentiometers are inexpensive, but
have other disadvantages. For example, the installation is a huge effort, especially determining the exact
Author
André Brauers is the
product manager
linear displacement
sensors and encoders at Turck Germany in Mülheim
Webcode | more11170e
The inductive linear
displacement sensors
of the new LI-Q17
series fit into the
smallest corner and
are insensitive to
electromagnetic
interferences because
of the oscillator within
the position generator
axial adjustment. For fast rotations, there is an additional torsion spring coupling necessary to compensate for the vibrations. Furthermore, it is necessary to
cover potentiometric odometers for security reasons
if they stick out from the machine. Last, but not least,
there is no enclosed housing possible for these sensors, which means a high maintenance and a higher
susceptibility to failure.
With the use of magnetic position generators, a
mechanical connection to the sensor is needless. Corresponding systems deliver exact measurements and
do not wear because of their closed housings. Despite
21
their high price, distance and angular sensors with magnetic position generators are used in numerous fields
of applications. However, magnetic measuring systems
are unsuitable where metallic splinters or electromagnetic fields are present. Furthermore, magnetostrictive
linear displacement sensors have a large blind zone of
up to 80 mm at each side – with a measurement range
of 50 mm at each side the user would have to trade off
an installation length of up to 210 mm.
Resonant circuit principle produces relief
Turck developed new distance and angular measurement sensors to put all these disadvantages in the
past. Unlike magnetostrictive or conventional inductive position sensors that use magnets, the new sensor
detects an object’s position via a resonant positioning
device. The functional principle: A transmitter coil integrated into the IP67-rated housing generates a highfrequency alternating magnetic field (190 kHz) that
activates the resonator integrated in the positioning
device. Each time the transmitting coil stops transmitting, the resonator induces voltage into two receiving
coils integrated in the sensor. The voltage intensity
depends on where the positioning device overlaps the
receiving coils. An integrated 16 bit processor provides
a corresponding proportional output signal in different
formats: 0 to 10 V, 4 to 20 mA, IO-Link or SSI.
Unlike magnetostrictive sensors, this resonant circuit principle is completely immune to external electromagnetic fields, like those caused by large motors or
welding cells, and since there are no magnets involved,
splinters do not accumulate on the positioning device.
Unlike potentiometric detection solutions, not even
dirt nor dampness affect the sensor – thanks to a fully
sealed IP67-rated housing.
LI-Q17 expands resonator portfolio
Turck uses the resonant circuit measuring principle for
three sensor families. The miniature linear displacement
sensor was developed especially for a very short measuring range between 50 and 200 mm. The compact
miniature sensor completes the portfolio consisting of
the inductive RI-series of angle sensors and the inductive displacement sensors of the LI-Q25-series that cover a measuring range of 100 to 1,000 mm.
The robust LI-Q17, in an IP67-rated housing, consists of four different models with measuring ranges 50,
100, 150 and 200 mm. With the 12-Bit-DA-converter,
the sensors reach 0.012 to 0.05 mm. The first models –
available in April – have an analog output (0 to 10 V, 4
to 20 mA, 0.5 to 4.5 V). An SSI model is in development.
Despite their compact design, Turck's new sensor family has extremely short blind zones of 10 mm
at the connecting end and 22 mm at the head end.
For the connection, a pigtail with a 30 cm cable and
an M12 connecter or an open connection line of
2 m is needed.
The pre-assembled concept lets the user install
and operate the LI-Q17 sensor and the provided standard accessories fast and easy. Robust metal clips are
integrated into the housing and allow either a vertical or a horizontal installation. The electronic module
of the positions generator is pivoted and provides
an exact position corresponding to the installation
situation. If an application needs a special measuring
range, a teach-adapter is able to provide it according to the requirements. LEDs on the sensor show the
user if the position generator is located within the
measurement range.
LI-Q25 for higher measurement range
The LI-Q17 is the next step in the resonator-technology
that Turck presented for the first time with the linear
displacement sensor series, LI-Q25. The LI-Q25 sensors
have a resolution of 1 µm (repeat accuracy 10 µm)and
are especially suitable for applications like mills, injection molding plants or metal processing machines that

 Quick read
The first fail-safe miniature linear displacement sensor for a measuring range of 50 to 200 mm has been presented
by Turck. The LI-Q17 doesn’t work with a magnetic locator, but with the resonant circuit measuring principle, where
an object’s position is detected via an inductive oscillating system, consisting of a condenser and a coil. Thus, the
LI-Q17 that combines all the positive qualities of customary measuring systems in one solution without having the
disadvantages.
more @
1_2011
The inductive angular sensors of the
RI-series are able to
compensate a radial
offset of 4 mm
22 T E C H N O LO G Y _ L I N E A R
The sensors, as
well as the pivoted
position generator,
can be installed
either vertically
or a horizontally
with the provided
installation clips
DISPLACEMENT AND ANGLE MEASUREMENT
have problems with the technical restrictions of the established
measuring systems. The housing
of the Q25-sensor features an aluminum profile that allows easy application via optional mounting accessories. Stainless steel accessories provide
safe mounting and flexibility with regard to
the alignment of the sensor. Extremely short
blind zones of only 30 mm on each side,
along with a wide temperature range of
-40 to 70 °C and the option to adapt the
sensor by programming it to different measuring ranges, allows users to dispense with
special variants for specific applications. Using
only one sensor family for measuring ranges between
100 and 1,000 mm simplifies warehousing and helps
users reduce their total cost of ownership.
The Q25 sensor family is available with different outputs. In addition to to electricity/voltage and
SSI-interface, Turck offers a high-end model with a
programmable IO-Link-interface where the user can
define the measurement range, as well as the output
signals. For applications in automotive engineering, for
example, there is an output signal of 0.5 to 4.5 V. Furthermore, up to four switching points can be adjusted.
RI-sensors measure swiveling angle
Along with the linear displacement sensors, the resonator portfolio contains a series of angular sensors.
The RI-sensors have a measurement range of 360° at
Turck offers the
LI-Q25 linear
displacement sensors
with a programmable
measuring range
of 100 to 1,000 mm
an accuracy of 0.15 percent of the full scale. The separated assembly of the sensor unit and the positioning
device, as well as a compensation of ±4 mm, provides
an easy installation and a safe operation of the sensors.
The RI-sensors can be easily attached with two shoulder bolts to solid or hollow shafts. With the help of
an integrated adapter with a diameter of 6 mm and 8
mm, a standardized hollow shaft sensor can be altered
into a solid shaft sensor.
The contact-free principle compensates application-specific bearing tolerances, such as vibrations that
are caused by the jolting of shafts. The sensor provides
an output of 0 to 10 V, 4 to 20 mA, 0.5 to 4.5 V and SSIinterface.
Conclusion
Because of their resistance to interferences and their
high resolution, the LI and RI-sensors can replace the
customary measuring systems for distance and angular measurement in nearly all fields of application.
Whether an application contains short or long-range
distances, limited installation space or external interferences – Turck’s LI and RI-sensors offer a flexible solution
that can easily be applied to various applications and
integrated into preexisting structures. With the M12x1
connection, linear distance and angular sensors can be
connected to fieldbus installations, like BL20, BL67 or
BL compact, easily. Turck developed the new sensors
true to their motto ”Sense it, Connect it, Bus it, Solve it”
– meaning not only to supply single components but
integrated solutions. 
– YOUR WEBSITE FOR PROFESSIONAL AUTOMATION
www.fotolia.com · Leo Blanchette
News,
products
and know-how
at a glance!
Gruber Str. 46a 85586 Poing, Germany Phone +49 (0)8121.95-1385
[email protected] www.computer-automation.de
24 T E C H N O LO G Y _ E N CO D E R S
Author
Nils Watermann is
product specialist
for position sensors
and encoders at
Turck in Mülheim
Webcode | more11171e
T
o measure distances, angles, positions or
revolutions of machines, numerous sensor
solutions are offered to the user, among
them a variety of encoders which are divided
in two different types: incremental and absolute measuring systems. The most cost-efficient
solution is an incremental encoder. It provides
signal periods whose numbers measure the
revolutions, the length or the position. Incremental encoders are usually used for monitoring
revolution and speed.
Absolute encoders are used to monitor positions or angles. Here, a code pattern is assigned
to each position. The user can chose between a
singleturn encoder, also called an angle sensor, that
measures the position over one rotation, or a multiturn encoder that can process several rotations.
The clear assignment of a code for each position
means that absolute encoders have exact information about the position, compared to incremental
encoders that calculate the position. Disturbances in the communication that lead to
miscounts are possible - especially at
long cable lengths. To prevent this,
the encoders have to be calibrated
to a zero position, which is difficult. Also, after a power failure, the
plant has to be set up again with a
reference run. Absolute encoders, on the other
hand, show the current position immediately, so
that the information is available directly after a new
activation of the plant.
Scanning technologies
Whether incremental, absolute, single
or multiturn, SSI or
fieldbus interface,
Turck offers a comprehensive standard
portfolio of encoders for numerous
applications
There are two established scanning technologies
for industrial encoders: optical and magnetic scanning. Optical scanning provides high resolution
and accuracy, as well as a high resistance against
electromagnetic interferences. Magnetic technology is especially shock resistant and may have a
high protection rating of IP69K. Furthermore, the
devices are compact and especially suitable for
high temperature fluctuations. Often magnetic
encoders are cheaper but have less resolution
and are less precise.
Turck offers both scanning technologies
for all categories of encoders (incremental,
absolute, singleturn, absolute multiturn and
analog) and has a standard comprehensive
portfolio, from which the user can apply the
most fitting technology for the corresponding
application.
Mechanical design
Linear position sensors and encoders are usually
placed in close proximity to the action and therefore need to resist environmental influences and
mechanical stress. Technical attributes, like protection category, temperature zone, resistance to
shock and vibrations, as well as load capacity of the
25
The Right Turn
Turck expands its sensor portfolio with encoders
in different types and designs
shaft, are important selection criteria for the user. However, these attributes don't guarantee absolute certainty about a long lifespan of the encoder under difficult
conditions.
When used outdoors, encoders have to withstand temperatures of -40°C and meet the IP67 protection category. But is this good enough? Often,
outdoor devices are exposed to strong temperature
fluctuations that leads to regular warming and cooling cycles that allow the formation of condensation inside the housing of the encoder. This can be
avoided through a stable and compact die-cast housing and multiple seals between the encoder flange
and the housing. The compact encoders only have
minimal airspace, which reduces the possibility of
condensation furthermore.
If the encoders are exposed to high-pressure
water or steam jets, as it often occurs when cleaning the machines, an IP69K-rated encoder is needed.
The connection technology must also withstand the
same conditions.
Next to environmental conditions, mechanical
stress through shock and vibrations has to be considered. An encoder that is used for a drive or engine
should have a shock resistance of at least 1,000 m/s 2
and a vibration resistance of at least 100 m/s 2. For
heavy industry applications, a shock resistance of
up to 2,500 m/s2 is recommended, and for extreme
stress found in some construction machines, up to
5,000 m/s2 is needed.
The deciding factor for the lifespan of encoders
is the quality of the bearing assembly. The maximum
radial and axial bearing load indicates the bearing
strength – for engineering and assembly at drives, 80
N radial load capacity of the shaft and 40 N axial load
capacity of the shaft are recommended. But this is not
the only quality feature. The bearing assembly also
defines what installation conditions the encoder is
able to tolerate. The encoders from Turck have a very
robust bearing assembly with two large ball bearings
that are mechanically interlocked and have a maximum
distance to each other.
Quick read
For nearly every automation task, positions and movements need to be measured exactly. The market offers
several sensor solutions for this task but encoders are
one of the most common. To offer its customers the
ideal sensor solution, Turck expanded its portfolio
with a standard comprehensive range of encoders for
different fields of application.
more @
1_2011
Interfaces
For the connection to the control systems, incremental
encoders either use a RS422 interface for large cable
length or push-pull. For higher resolutions sine signals
are used. The common push-pull interface is used for
the connection to counter cards, electrical counters
and SPS-inputs. The synchronous serial SSI-Interface
has prevailed as the standard for absolute encoders.
For real-time capability, the parallel output is irreplaceable, although it needs a complex wiring. For the different fieldbus systems like Profibus-DP, CANopen,
DeviceNet, EtherCAT and Profinet, Turck offers absolute
multiturn encoders that can be connected directly
to the particular system.
Speed
Encoders with precise integral bearings and powerful
electronics can also be used for procedures with high
operational speed. The reaction rate of the sensor plays
a role for the measuring speed, but normally the interface or the communication structure is the limiting factor. The incremental encoders from Turck are equipped
with especially fast electronics with a frequency of up
to 300 kHz. The absolute encoders provide very fast
SSI-interfaces with a frequency of 2 MHz. The refreshing rate of the position value lies with more than 100
kHz at a maximum jitter of 1 μs real-time. Because of
the short control cycles, this precision allows a high
productivity of the application. If a high resolution
feedback system in real-time is needed, for example for
gearless-drives, the type with additional SIN/COS-track
would be the best option. Many attributes
define the quality of an encoder,
among them a
robust mechanical design
26 A P P L I C AT I O N S _ R F I D
Efficiently Stored
The Bachofen AG from Switzerland optimizes their logistics system with the wireless
identification system, BL ident, from Turck for automatic guidance
A
3,000 square meter storage space over three
stories, a bidirectional elevator system, approximately 350 transport boxes and a stock of
mechanical, pneumatic, hydraulic and electronic articles worth several millions of Swiss francs are the key
Author
Frans Brouwer is
the regional sales
manager Western
Europe at Turck
in Mülheim
Webcode | more11150e
Intelligent circle: About
350 transport boxes
reach their destination
at the Bachofen warehouse thanks to the
RFID-system, BL ident,
from Turck
User www.bachofen.ch Integrator www.gilgen.com
points for the latest automation project undertook by
the Bachofen AG from Uster in Switzerland. The family business began in 1945 and offers industrial automation solutions for motion engineering, fluid control and pneumatics, hydraulics, robotics, vision and
27
RFID to OEM and end customers from Switzerland
and Liechtenstein. Along with single components,
Bachofen's portfolio also contains special branch and
system solutions.
Walter Landtwing,
director of sales at
Gilgen Logistics,
was convinced
by “the flexible
integration of the
system from Turck
into the existing
controls.”
Modification during operation
Within the restructuring of the logistics between March
and May 2010, the container conveyor system in the
storage space was also modernized to meet the growing requirements of the future. “The replacement of the
equipment had to happen during operation, so we had
to keep the time for modification as short as possible,”
Walter Landtwing, director of sales at the assigned system integrator Gilgen Logistics AG, describes the task.
Further important requirements were the modularity of
the transport system and the zero-pressure transport
of the boxes. “The old transportation plant was nearly
40 years old and we weren't satisfied with its performance any longer,” Kurt Gfrerer, product manager automation of the Bachofen AG, summarizes.
In consultation with Bachofen, the system integrator decided to implement a touchless, wireless
identification system in order to organize the transport processes of the goods more efficiently. Although
Bachofen is the sales partner of Turck in Switzerland,
RFID solutions from different providers were evaluated
before the decision was made in favor of the modular
RFID system, BL ident, from Turck. “We were convinced
by the intelligent design of decentralization, the easy
and flexible integration into the already existing controls and the flexibility of the whole system,” Landtwing
explains. “With the decision for the RFID system from
Turck, Bachofen relies on intelligent control technology
for their logistics. The decentralized intelligence has
the advantage, that the superior controls of complex
applications are considerably relieved.”
Intelligent transport system
And that's how the transport system works: At one of
the three stations, the staff of the warehouse manually assigns a destination at one of the three stories
to the transport box via an operation unit – incoming goods, commissioning or outgoing goods. As
soon as the box is transported, a special read/write
head (TNL R-Q80L400) that is integrated into the runways, writes the destination onto a FRAM data carrier (tag) underneath the box. The read/write head

 Quick read
During the operation of their plants, Bachofen AG from Uster in Switzerland,
equipped their box conveyor system with a wireless identification system (RFID)
for automatic guidance. Read/write heads are integrated into the roller conveyors, read the data tags that are attached to the bottom of the transport boxes
and make the data available via Profibus DP. Thanks to its modular concept with
tags, read/write heads and interface components, the RFID system, BL ident,
from Turck allows a custom automation solution.
more @
1_2011
28 A P P L I C AT I O N S _ R F I D
At each floor, three special Q80 read/write
heads for roller conveyors read the data
tags that are attached to the bottom of the
transport boxes – contactless and reliable
“
The function
module that is
needed for the PLC
is executed directly
in the gateway,
therefore the superior S7-control is
relieved. It couldn't
be easier.
„
Kurt Gfrerer,
Bachofen AG
that is used fits exactly into the spaces of the 80 cm
wide standard roller conveyor. Now the transport is
fully automated.
If the box has to be transported into another story
because of commissioning, another read/write head
located on the service lift reads the destination at the
tag. If all spaces at the destined story are occupied,
the box stays in front of the lift until there is free space
again. The boxes from the upper stories reach their destination on the ground level in the same way. A third
read/write head at the exit of the service lift reads the
according target data.
CoDeSys programmable gateways
With only three read/write heads on each story,
Bachofen realized an efficient and fully automated
destination guidance system – a circle with decentralized intelligence at the I/O stations. First the read/
write heads forward the target data of the boxes to
the modular fieldbus system, BL67, from Turck. BL67
includes a programmable gateway for fieldbus communication and individual integrated interface modules with numerous advantages: Since the I/O modules
are independent from fieldbus and can be replaced
during the operation of the plant, the whole communication environment can be upgraded flexibly
and adapted to new automation requirements – no
matter if more RFID-interfaces, additional sensors or
actuators are needed.
By request, CoDeSys programmable gateways
(IEC 61131-3) that support the consistent decentralization with additional control and diagnostic functions
are available. Bachofen relies on an easy programmable Profibus gateway. “The biggest advantages are the
onsite intelligence regarding the data handling and the
uncomplicated integration into the controls,” Gfrerer
explains. “The function module that is needed for the
PLC is executed directly in the gateway, therefore the
superior S7-control is relieved and only relevant data
is exchanged. It couldn't be easier,” the automation
specialist summarizes. 
In front of the service lift, a read/write head reads the destination data from the tag at the bottom of the box
S E R V I C E _ P R O D U C T I N F O R M AT I O N
29
Product Data on DVD
Fresh from the press, the new “Full Range” DVD offers you an
original view of our product database on the Internet for
offline use.
THE
FULL
E
RANG
EETS
H
S
A
DAT
O
APPR
VALS
ARE
W
T
F
SO
FLYER
Regardless of what information source you use, the Turck
product database on DVD
or on the Internet will provide
comprehensive information
material focusing on Turck
solutions for plant and process
automation. There you can find
data sheets, brochures, catalogs, and even software. Different search functions will help
you find the right solution for
your automation needs.
S
UE
G
O
L
CATA
com
.
k
c
r
u
ww.t
w
 Do you want CAD data?
No problem! Simply generate
the data record that you need
in our product database on the
Internet – you can choose from
between 80 export formats
in 2D and 3D. This service is
absolutely free, registration is
also not required.
Product Data on the Web
The Turck product database on the Internet promises all data – including CAD data
– at a glance. Routine changes and additions guarantee you the most up-to-date
information at all times. Find out for yourself under www.turck.com
more @
1_2011
30 A P P L I C AT I O N S _ R F I D
Author
Yonglai Zhang is a
product engineer
at Turck China
in Tianjin
Webcode | more11151e
SMTCL plants
contain horizontal
and vertical
machining centers,
conventional and
CNC-machine tools
User www.smtcl.com
Easy Cutting Tools
Turck’s RFID-system, BL ident, creates transparency for the cutting tool management of
the Shenyang Machine Tool Co. Ltd. (SMTCL)
W
ith a business volume of about 660 million Euro in 2009 the Northeast-Chinese
Shenyang Machine Tool Co. Ltd. (SMTCL) is
not only the biggest manufacturer of tools in China
– the company is also one of the biggest providers of
metal processing lathes, drilling and milling machines
worldwide. The company was founded in 1995 and
offers conventional and CNC-machine tools for numer-
ous industries, including automotive, rail (transit), shipping, aviation and aerospace, and defense.
To guarantee the high performance and reliability of the machine tools, and to optimize production
capacities to ensure plant availability, the Chinese
manufacturer relies on identification technology from
Turck. The BL ident modular RFID-system provides
a reliable and powerful solution for monitoring
31
Turck's BL ident gateway communicates via Profibus-DP with the PLC
The robust read/write head on the machine reads the RFID tag on the
cutting tool as soon as it is inserted
and tracing the diverse cutting tools that are used
in the machine tools.
effort during the implementation of the system, and
that is why we will rely on Turck's BL ident system in the
future,” asserts Chengjun Lin, construction engineer at
Shenyang Machine Tool Co. Ltd.
Continuous monitoring is well organized at SMTCL: A FRAM data carrier with a memory capacity of
two kilobytes is attached to every new cutting tool.
Before the tool is sent to the warehouse, all the relevant data, such as unique ID, type, control time or current position, is written to the tag. The data is read by
the read/write heads on the warehouse doors at the
production plants and forwarded to the controls at a
central database. In this way, personnel knows where
each cutting tool is located at any time – even during
the plant operation – and if it needs to be replaced
or repaired.
Frequent tool changes
The need for real-time information about the current location of each tool is rising with the increasing
degree of automation at the manufacturing plant and
the rising frequency of tool changes. Because of this,
SMTCL decided to replace their identification system
with the wireless solution from Turck. Thanks to this
modular system with robust data carriers (tags), read/
write heads of different types and sizes, as well as IP20
and IP67 rated gateways, the identification system from
Turck can easily be integrated into already existing
automation structures and expanded if needed. That
is how SMTCL could achieve communication with controls from different manufacturers, like Fanuc Robotics
and Siemens. “There was no additional programming

 Quick read
Since the current identification tool couldn't meet
the growing requirements of the plant any longer, the
Shenyang Machine Tool Co. Ltd. replaced it with wireless
RFID technology from Turck. The BL ident system can
easily be integrated into already existing infrastructures,
due to the variety of available components, like tags,
read/write heads, and IP20 and IP67 rated gateways and
interface modules.
more @
1_2011
Flexible solution
Implementing Turck's BL ident RFID system allowed
SMTCL to increase its production efficiency remarkably and reduce manufacturing and maintenance
costs at the same time. The variety of available components – from tags to read/write heads to IP20 and
IP67 rated gateways and interface modules – allows
Turck's BL ident system to adapt to nearly all identification scenarios. Different fieldbus protocols (ProfibusDP, DeviceNet, CANopen, Profinet IO, Ethernet Modbus
TCP and EtherNet/IP) and transmission frequencies
(HF/UHF) increase the versatility even further, and allow
an efficient identification solution. N
“
There was no
additional programming effort
during the implementation, and
that is why we will
rely on Turck's BL
ident-system in
the future.
„
Chengjun Lin,
Shenyang Machine
Tool Co. Ltd.
32 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
Cards on the Table
Elantas Beck modernizes 19” interface cards with the compact remote I/O system,
excom, from Turck
T
he products made by Elantas Beck are found
in numerous electrical devices, including
household appliances, television sets, wind
turbines, computers and lighting. The company
develops, produces and sells impregnation resins,
potting compounds and encapsulating resins (thin
or thick layer), that are used in electric motors, transformers, generators, capacitors, printed circuit boards
and sensors. Elantas Beck is part of the Elantas Electrical Insulation of Altana AG, one of the leading
developers of specialty chemicals .
Author
Stefan Kappel is
the head of key
account management process
automation at
Turck in Mülheim
Webcode | more11152e
The excom remote
I/O system from Turck
provides 128 binary
or 64 analog channels
in a very small space
User www.elantas.de Integrator www.eab-automation.de
At the company's headquarters southeast of Hamburg, approximately 120 employees develop and
produce several thousand tons of resins for the electrical industry every year. During production, the
products run through reactor line where the synthetic resins are heated, condensed and processed in
vacuum. To carry out this process reliably, numerous
monitoring stations are installed. During the construction of the plant, the analog and binary measuring signals were sent to 19” interface cards installed
in large racks.
33
Fieldbus instead of 19“ cards
After many years of use, the cards became susceptible
to defects. Since new cards were more and more difficult to obtain, an alternative was sought out. The decision was made to modernize the interface technology
for one reactor line first and use the still intact cards as
spare parts for the other reactor lines. Thomas Pölking,
head of maintenance, chose from different alternatives,
like modern 19” cards or DIN rail devices, and decided
on a fieldbus solution in the end. “We wanted an easy
and modern solution, with integrated Ex-separation and
easy, direct connection to our S7-PLC,” Pölking explains.
“Before the modification, the connection worked only
indirectly. The signals were sent to Ex-barriers, then to
an old PLC and only then via Profibus to the S7.”
After the fundamental decision for a remote I/O
system was made in the summer of 2008, the search for
a qualified provider began. EAB Automation, a compa-
ny that specializes on modernizations, extensions and
new constructions of procedural and manufacturing
automation plants, was retained to aid in the search.
EAB employees and manager, Jochen Ahrend, support
their customers during the design and control engineering realization of the projects, create the software
and the switching cabinets and carry out the assembly
and the startup.
Assembly in 19” rack
Within the search for a remote I/O system provider,
EAB compared solutions from different manufacturers
before the decision was made in favor of the excom
remote I/O system from Turck. "With the excom system
from Turck, we found a remote I/O solution that is really
easy to handle and so compact that we could install it
into the already existing 19” racks, together with all 150
I/Os,” Jochen Ahrend says. The excom systems fulfills

 Quick read
Elantas Beck produces liquid impregnation resins and varnishes in Hamburg, and is
one of the leading manufacturers in this market. On their way to the end product,
the resins run through a reactor line that is equipped with numerous monitoring
stations for temperatures, pressures and more process relevant parameters. The
19” interface technology was installed in the 1990's and there are only few spare
parts available today. That is why the company upgraded the first reactor line with
modern technology – Turck's excom remote I/O system.
In the reactor lines
at Elantas, numerous analog and
binary signals are
forwarded from the
switching room to
the interface cards
and the excom system to the controls
Thomas Pölking,
head of maintenance at Elantas,
wanted a compact
and modern solution that could be
connected directly
to the control
system without a
detour over the
PLC
more @
1_2011
34 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
Since the modernization of the plant, the 19” rack (in the back) hosts
two excom systems instead of the interface cards
“
With the excom
system from Turck, we
found a remote I/O
solution that is really
easy to handle and
so compact that we
could install it into
the already existing
19”-racks, together
with all 150 I/Os.
„
Jochen Ahrend,
EAB Automation
In only one weekend, EAB Automation installed
the new excom systems into the 19” racks
another requirement of Elantas, because the additional
PLC for the reactor line is no longer necessary. “Now the
signals are sent to the excom system from Turck and
then directly to the S7, so we can save a detour over
another control,” Pölking states.
Even though this was the first project where EAB
implemented excom, the plan was as successful as the
realization. In the fall of 2008, employees were able
to install and start the system over the course of only
one weekend, so the plant was fully operational again
on Monday morning. “We had no experience with the
product then, insofar the support from Turck helped
a lot,” Ahrend explains. “Even the description was particularly good, and all our additional questions were
answered by the specialists from Turck quickly so we
could continue on our project successfully.”
Flexible system
Even though the remote-I/O system wasn't installed in
a hazardous area for this project, it is possible to install
excom in zones 1 and 2. The field circuits are approved
for the use up to zone 0. The IP20 rated I/O modules
offer four analog or four to eight binary inputs or outputs at a width of 18.2 mm. Two redundant power
supplies, two redundant gateways and up to 16 E/Amodules can be installed on an area of 43.2 cm by 20.6
cm by 11 cm. In this configuration, up to 128 binary or
64 analog channels are available in a very small space.
The SC12Ex segment coupler is used for intrinsically safe separation of RS485 and RS485-IS
All modules have “EEx ia” interfaces, so that no further
protective measures are needed. The energy supply is
available in 24 VDC or 230 VAC. All modules – including the power supplies – can be replaced during full
operation, even in zone 1. In addition to increased availability, hot swapping and ex-protection, the system
allows a general HART-parameterization of the fieldbus
devices via bus. N
quality
www.process-worldwide.com
quality
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www.vogel.de
36 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
The Right Mix
Somakon Verfahrenstechnik uses Turck's HMI/PLC solution, VT250, for
intelligent control and operator guidance of its MP blender family
Author
Jörg Süßmann is a
sales specialist at
Turck in Mülheim
Webcode | more11153e
Turck's HMI/PLC
solution, VT250, is the
central control and
operating element of
the MP blenders
User www.somakon.de
B
lending, as an independent procedural step in
development laboratories, has become more
and more important over the last couple of
years. Combined with the demand for small quantities and transferability to larger systems, a need arose
on this area that can only be fulfilled by few laboratory
blenders today.
Wolfgang Naton has dealt with the problem of
mixing and granulating on a laboratory scale for the
last ten years. The process engineer is the manager for
Somakon Verfahrenstechnik, a company that develops and sells blending systems for numerous fields
of application. The blenders from Somakon are used
in the research laboratories of the chemical industry and the producers of pharmaceuticals and pesticides. Along with their entry model, the LB, which was
designed as a pure blender, Somakon also offers the
MP blender family.
37
The VT250 (at the slant) communicates via Ethernet over the BL20
remote I/O (upper left) with sensors and frequency converters
Modular blender concept
“MP stands for multi-purpose, which means that we
can configure the systems individually according to the
requirements of the customer,” Naton explains. “Many
customers start with a base model, but quickly request
further functions. With our MP solution, we have the
flexibility to update the base model according to our
customers wishes, and add temperature, pressure or
humidity measurements. With this you can handle
whole processes.”
In addition to blending, the MP machines can be
used for granulating, pelletizing, emulsifying, suspending, kneading, loading, crushing or drying – based on
the configuration level. Along with the containers and
tools, the blender is equipped with sensors and actuators, depending on the process steps that are performed. To offer the needed flexibility of its machines,
Somakon turned away from mechanical control elements and classic controls, and tried the VT250 from
Turck instead.
The VT250 is a compact operator terminal with a
PLC that was developed especially for independent
control and the operation of small and medium sized
machines – the ideal solution for the MP blender family. VT250 includes a 5.7“-QVGA-TFT touchscreen in a
compact plastic housing; QViS visualization software
provides the communication between human and
machine, which is implemented by the common control software CoDeSys 3. “With the VT250 from Turck,
we have a PLC that meets all our requirements at an

 Quick read
The blenders at Somakon are very popular at the
research and development departments of renowned
industrial users, because they can be adapted individually to most tasks because of their modular concept.
To offer this flexibility at a good price performance
ratio, Somakon uses Turck's HMI/PLC, VT250, as efficient
control and operation unit.
more @
1_2011
optimal price performance ratio,” Naton adds. “We have
implemented the first project with Turck and received
a lot of support during the set-up of the new machine.
This includes the programming of the controls with
CoDeSys.” Naton has had bad experiences with other
renowned PLC providers in the past, especially in regard
to their support: “I worked with the PLC from another
provider, but as a comparatively small company, it takes
ages until you get the right contact on the phone. That
is different with Turck. We experienced exceptional support from the product management, as well as the field
and indoor service.”
As well as using the VT250, Somakon uses the
economy version of Turck's BL20 I/O system to connect the sensors and drives of the blenders. The BL20
Ethernet gateway coordinates the communication
with four I/O modules and serves as the interface to
the controls within the VT250. For example, one module with eight analog inputs may be used for PT100 or
pressure signals, another module with four analog outputs is used for the frequency converter, as well as two
modules with 16 digital inputs and outputs are used
for the binary signals.
Container identification via RFID
The subject of wireless container identification is
another important factor for the future plans of Naton.
In this area, Turck's modular RFID system, BL ident, with
tags that can be installed directly onto metal and the
possibility to connect the combined read/write head
via RFID module over the existing BL20 I/O system,
can be easily included into the machine. Alternatively,
there also is the possibility to connect the combined
read/write head to the VT250 directly. The RFID labeling
makes sure that containers or tools are used exclusively
for the process steps for which they are designed. That
increases the safety and the lifespan of the blender.
Concludes Naton, “Turck doesn't just offer the
fitting products for my requirements but also has
employees that are very supportive and find a solution
for everything.” N
MP blenders from
Somakon can be
adapted to the
requirements of
the customer
“
With the VT250
from Turck we have
a PLC that meets
all our requirements at an optimal price performance ratio.
„
Wolfgang Naton,
Somakon
38 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
Author
Michiel Kuijer is
account manager
for process automation at Turck
Netherlands in
Zwolle
Webcode | more11154e
With about 30 million
tons of iron ore and
coal, the plant from
EECV is one of the biggest bulk handling
installations in Europe
User www.eecv.nl
Good Listener
Ertsoverslagbedrijf Europoort C.V. installed the Ethernet-Profibus-Interface, PB-XEPI, from
Turck for constant monitoring of the fieldbus communication
A
t the harbor of Rotterdam, Ertsoverslagbedrijf Europoort C.V. (EECV) runs one of Europe's
biggest bulk handling installations. On an
area of about 82 hectare, every year roughly 23 million tons of iron ore and up to 5 million tons of coal
are unloaded, stored temporarily and loaded from
sea-going vessels onto smaller transport ships for
the transportation into the Ruhr area. Size and age of
the plant – the facility is modernized and has been
updated consistently for the last 40 years – are a challenge for the logistics, as well as for the automation
technology of the robust load cranes, conveyer belts
and loading installations. Because the communication between the automated equipment components
and the superior controls has to be very robust and
reliable, EECV relies on the Profibus protocol. Fiber
39
optics lines have to bypass large distances of up to one
kilometer which makes the fieldbus communication
susceptible to failures.
Easy to diagnose
Last summer, the general wish was expressed to
monitor the overall 20 Profibus networks and all participants centrally, to recognize and avoid failures
at an early stage. During their research for a powerful surveillance tool, the responsible staff from the
electrotechnical office found the Ethernet-ProfibusInterface, PB-XEPI, from Turck. The decisive factor for
the decision was mainly the diagnostics functionality:
“The Ethernet-Profibus-Interface from Turck is ideal
for us, because you can figure out where the mistake
lies – down to the single participants,” John van Hoorn,
planning engineer, explains.
So far, EECV uses five interfaces for diagnosis, seven more are already scheduled and eight additional
interfaces could be in use for the coal facility soon too.
The interfaces make an important contribution to the
vertical communication and maintenance concept
over the office to the single field components. With
the new interfaces, the staff of EECV is able to monitor the connected Profibus networks simultaneously,
constantly and centrally for the first time. Unlike the
local proprietary diagnostic tools, the PB-XEPI, that
is acting as a webserver, allows the remote maintenance over a PC webbrowser – the equipment or
number of participants of the plant isn't important.
“You assign an IP-address for the interface, connect the
Profibus-cable and it works,” van Hoorn exclaims.
Error message by e-mail
At the Profibus network of the huge bulk handling
installation, Turck's PB-XEPI's are configurated merely
Ethernet-Interface and webserver of the PB-XEPI
allow a central monitoring of the Profibus network
more @
1_2011
as listeners. Without an own Profibus address, the diagnose units monitor the data flow of the networks without taking part in the communication. In the case of a
malfunction of the network communication, the interface concerned records an error message independently or sends it by e-mail. Over an attached link, the
maintenance staff can access the interface and retrieve
detailed information and instructions.
Thanks to the system-independent communication via Ethernet and integrated webserver, there
is no special software or license needed to reach the
full diagnostic functionality – a webbrowser is all
that is needed. “Some time ago, a PB-XEPI showed
so called repeats from an old part of the facility. I
could read the error report in my office and immediately replace a part of the cable before there was a
bigger failure.”
Future-proof functionality
As a universal interface for the Profibus-net, PB-XEPI
supports the standard FDT/DTM. Thanks to the license
free software PACTware and fitting “device drivers” for
the field components (so called Device Type Manager)
the user can easily visualize and manage the diagnose
data of the participants. The easy handling also supports future upgrades of the fieldbus net and turns the
diagnose interface into a future proof enrichment for
automation technology. N
“
Some time ago,
a PB-XEPI showed so
called repeats from an
old part of the facility.
I could read the error
report in my office and
immediately replace a
part of the cable before
there was a bigger
failure.
„
John van Hoorn,
Ertsoverslagbedrijf
Europoort C.V.

 Quick read
At the harbor of Rotterdam, numerous field devices in robust load cranes, conveyer
belts and loading installations communicate with the controls via Profibus protocol. As soon as failures of the fieldbus communication are signaled, the maintenance staff can identify and fix the problem centrally with the help of a webbrowser
– thanks to the support of the Ethernet-Profibus-Interface PB-XEPI from Turck.
If the PB-XEPI is configurated as a listener, the diagnose-tool is able to
monitor the whole network without an own Profibus address
40 A P P L I C AT I O N S _ S E N S O R T E C H N O LO G Y
Preventing Rollovers
Ferrara Fire Apparatus uses Turck’s inclinometer for tilt testing to make sure that its
fire trucks are stable in the field
F
irefighters put their lives on the line doing far
more than running into burning buildings. Even
getting to the emergency scene can be dangerous. That is why the National Fire Protection Association (NFPA) developed standards for new fire apparatus equipment used to transport firefighters. The code,
1901 Standard for Automotive Fire Apparatus, outlines
the standards required for manufacturing a fire truck to
ensure the firefighters’ safety.
One of these requirements involves vehicle stability to ensure that the fire truck does not roll over during
operation. NFPA 1901 4.13.1 outlines the ways in which
Author
Marty Cwach is a
product specialist for
sensors at Turck USA
in Minneapolis
Webcode | more11155e
Ferrara Fire Apparatus
uses inclinometers
at its on-site
testing facility
User www.ferrarafire.com
a fire truck can adhere to this standard: by tilting the
truck on a tilt table to 26.5 degrees in both directions
or to equip the truck with an electronic stability control
(ESC) system. According to A.K. Rosenhan, a consulting engineer specializing in fire apparatus construction, testing, evaluation and failure analysis: “ESC systems are expensive, prone to problems and not available on all chassis. Plus, many drivers do not like their
controls being overridden. Though using a tilt table is
a quasi-static test, it is much easier and less dangerous to conduct – and certainly much easier on the fire
truck than driving around in a circle of a specified radius
41
The tilt table is moved to 26.5 degrees in both directions
at a specified speed to see if you roll over.” Ferrara Fire
Apparatus, a leading manufacturer of custom emergency
response vehicles located in Holden, Louisiana, has been
heavily involved in crash testing and safety analysis, and
offers both electronic stability control systems and on-site
tilt table testing for their vehicles. “Knowing that stability
testing was coming with the new 1901 standard, Ferrara
Fire Apparatus made the investment in a test facility at our
factory, compliant with SAE 2180,” says Chris Ferrara, President of Ferrara Fire Apparatus.
Tilt Table Testing
Turck inclinometers detect the angle of a tilt table

 Quick read
Before a fire truck can be used in the field, it must
conform to all the requirements set forth by NFPA
1901 Standard for Automotive Fire Apparatus. Ferrara
Fire Apparatus uses Turck inclinometers to ensure the
requirements for vehicle stability are met.
more @
1_2011
The tilt table at the Ferrara factory is 12 feet wide by 50
feet long, actuated by jackscrews, and is capable of handling vehicles up to 150,000 pounds. It is also equipped
with digital scales to ensure compliance with other NFPA
requirements dealing with total weight, axle loading,
and transverse loading. An important component of the
tilt table is to accurately measure the amount of tilt and
to record other test parameters, such as body shift, for
documentation and ultimate certification. After using
a simple pendulum type angle indicator to gauge the
tilt of the table, Ferrara chose to use Turck’s single axis
inclinometer because of its reliability and ease of use.
“Many driver/operators have a strong preference for tilt
table testing, wanting to avoid the throttle limitations
associated with ESC,” notes Ferrara.
“As gravity is pretty constant, the results of a tilttable test are consistent, not prone to error or interpretation, and have rather graphic proof that a fire apparatus
is compliant with the NFPA standard,” adds Rosenhan.
“Turck’s inclinometer does a fine job of providing such
data.” “It’s a dramatic thing to see some 65,000 pounds
of fire apparatus, worth up to $1 million, hanging up
in the air. Obviously there are chains and straps that
loosely anchor the apparatus but do provide for enough
movement to determine if the vehicle 'flunks' testing,”
concludes Rosenhan. N
“
As gravity is
pretty constant, the
results of a tilt-table
test are consistent,
not prone to error or
interpretation, and
have rather graphic
proof that a fire
apparatus is compliant with the NFPA
standard. Turck’s
inclinometer does a
fine job of providing
such data.
„
A.K. Rosenhan,
Consulting Engineer
42 S E R V I C E _ CO N TA C T
Turck at Trade Shows
At numerous national and international trade shows, Turck will introduce you
to current product innovations and reliable solutions for plant and process
automation. Be our guest and see for yourself.
Date
Trade Show
City, Country
05.04. - 08.04.2011
04.04. - 08.04.2011
12.04. - 15.04.2011
13.04. - 14.04.2011
09.05. - 13.05.2011
12.05. - 18.05.2011
24.05. - 27.05.2011
20.05. - 22.05.2011
24.05. - 26.05.2011
21.06. - 24.06.2011
03.10. - 07.10.2011
20.09. - 22.09.2011
04.10. - 06.10.2011
11.10. - 14.10.2011
26.09. - 28.09.2011
13.11. - 16.11.2011
22.11. - 24.11.2011
Automaticon
Hannover Messe
Electron
ISA
Technical Fair
Interpack
MSV
Indumation
SPS
Neftegaz
MSV
Assembly Technology Expo
Smart Automation
EloSys
Pack Expo
Metalform
SPS/IPC/Drives
Warsaw, Poland
Hanover, Germany
Prague, Czech Republic
Calgary, Canada
Belgrade, Serbia
Düsseldorf, Germany
Nitra, Slovakia
Kortrijk, Belgium
Parma, Italy
Moscow, Russia
Brno, Czech Republic
Rosemont, USA
Linz, Austria
Trencin, Slovakia
Las Vegas, USA
Chicago, USA
Nuremberg, Germany
 Full Text Search – Are you looking for a
product name, a known identification number
or a special feature? Then simply enter it in the
above left search field.
 Hierarchical Structure – Are you looking for
products from a certain group, such as inductive
sensors in cylindrical design? Then click through
the menu structure on the left.
 CAD Data – Simply generate the data
record that you need in our product database on the Internet – you can choose
from between 80 export formats in 2D
and 3D. This service is absolutely free, registration is also not required.
 Power Search – Are you looking for a product that meets very specific technical parameters? Then use the feature search that specifically
leads to your solution.
Turck on the Internet
Whether sensor, fieldbus, interface or connection technology, HMI/PLC or RFID, in
the product database on www.turck.com you will find the right solution to your needs
at the touch of a button. Three search functions will help you.
43
Turck on Site
With 27 subsidiaries and numerous branch offices, Turck is always nearby,
anywhere in the world. This guarantees fast contact to your Turck partners and
direct support on site.
GERMANY
Headquarters HANS TURCK GmbH & Co. KG
Witzlebenstraße 7 ı Mülheim an der Ruhr ı (+ 49) (0) 208 4952-0 ı [email protected]
www.turck.com
Imprint
Publisher
Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
Tel. +49 (0)208 4952-0
[email protected]
www.turck.com
Editorial Staff
Klaus Albers (responsible)
[email protected]
Karen Keller
[email protected]
Contributors to this issue
Mathis Bayerdörfer, André Brauers, Markus Bregulla,
Frans Brouwer, Marty Cwach, Dr. Bernhard Grimm,
Walter Hein, Stefan Kappel, Michiel Kuijer,
Jörg Süßmann, Nils Watermann, Yonglai Zhang
Art Direction / Graphic Design
Arno Kraemer, Britta Fehr (Art design)
Printing
Medienhaus Ortmeier, Saerbeck, Germany
All rights reserved. We reserve the right to make technical changes or correct errors. Reprint and electronic
processing permitted with written approval from the
publisher.
 Webcodemore11180e
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more @
1_2011
LARGENTINA ı Aumecon S.A.
(+54) (11) 47561251 ı [email protected]
AUSTRALIA ı TURCK Australia Pty. Ltd.
(+61) (0) 395609066 ı [email protected]
AUSTRIA ı TURCK GmbH
(+43) (1) 4861587 ı [email protected]
LBAHRAIN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
BELARUS ı FEK Company
(+375) (017) 2102189 ı [email protected]
BELGIUM ı Multiprox N. V. (TURCK)
(+32) (53) 766566 ı [email protected]
BRAZIL ı Sensor do Brasil
(+19) 38979412 ı [email protected]
BRUNEI ı TURCK Singapore
(+65) 65628716 ı [email protected]
BULGARIA ı Sensomat Ltd.
(+359) (58) 603023 ı [email protected]
LCANADA ı Chartwell Automation Inc.
(+1) (905) 5137100 ı [email protected]
CHILE ı Seiman S.A.
(+56) (32) 2699310 ı [email protected]
CHINA ı TURCK (Tianjin) Sensor Co. Ltd.
(+86) (22) 83988188 ı [email protected]
COLOMBIA ı Dakora S.A.S.
(+57) (1) 8611888 ı [email protected]
COSTA RICA ı TURCK USA
(+1) (763) 5539224 ı [email protected]
CROATIA ı Tipteh Zagreb d.o.o.
(+385) (1) 3816574 ı [email protected]
CYPRUS ı AGF Trading & Engineering Ltd.
(+357) (22) 313900 ı [email protected]
CZECH REPUBLIC ı TURCK s.r.o.
(+420) 495 518 766 ı [email protected]
LDENMARK ı Hans Folsgaard A/S
(+45) (43) 208600 ı [email protected]
LECUADOR ı Bracero & Bracero Ingenieros
(+593) (9) 7707610 ı [email protected]
EL SALVADOR ı Elektro S.A. de C.V.
(+502) 7952-5640 ı [email protected]
ESTONIA ı Osauhing “System Test”
(+37) (2) 6405423 ı [email protected]
EGYPT ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LFINLAND ı Oy E. Sarlin AB
(+358) (9) 504441 ı [email protected]
FRANCE ı TURCK BANNER S.A.S.
(+33) (1) 60436070 ı [email protected]
GREECE ı Athanassios Greg. Manias
(+30) (210) 9349903 ı [email protected]
LGREAT BRITAIN ı TURCK BANNER LIMITED
(+44) (1268) 578888 ı [email protected]
GUATEMALA ı Prysa
(+502) 2268-2800 ı [email protected]
HONDURAS ı TURCK USA
(+1) (763) 5539224 ı [email protected]
LHONG KONG ı Hilford Trading Ltd.
(+852) 26245956 ı [email protected]
HUNGARY ı TURCK Hungary Kft.
(+36) (1) 4770740 ı [email protected]
LICELAND ı Km Stal HF
(+352) 56789-39 ı [email protected]
INDIA ı TURCK India Automation Pvt. Ltd.
(+91) (20) 25630039 ı [email protected]
INDONESIA ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
IRELAND ı Tektron Electrical
(+353) (21) 4313331 ı [email protected]
ISRAEL ı Robkon Industrial Control & Automation Ltd.
(+972) (3) 6732821 ı [email protected]
ISRAEL ı Nisko Electrical Engineering & System Ltd.
(+972) (8) 9257355 ı [email protected]
ITALY ı TURCK BANNER S.R.L.
(+39) (02) 90364291 ı [email protected]
LJAPAN ı TURCK Japan Office
(+81) (3) 54722820 ı [email protected]
JORDAN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LKOREA (SOUTH) ı TURCK Korea Co. Ltd.
(+82) (31) 5004555 ı [email protected]
KUWAIT ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LLATVIA ı Will Sensors
(+37) (1) 7545217 ı [email protected]
LEBANON ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LIBYA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LITHUANIA ı Hidroteka
(+370) (37) 352195 ı [email protected]
LUXEMBOURG ı Sogel S.A.
(+352) 4005051 ı [email protected]
LMALAYSIA ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
MACEDONIA ı Tipteh d.o.o. Skopje
(+389) 70399474 ı [email protected]
MEXICO ı TURCK Mexico S. DE R.L. DE C.V.
(+52) 844 4116650 ı [email protected]
LNEW ZEALAND ı CSE-W Arthur Fisher Ltd.
(+64) (9) 2713810 ı [email protected]
NETHERLANDS ı TURCK B. V.
(+31) (38) 4227750 ı [email protected]
NORWAY ı HF Danyko A/S
(+47) 37090940 ı [email protected]
LOMAN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LPANAMA ı TURCK USA
(+1) (763) 5539224 ı [email protected]
PERU ı NPI Peru S.A.C.
(+51) (1) 2731166 ı [email protected]
PHILIPPINES ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
POLAND ı TURCK sp.z o.o.
(+48) (77) 4434800 ı [email protected]
PORTUGAL ı Bresimar Automação S.A.
(+351) 234303320 ı [email protected]
PUERTO RICO ı TURCK USA
(+1) (763) 5539224 ı [email protected]
LQATAR ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LROMANIA ı TURCK Automation Romania SRL
(+40) (21) 2300279 ı [email protected]
RUSSIA ı O.O.O. TURCK Rus
(+7) ( 495) 2342661 ı [email protected]
LSAUDI-ARABIA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
SERBIA AND MONTENEGRO ı Tipteh d.o.o. Beograd
(+381) (11) 3131057 ı [email protected]
SINGAPORE ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
SLOVAKIA ı Marpex s.r.o.
(+421) (42) 4440010 ı [email protected]
SLOWENIA ı Tipteh d.o.o.
(+386) (1) 2005150 ı [email protected]
SPAIN ı Elion S.A.
(+34) 932982000 ı [email protected]
SOUTH AFRICA ı R.E.T. Automation Controls (Pty.) Ltd.
(+27) (11) 4532468 ı [email protected]
SWEDEN ı TURCK Office Sweden
(+46) (31) 471605 ı [email protected]
SWITZERLAND ı Bachofen AG
(+41) (44) 9441111 ı [email protected]
SYRIA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LTAIWAN ı Taiwan R.O.C. E-Sensors & Automation Int‘l Corp.
(+886) (7) 7220371 ı [email protected]
THAILAND ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
TURKEY ı TURCKBANNER Consulting Office Turkey
(+90) (216) 5722177 ı [email protected]
Ukraine ı SKIF Control Ltd.
(+380) (44) 5685237 ı [email protected]
LUNITED ARAB EMIRATES ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
URUGUAY ı Dreghal S.A.
(+598) (2) 9031616 ı [email protected]
USA ı TURCK Inc.
(+1) (763) 553-7300 ı [email protected]
LVENEZUELA ı CADECI C.A.
(+58) (241) 8345667 ı [email protected]
VIETNAM ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
LYEMEN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
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Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
[email protected] | www.turck.com
*D900901 0411*
D900901 0411
Hans Turck GmbH & Co. KG
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