moreTurck 2 10 EN
Issue 02
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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
Focused on Solutions
Christian Wolf talks about
Turck’s formula for success for
the future
Page 14
Data at a Glance
Bayer CropScience tests
new components with RFID
support from Turck Page 21
Car Bodies in View
Volkswagen relies on Turck's
measuring light curtains and
BL67 I/O system
Page 24
A New Era
Inductive resonant circuit technology ushers in a new era
of position detection
02 Editorial_Ulrich turck
Full Speed
Dear readers, when the SPS/IPC/Drives 2010 opens
the gates again, all visitors and exhibitors can get
together in Nuremberg, Germany, with a good feeling. As fast and dramatic as the crisis arose last year, it
seems to be over just as quickly this year. Mechanical
engineering gathered speed at the beginning of 2010,
and the whole automation industry followed along. The
growth rates are rising, so much so that even the good
sales figures from 2008 are near at hand. The Turck group
could increase its sales volume more than 30 percent
this year.
Nonetheless, we should not let ourselves be blinded by this dynamic. We expect the effects of the crisis to fade
slowly and that normal growth rates will presume in the upcoming year. In the meantime, this will lead to a reduction in the long
delivery times and the high prices for prefabricated parts that were
caused by the high demand experienced this year.
This issue of [email protected] features an interview with Christian Wolf that gives insight to where we face challenges in the
upcoming years and how we place ourselves in the market so
that we are still able to provide innovative solutions for our customers with market-driven prices. On the pages preceding the
interview, we showcase our latest news from the Turck portfolio.
If would like to experience this in person, visit us at the
SPS/IPC/Drives at our booth 351 in hall 7.
Be our guest and see for yourself how the specialists from Turck
present efficient products and innovative solutions for your
We are looking forward to meeting you!
Warmest regards,
Ulrich Turck, Managing Partner
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innovations for the Automation industry
SENSOr tEchNOlOGY: A New Era
inductive resonant circuit technology ushers in a new era for position detection
iNtErViEW: “Focusing on Solutions”
angela Scheufler, editor in chief of, talked to turck's managing
director, Christian Wolf, about the formula for success for the upcoming years
iNtErFAcE tEchNOlOGY: Alternatives to 19 inch Systems
Many 19 inch systems are in need of replacement. in addition to plug-in card exchanges
and diN-rail devices, turck offers another alternative – the excom remote i/o system
PrESSUrE MEASUrEMENt: Flexible hydraulics Specialists
the new PC200 and PS300 pressure sensor family by turck meets the requirements for
hydraulics engineering
SENSOr tEchNOlOGY: Safe transfer
Volkswagen aG in Wolfsburg relies on measuring light curtains and the Bl67 i/o system
from turck for a flawless vehicle transfer from a lifter onto an overhead monorail
SENSOr tEchNOlOGY: cast Off
Updated level measurement system for the sea and domestic port in Papenburg uses
wireless data-transfer as a cost-saving alternative to complex cable laying
SENSOr tEchNOlOGY: hot iron
inductive sensors from turck's robust uprox+ family guarantee the reliable operation
of hot rolling mills from the Ningbo iron & Steel Corporation in China
FiElDBUS tEchNOlOGY: intelligent Water treatment
Water treatment plants from WJP Solutions are used in many australian buildings –
now they are working with deviceNet fieldbus technology from turck
FiElDBUS tEchNOlOGY: let the Water Flow
an extensive sprinkler system reduces the dust pollution that is caused by shipping
iron ore in the taicang port
cONNEctiVitY: Facing the Winter
Using connectivity solutions by turck, Cirus Controls creates deicing systems that clear
snow and ice from roads and lessen the environmental impact of sodium chloride
cONtAct: the Fast lane to turck
We will show you how, when and where turck is there for you
cONtAct: imprint
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there are alternatives for updating 19-inch interface
technology – from plug-in card exchanges to remote
Page 16
rFiD: Efficiently control
Bayer CropScience tests new active components with rFid support from turck
turck’s dX70 guarantees an efficient, wireless datatransfer of the water level measurement at the sea and
domestic port in Papenburg.
Page 28
in australia, WJP Solutions uses turck's robust connection technology and Bl20 distributed i/o system for
their modular water treatment plants.
Page 32
04 N e w s _ i n n o vat i o n s
 Turck expects a considerable
increase in sales of more than 30 percent for the business year 2010. The
managing director of Turck, Christian
Wolf, disclosed that the consolidated
transaction volume of the Turck-group
should exceed 350 million Euro at
the end of this year. The number of
employees at all 27 sites increased in
2010 about 7 percent to 2,740 employees worldwide. In Germany the family
business employs about 1,400 members of staff at its sites in Mülheim an
der Ruhr, Halver and Beierfeld. “After
a fantastic year 2010 we are going to
position the company for a lasting successful future,” says Wolf. “We are ambitious and target-orientated and therefore want to reach a 400 million Euro
transaction volume in 2011.“ To reach
this goal, there will be an adjustment
of the model's parameters, according to the managing director of Turck.
Among them, will be the redefinition of
regional, trade and application specific
solution portfolios with corresponding
sales and marketing, the reduction of
complexity by the modularization and
the development of platforms, plus the
definition of adequate pricing systems
for system solutions and service features. The focus will lie on the internationalization strategy as well.
You can find more information on the
reports or product presentation in
[email protected] under
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 ca n download or send the
article as a PDF.
Angle Sensors
 After the success of the inductive linear displacement sensors, LI-series, Turck
presents an angle sensor family that works with the same revolutionary measuring principle and unites all the positive qualities of customary measuring systems in one solution. With the new RI-Sensors, the position of the angle isn't
measured with a magnetic locator any longer, but by an inductive resonant
circuit. That way, the sensor
is utterly insensitive to magnetic fields, like those produced by large drives or welding
machines. The RI-sensors have
a measurement range of 360°
at an accuracy of 0.15 percent
of the final value. The separated construction of the sensor
unit and the locator, as well
as an offset compensation of
±4 mm, guarantees an easy
installation and a safe operation of the sensors. The locator
can be mounted flexibly on to solid or hollow shafts. The contactless principle compensates bearing tolerances of the applications as reliably as vibrations that are caused by the jolting of shafts which guarantees a high linearity.
The sensor also adapts on the output side: 0 to10V, 4 to 20mA, 0.5 to 4.5V and
more on page 08 
SSI-interfaces are available.
AIDA Profinet Gateway
 Turck developed new Profinet fieldbus gateways for its I/O system
BL67, in accordance to the guidelines of AIDA (Automation initiative of
German automobile manufacturers), that are mainly intended for use
in the automobile bodyshell work. While the type BL67-GW-PN-AC is
designed for AIDA-RJ45-copper-connecters, the type BL67-GW-PN-AF
is suitable for the use with AIDA-SCRJ-optical fibers. The AIDA gateways can be expanded
with the already existing BL67 I/O modules or
with a directly connectable valve cluster to an
integrated solution. This
option was developed
in cooperation with the
pneumatic manufacturer
Parker Hannifin for use in
the automobile industry.
This coordinated concept increases the availability of the equipment
and reduces the service and start-up efforts for the user. Next to the standardized connectors, the AIDA guidelines demand a fast start-up of the
fieldbus stations (under 500 ms), the automatic recognition of the topology within the network and software support through the Tool Calling
Interface (TCI), among other things. All these guidelines are met by the
gateways from Turck.
New Building
Signal Processors for
Flow Sensors
 With a new signal processor family, Turck completes its range of surveillance products for flow. The developers of the FM (Flow Module) family focused on easy usability, high functionality and a connection variety, which covers all modern requirements.
The modules are implemented into the approved IM DIN-rail rack and may be configured at the push of a button or via IO-Link, respectively HART. Indicator-LED's, as well as a
10-segment-LED-bargraph show the current measuring status on-site. In addition to the
flow, all modules continuously measure the temperature and possible failures. The FMfamily consists of six types: three are applicable for the non-ex-area and three for the exarea. Next to the FM-IM-3UP with three switching outputs and the FM-IM-3UR with three
relay-outputs, the FM-IM-UPLI offers an analog output and two switching outputs. The
FMX ex-type is additionally equipped with a HART-interface, while the other five types
have an IO-link interface.
Wireless Modbus Network
 A scalable wireless network that can monitor and control I/O functions or provide serial communication at up to 56 locations has been
introduced by Turck and Banner Engineering. The new SureCross DX80
product line replaces costly wiring in a wide range of industrial, agricultural, power generation, water supply
and waste disposal applications. Discrete, serial and analog devices that can
be controlled by the network include
ultrasonic and photoelectric sensors,
pumps, counters, thermocouple and
RTD temperature sensors. The remote
nodes gather data and transmit control commands between the sensors
or other devices and a central Gateway.
The Gateway maps inputs from the
remote nodes and interfaces with a PLC
or HMI via RS-485 modbus or Ethernet/
IP. Designed for applications where wiring is impractical or unaffordable, DX80
nodes and the devices they monitor
can be powered by 10-30 VDC, battery
or solar panels.
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 The Turck group will invest about
15 million Euros into a new production facility at the site in Halver. The
building is expected to be finished in
the spring of 2012 and extends the
capacity in Halver by about 11,000
square meters of production area and
1,100 square meters of office space.
Together with the existing buildings
at the Kirchlöher Weg, the family business will have a production area of
26,000 square meters. The new construction will be erected on an area
of 18,500 square meters, directly next
to the already existing production
area. On 33,000 square meters, Turck
has centralized all activities of production in Halver in close proximity. Everything is within easy walking distance
which is the best condition for efficient internal logistics. “With the new
building in Halver, we set the course
for the future,” says Werner Turck,
founder of the company.
RFID panel at the
 True to the motto “Choco Visions
– optimization of the chocolate
production with RFID”, Turck and
three partners present a user panel
for interested end useres from the
food industry at the SPS/IPC/Drives
show in Nuremberg, Germany. During
the 45-minute panel, the partners will
introduce the advantages of RFID for
the production process of chocolate. Next to Turck's manager for the
food & beverage industry, Dr. Bernhard
Grimm, the managers of the companies agathon (chocolate forms)
and Hildebrand (industrial cleaning
machines), Volker Krämer and Harry
Imhof, will answer your questions, as
well as and Bernd Plies, head of electronic department at Winkler and
Dünnebier Süßwarenmaschinen
(confectionery plants).
UsC_ iInAnso vat
O Pions
06F NI D
supplier award
from Hauni
 The Hauni Maschinenbau AG, Germany, awarded Turck with the first
supplier Award in the commodity
group electro-technics/electronics as
the “Best supplier for the tobacco
industry 2009“ with 95 out of 100
points, Turck has succeeded against
the other competitors and fulfilled the
sophisticated requirements for performance and quality of the world market
leader in the field of engineering for
the international tobacco industry.
automation Line
 with the new automation Line
from escha, specialist for cable and
connection technology, Turck now
offers a wide range of connector products which meet nearly all demands
of engineering. The Automation Line
with the new s370 cable is UL-approved and suitable for drag chains. It
is free of halogen, silicone and PVC,
flame-retardant and resistant against
welding sparks, chemicals, oil, micro-
bes and hydrolysis. The Automation
Line consists of M8x1 and M12x1
round plug-in connectors in different
types and polarities. The two designs
are also available with LeD in an angular type. All products are available with
3, 4 or 5 poles.
 webcode
i/o Block Modules in iP67
 Turck supports the continuing trend of the use of ethernet within the automation technology with new i/o block modules for CANopen, ethernet/IP
and Modbus TCP. Together with
the already existing modules
for Profibus-DP and DeviceNet,
the robust series now covers all established fieldbus
and ethernet standards. The
ethernet versions contain an
internal switch and allow a network installation in line topology. The fully encapsulated BL
Compact blocks combine a
great variety of signals within
a minimum of space: No matter if discrete signals or special
applications like RFID – up to
16 digital and/or analog I/Os of the BL Compact blocks allow a new compatibility for applications which is the next step on a way to a consistent, local
automation. The combination of different field signals – analog and digital I/
Os, PT100, thermocouples, Rs232, ssI and RFID – in a compact case makes
it easy for the user to find a solution. The new concept is based on the BL67
I/O system from Turck and combines the electronics of different BL67 modules in a single housing that is resistant against strong vibrations and dirt. The
modules are equipped with either M8, M12 or M16 metal connectors for full
plug-and-play functionality, monitoring diodes for on-site diagnostics and a
dip switch for easy set up.
Laser Displacement
 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 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.
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08 C o v e r s t o r y _ L I n e a r
André Brauers is the
product manager for
linear displacement
sensors and rotary
encoders at turck
Germany in Mülheim
Webcode | more21000e
The solid IP67-rated
housing protects the
new linear displacement
and angle sensors
from failures
DIsPLaCemenT anD angLe sensors
A New Era
Inductive resonant circuit technology ushers in a new
era of position detection
here are plenty of sensors
for measuring distances and
angles in industrial applications, as well as different measuring
methods. When introducing a new
sensor to the market, a company
must provide more than just new
housing and slight accuracy improvements. turck, the sensor, interface,
fieldbus and connection specialist,
has introduced a new measuring
principle that ushers in a new era for
distance and angular measurement.
the biggest challenge is the
transmission of the current position Turck offers the LI -sensors with a programmable measuring
to the measuring system. the easi- range of 100 to 1,000 mm
est way to accomplish this is a direct
mechanical connection between the position detection and the sensor, like a potentiometric sensor. though these sensors are inexpensive, they have their disadvantages; installation is a huge effort, especially achieving the exact 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 if they stick out from the machine. Last but not least, there is no
enclosed housing possible for these sensors, which means a higher
susceptibility to failure.
With the use of magnetic position detectors, a mechanical connection to the sensor is unnecessary. Corresponding systems deliver exact
results of measurement and do not wear because of their enclosed
housings. Although they are more expensive than alternative sensing
options, linear displacement and angle sensors with magnetic position
detectors are used in numerous applications, but they are not suitable
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 an installation length of 200 mm,
the user would have to trade off a measuring range of 40 mm with a
blind zone of 160 mm.
Resonant circuit principle provides alternative
turck developed new linear displacement and angle sensors that
overcome these challenges. Unlike magnetostrictive or conventional
inductive position sensors that use magnets to detect position, the new
sensor detects an object’s position via a resonant positioning device.
 Quick read
With its new linear displacement and angle sensors, turck shows that
a developmental leap in sensor technology is still possible. the sensors unite all the positive qualities of customary measuring systems in
one solution and eliminate the disadvantages. the new sensors work
with the resonant circuit principle and detect an object’s position via a
resonant positioning device.
more @
10 C o v e r s t o r y _ L i n e a r D i s pl a c e m e n t a n d a n g l e s e n s o r s
The robust IP67-rated linear displacement and angle sensors are
ideal for renewable energies, as well as for…
…use in automotive engineering – models with 0.5 to 4.5V output
and a temperature range of -40 to +70 °C are available
The functional principle: A transmitter coil integrated
into the IP67-rated housing generates a high-frequency
alternating field that activates the resonator integrated
into the positioning device. Each time the transmitting
coil stops transmitting, the resonator induces voltage
into two receiving coils integrated into the sensor. The
voltage intensity depends on where the positioning
device overlaps the receiving coils. An integrated processor provides a corresponding proportional output
signal in different formats: 0 to 10 V, 4 to 20 mA, IO-Link
or SSI. The linear displacement sensors of Turck's LI-family
have a resolution of up to 1 μm and the resolution of the
angular sensors of the RI-family is up to 0.005°.
Turck's LI-sensor has high accuracy and reproducibility: To increase the measuring accuracy and the
flexibility, the developers from Turck equipped the sensors with a coarse and a fine receiving coil system. The
coarse system locates the resonant positioning device
and finds out in which segment it is located. Then the
sensitive receiving coil system performs a measurement that shows a high-precision determination of
position. The advantage of this procedure is sensor to
element distance independence resulting in consistent
accuracy and reproducibility with the LI-sensor.
Fail-safe measuring system
Unlike magnetostrictive sensors, this resonant circuit
principle is completely immune to external electromagnetic fields, and since there are no magnets involved,
splinters that may affect the sensor’s function do not
accumulate on the positioning device. Unlike potentiometric detection solutions, not even dirt or dampness affect the sensor – thanks to a fully sealed housing.
Moreover, the coils’ special design guarantees that the
output signal is not affected by the distance between
the sensor and the positioning device. Because of this,
measuring errors caused by slight deviations are effectively eliminated, as long as it is within the sensors 0 to
4 mm measuring range.
Wide range of application
The sensor’s flexibility allows users to apply it to diverse
applications like injection molding machines or metal
working, where chippings or external magnetic fields
might affect the sensor’s functionality. The versatile
LI-sensor series helps users optimize their applications and increase the machine’s availability. Turck’s
linear displacement sensors are also suited for welding
machines, as they are absolutely insensitive to strong
magnetic fields that occur during welding processes.
This feature allows users to utilize inductive linear displacement sensors in various applications like machine
tools, molding presses, rolling machines, die-casting,
bending or lining machines, dosing systems, mixing
units, packing machines, wind turbines or stroke and
alignment control systems.
With its high interference resistance and infinite
mechanical life-span, RI-sensors for angle detection are
suitable for numerous tough applications. For example,
when adjusting rotor blades at wind energy plants,
tracking solar panels or swiveling handles at the entry
of a supermarket.
Easy to adapt
Due to their high accuracy and resistance to interference, the wear-free LI- and RI-sensors can replace many
current solutions for distance and angular measurement. The linear displacement sensors include features
that make them easy to apply in many areas. Opposite
to the active sensing face, the sensor housing features
an aluminum profile that allows easy application via
optional mounting accessories, and 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 -25 to 70 °C and the option
to adapt the sensor by programming it to different
measuring ranges, allows users to dispense with special
Inductive RI-sensors
measure the
opening angle of
swiveling handles,
like those used at
the entry of a
more @
12 C o v e r s t o r y _ L i n e a r
have proved
effective in
injection molding machines
D i s pl a c e m e n t a n d A n g l e s e n s o r s
sensors 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 RI-angular sensors can be easily attached with
two shoulder bolts to solid or hollow shafts. With the
help of an adapter with a diameter of 6 mm and 8 mm,
a standardized hollow shaft sensor can be altered into
a solid shaft sensor.
Both sensor families are available with different
outputs: current/voltage and SSI-interface. Users can
rely on Turck for the most versatile linear displacement
solution for their application. Flexible output configurations allow the sensor to be easily integrated into
existing automation structures. Whether the application calls for an analog output, IO-Link or SSI, a standard
M12x1 connector provides a convenient connection to
a wide range of fieldbus installations, including Turck’s
BL20, BL67 and BL Compact families.
LI-version with IO-Link
The LI-sensor is also available as a programmable highend-model with an IO-Link interface where the user
can define the measurement range, as well as the output signal from 0.5 to 4.5 V. Furthermore, up to four
switching points can be adjusted.
Based on the popular three-wire technology, the
IO-Link standard enables users to commission their
intelligent field devices faster and maintain them more
conveniently. Requiring only one cable for data transmission and power supply, IO-Link simplifies connection diagrams and reduces cabling expenses, in addition to allowing users to download device parameters
from one sensor to an identical replacement sensor.
In this way, cumbersome manual parameterization on
site becomes unnecessary. Since IO-Link sensors may
provide additional diagnostics data via the combined
process/configuration data channel, failures can be
localized faster – allowing plant operators to reduce
machine downtime significantly. Turck provides a corresponding driver – the device type manager, DTM
– for its new LI-Q25 series. Allowing user-friendly visualization via a non-proprietary software tool like PACT
ware, DTM enables users to manage and parameterize
their intelligent sensors with only a few mouse-clicks.
Based on the resonant circuit principle, the new linear
displacement and angle sensors can be used in a wide
area of applications that could not be solved efficiently
in the past. Whether an application contains short or
long-range distances, limited installation space or
external interferences – Turck’s new LI- and RI-sensors
offer a flexible solution that can easily be applied to
various applications. 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. N
14 I N S I D E _ I N T E R V I E W
Christian Wolf expects a
growth rate of more than
30 percent for 2010
“Focusing on Solutions”
Angela Scheufler, editor in chief of the engineering portal,, talked to Turck's
managing director, Christian Wolf, about the company's formula for success for the upcoming years
Where is Turck’s place in the market
currently? Do you classify the company as a component supplier or as
a solution provider?
More and more companies pursue multiple
business models at the same time and the
lines are increasingly blurred. Today, we are
mainly a provider of solutions with advisory skills and technical expertise, but we
still have product and customer segments
where we offer complete system solutions.
Our core competence lies in providing solutions. We position our company on three
business models: complex components,
problem solutions and systems business.
You established a strategic plan for
2010 to 2015. What does it contain?
To face future challenges, we included
some of the following points into our plan.
With regard to sales, the vertical integration
of industries is very important. We need
a well-balanced mix between product/
regional sales and solutions/industry sales.
Therefore, it is essential to understand what
our customers do and what their needs are.
Our internal processes need to be reorganized to enable the vertical integration of
the industries. We also need a global production footprint that identifies the cost of
design and localized production. We also
have to reduce the complexity of our product portfolio by returning to the modular
concept and pushing the modular principle. In this way, we will not be able to satisfy
every request the customers have, but we
will be able to offer innovative solutions at
market-driven prices.
technology. We don’t announce this on
the market since it is not our task to merchandise the IO-lINK system. We focus
more on the benefits to our customers. There are a lot of applications where
IO-lINK is advantageous, but there are
also applications where this technology
isn’t relevant.
Modularization and not fulfill every
request – isn’t that less customer
specific and therefore less customer
Within the limits of a strategic plan, the
question is always: “What are we going to
do?” and “What are we not going to do?”
With the business models Turck has chosen to pursue, the risk lies in significantly
increasing costs and complexity. To meet
this challenge we have to slim down
some business fields and therefore can’t
satisfy every single customer request.
This is a difficult process, because if you
remove products from your portfolio, you
may be forced to say ’no‘ to the customer.
But we never say ‘no’ without offering an
alternative solution.
But you were one of the initial companies that promoted the IO-lINK.
Aren’t you interested in pushing the
technology further?
It is not our task to push a technology. It is
our task to provide solutions that our customers really need and that are optimized
for their specific requirements. Even if we
use the IO-lINK technology on a regular
basis, we don’t make it a point to promote
it. We support our image with unique
features; IO-lINK is not a unique feature,
but an initiative that we gladly support. We
distinguish ourselves by the benefits of our
solutions and products.
You announced a significant growth
rate of 30 percent in sales for 2010.
Do you have the capacity for that?
In regard production capacity, we had to
restock our resources in 2010 as fast as we
had to reduce them in 2009. We are organized very flexibly to support our modular
concept and redundant operations at our
different sites. However, we have experienced problems within the supply chain.
In particular, electronic components have
extremely long delivery times or you are
forced to pay horrendous prices for them.
But overall, we do a good job within the
supply chain, which explains our good
growth rates.
What industry provides the biggest
challenge for your company at the
The industries that were hit very hard by
the crisis have higher needs than before
the crisis, such as increased cost pressure
and need for efficiency in operations. The
requirements for advanced technology
and promptness in delivery while reducing
costs leads to a vicious cycle that intensified during crisis.
What is the current status of IO-lINK
technology with your products?
We use IO-lINK for many products from
Turck, but only for those where the user
gains additional benefits through the
more @
Turck also supports wireless technology. Will cables disappear in
your opinion?
I don’t think that they are going to disappear at all. In the biggest automation market, the USA, Turck is the market leader in
the field of connectivity with more than
$90 million in sales volume. That shows
the significance of the classic connection
technology. Wireless is advantageous for
some applications, but will not become
the exclusive connection technology for
production sites. The susceptibility for
interference and an – admittedly small –
default risk cannot be entirely eliminated.
In reality, wireless is more a hype than
a comprehensive solution. But if a customer wants a wireless solution, we are
able to provide it through our strategic
partner, Banner Engineering.
What are the innovations Turck is
going to present at the SPS/IPC/
Drives in Nuremberg?
We have a few interesting new developments, among them a swiveling angle
sensor family, which works with the same
revolutionary system as the inductive linear displacement sensors of our LI-series.
It makes the sensor absolutely insensitive to electromagnetic fields. Furthermore, we are going to show a new set
of stream sensors and our new Profinet
gateway that was developed in accordance to the guidelines of AIDA and the
new modules for our block I/O system,
BL compact. “
We need a well-balanced mix
between product/regional sales and
solutions/industry sales. Therefore,
it is essential to understand what
our customers do and what their
needs are.
Christian Wolf
It is not our task to push a technology but to provide solutions
that our customers really need and
that are optimized for their specific
Christian Wolf
Angela Scheufler
is editor in chief of the
design engineering portal
Webcode |
16 T R E N D S _ I N T E R FA C E
Alternatives to
19 inch systems
Many 19 inch systems are in need of replacement. In addition to plug-in card exchanges
and DIN-rail machines, Turck offers another alternative – the excom remote I/O system
fter decades of use, many 19 inch systems are in
need of replacement. In addition to plug-in card
exchanges and DIN-rail machines, Turck offers
another alternative - the excom remote I/O system. Even
if most of the old 19 inch cards still work – the electronic
components are aging continuously and the older the
cards get, the more likely a failure is to occur. To reduce
this risk, the replacement of the 19 inch technology is
recommended. A lot of manufacturers back out of this
segment slowly.
As a specialist for interface and fieldbus technology,
Turck offers its customers a choice for the modernizing
Stefan Kappel is key
account manager
process automation
at Turck Germany
in Mülheim
Webcode | more21005e
The interface technology
in 19-inch racks that was
first installed in the 80s,
is increasingly replaced
by modern solutions
existing 19-inch installations: users can choose 19-inch
interface cards, a DIN-rail machine, the interface modules backplane with their high packing density or the
remote I/O system, excom.
A modern concept
When a user thinks about an acceptable way to modernized their equipment, many questions come to
mind: What are the arguments for one method over
the other method? How much of the existing structure
can continue to be used? How much additional infor-
mation from the field is needed to organize a good
asset management system?
If the user decides to keep the 19 inch format, the
replacement is done with little effort. With cards from
Turck, the user also receives a guarantee Turck still will
support the 19-inch format in the future.
If the user decides to replace the 19-inch technology,
DIN-rail technology is suitable. Turck also offers numerous
solutions for the separation, forming, processing, converting and adapting of analog signals for nearly all operational areas. However, this option involves more time dedicated to installation, and problems with the packing density
and the documentation could occur if there are too many
signals in the old 19-inch base frame at the same time.
To avoid this issue, Turck provides an interface module backplane solution (IMB). It can process up to 32
I/O channels on a backplane with an area of 175 x 210
mm. The IMB combines a high channel density with a
galvanic division and redundant power supply within
a small space, thereby creating more space within the
control cabinet. Analog cards that are pervious to HART
and measurement amplifiers for temperature that are
able to be parameterized via DTM complete the I/O solu-
The new excom Profibus gateway, GDP-IS, from Turck offers more
functionality with little dissipation loss
tion and allow integrated asset management concepts
for the physical layer. However, the use of the IMB system requires some structural alterations of the already
existing 19-inch installations.
Remote I/O in 19-inch rack
Turck's excom system is a viable alternative for users who
want to replace the classic point-to-point technology with
a remote I/O solution. The modular rack is 19-inch compatible and can be easily installed into preexisting frames.
Only a fieldbus cable needs to be laid, which forwards all
signals to the control system. excom is very user-friendly
in general, because it is possible to run a signal transmission test during start-up without requiring the connection to a PLC (Masterclass 1). In regard of the chosen
redundancy procedure, complete stations can be added
or removed from the bus – an important criterion for a
retrofit or the initial configuration of a plant.
The excom system can be operated by 24 VDC, 115
or 230 VAC. The rack has space for two power packs, two
Profibus gateways and up to 16 I/O cards. This equates a
maximum expansion of 128 binary (NAMUR) or 64 analog signals. All cards are hot-swap-able and have an additional LED status display on the front of the card. All Zone
0 and Zone 1 signals can be operated from the field. The
connection of the system to the controls is carried out by
Profibus-DP V1. Profibus can be configured to be redundant if needed – just like the feed-in. The connection via
Profibus has the advantage of additional enhanced diagnostics, and direct and automatic HART access to the
field devices is possible. Quick read
About 30 years after its launch, many 19-inch cards can
be found in numerous plants. Turck supports updating
these systems with a large portfolio of FDT/DTM-based
interface solutions that ranges from modern 19-inch
cards, over DIN-rail machines, to the convenient remote
I/O system, excom, that easily can be installed into
19-inch racks.
more @
18 T e c H n O l O g y _ P r e s s u r e
Thorsten evers
is the product
specialist for
fluid sensors at
Turck germany
in Mülheim
Webcode | more21070e
The PC200 and Ps300
(with display) sensors
are available with
G1/4“, 1/4“-NPT
and r1/4“ process
Flexible Hydraulics
The new PC200 and PS300 pressure sensor family by Turck meets the requirements for
hydraulics engineering
ressure sensors that are used for hydraulic systems have to meet specific requirements, but
mainly they have to be very robust. Usually the
hydraulic pressure is between 6 and 600 bar, but it is
dynamic and not static. The constant alternating pressure not only strains the cells and the sealing material,
but also the housing itself. It is important to choose the
right combination of cell technology, sealing material
and the sensor's housing to ensure reliable pressure
To resist dangerous pressure peaks that may
exceed the normal operating pressure by several
times over, the choice of the right cell technology is
essential. Pressure measuring cells made of ceramic
are approved for these kind of applications. They offer
over-pressure capability, a good drift performance and
a fast reaction time. Furthermore, ceramic is resistant to
aggressive substances..
Because of these positive qualities, a measuring
cell made of ceramic is the core of the new pressure
sensor families, Pc200 and PS300, from Turck. This
piece of equipment processes the measuring signals
directly from the cell and forwards them digitally to
the evaluation electronics. The result is better performance when it comes to excess pressure, compared to
standard ceramic cells.
High protection category IP69K
The pressure sensor is not only stressed by the hydraulic pipes, but also through outside influences like oil
spray, mechanical forces or eMc influences. The Pc200
and PS300 family (with display) are IP69K-rated for all
areas of pressure measuring. The housing is made of
special steel and the sealed control and display elements don't allow moisture into the device. Further,
mechanical forces up to seven joules – even on the
display – don't have any effect. Because of the new cell
technology with integrated digitalization of the data,
the PS300 achieves a high electromagnetic tolerance,
as well as a high accuracy of 0.5 percent. The repeatability of sensors like this is mostly underestimated.
Often, people look at the data sheet for the tolerance
and the error information first, but what looks accurate
at first may not be because temperature, hysteresis and
other factors have not been considered.
The reason for inadequate repeatability often
results from choosing the wrong material, which cannot guarantee the ideal interaction under pressure and
temperature load changes. naturally, the electronic
components play an important role. Turck took this
into account and made sure that the new cells had an
improved repeatability by working on the signal processing. The signal is no longer analog but digital, which
reduces interfering signals that occur through the
development of extra-low voltage.
 Quick read
To measure hydraulic pressure doesn't seem to be a big challenge at first glance, but it is not easy to find the
right pressure sensor for this application in the right range. not every sensor can cope with the special requirements
of the hydraulic industry.
more @
The sensors from
Turck with their
robust, ceramic
measuring cells
and integrated
digital signal
processing show
a considerable
better performance than a
standard ceramic
cell, because the
measuring signals are digitally
forwarded to the
evaluation electronics
20 T e c h n o l o g y _ P r e s s u r e M E A SURE M E N T
The PS300 is parameterized with two push buttons that are easily operated with gloves
IO-Link in the future
Product characteristics are not the only important factors; manageability is essential. This includes, among
other things, enough space for the use of tools during
mounting, sufficient access for the electronic connections and adequate programming possibilities.
Turck built upon its PS400/500 pressure series
in the new sensor family. A large, four-digit display
shows the user the operating pressure, even through
oily glass. The equipment is parameterized with two
push buttons that are easily operated with gloves.
A recessed push button needs to be pushed to confirm the changes with the parameterization; mistakes
can be avoided with this safety feature. Optionally,
the PS300 family can be operated according to the '
VDMA specification 24574-1.
Until 15 years ago, mainly contact switches
were used for monitoring pressure. These were reliable, but only to a certain extent. Higher requirements demanded by applications – like easily switching the units or reprogramming the switch points
– made the electronic push button necessary. Today
we face a change again: Better access to the instruments is needed to read the sensor data more easily. These days, a simple binary or an analog signal is
not sufficient.
IO-Link is the technological solution to these changing
demands, and provides users with a standardized tool
for the world of sensor technology and actuating elements. The technology offers new possibilities to make
machines and systems even more efficient. The IO-Link
technology is integrated into the PS300 sensors, so that
users can switch to the IO-Link in the future and not at
the present moment if they choose. If you talk about
investment protection, you also have to talk about reliability and quality. A low price is tempting, but if there
is a quality problem with the equipment it gets more
expensive in the end, i.e. when there is a shutdown of a
machine because of a low-quality sensor.
During the development of the PC 200 and PS300
family, Turck focused on quality and longevity of the
product, as well as on the cutback of storage costs.
The sensors with their robust, ceramic measuring cells
and integrated digital signal processing show a considerable better performance than a standard ceramic
cells. The two sensor families offer a device for all applications, and with the IO-Link the sensors adapt very
quickly to different situations. N
A P P L I C AT I O N S _ R F I D
Stefan Kappel is
a key account
manager for process automation
at Turck Germany
in Mülheim
Webcode | more21050e
Primary-screening: In
three spraying units,
the plants are sprayed
automatically with the
substance that is about
to be tested to see if
there is any effect
User Integrator
Efficiently Control
Bayer CropScience tests new active components with RFID-support from Turck
n their research laboratories in Monheim, Germany,
scientists at Bayer CropScience are continuously
looking for new active components with the help
of new and modern machines. After a lengthy process,
these active components are developed into efficient
agricultural pesticides for worldwide use.
One of the first steps in this process is called primary-screening. During this process, the newly developed
substances are tested for their effectiveness by applymore @
 Quick read
Scientists from Bayer CropScience AG test new
active components for their suitability as agricultural
pesticides by spraying them onto plants in an automated system. The RFID-system, BL ident, from Turck
guarantees transparency and the clear identification
of each plant.
22 A P P L I C AT I O N S _ R F I D
After the plant
pots leave the
spray units, all
the relevant data
is written onto
the RFID tag in
the middle of
the plant pot
ing them onto plants automatically. Depending on the
effect of the application, further research is conducted
in the laboratory, then in the greenhouse and finally
Fully automatic primary-screening
Bayer CropScience developed a fully automatic spraying line for the primary-screening process that manages
more than 25,000 spraying operations every year. During each application cycle, three plant sets are sprayed
with three different test components simultaneously.
The plant sets contain the host plants for eight plant
diseases. “During the primary-screening process, we
spray up to 100 new substances in different concentrations onto the plants on a daily basis,” says Bernd
Schulten, operating engineer at Bayer CropScience. “To
not lose the general view and the control, we use soft-
After the plants have passed through the current
program, the data can be read on the display
BCS engineer Bernd Schulten sees the current status
of the machine at a glance
ware support for our tests. We get the test series designs
from the data processing service center. We import
them here, execute them and send back the results,” says
The most important factor during this process is
the clear identification of the plant sets and the correlation to the substances applied to them. Originally,
barcode-stickers were used, but the machines were
recently updated with contact-free RFID-technology. “In
cooperation with the industrial supplier Tectrion, who
maintains and updates all our machines in Monheim,
we updated our machines with a third spraying booth
and the whole system with a new SPS. Previously, only
single machine processes, like the spray booth, conveyor and pipette machines, could exchange signals,
but now we can control and monitor everything via SPS,”
Schulten explains. “In this context we wanted to get rid
of the barcode-stickers, because they were not ideal for
the wavy design of the plant pots and the environmental conditions they were exposed to. Also, the printer
was high-maintenance.”
During the search for the ideal RFID-solution, the
technical project-team considered various different systems and providers. In the end, the decision was made
in favor of the BL ident RFID system from Turck. “We
wanted an RFID system that is easy to handle, robust and
cost-saving in comparison to other products. We found
all this with the system from Turck,” Schulten comments.
Easy handling with CoDeSys
For Volker Bachmann, a specialist for controls in the
Robotik department at Tectrion, BL ident has another
unbeatable advantage: “Turck's RFID-System is programmable with CoDeSys and therefore creates the
flexibility to outsource complex actions to the controls
on-site. That is how we unburden the computer that
controls the test procedure.”
During the change to RFID, the technicians from
Tetricon had to equip about 1,000 plant pots with a tag
that was glued to the center of the pot. Each tag has a
memory space of 128 Byte and contains all the information regarding the specific plant. “Originally, we con-
Dietmar Kleist, laboratory assistant for biology, is able to read the data
from each plant pot with a handheld-reader, if needed
sidered saving only the ID-Number on the tag, but that
wouldn’t ensure enough flexibility. Now, where all the
information is saved on the tag, the machine can work
self-sufficient and every single plant pot is identifiable,
even without a central computer,” says Bachmann.
A Turck Q80 combined read/write RFID head writes
and reads the data directly after the plant pots have left
the spraying units. Another read/write head is located at
the spot where the plant pots leave the machine. If the
machine fails or the pots have to be identified for some
other reason, Bayer employees can read the current
status of the pots with a handheld RFID reader. The
read/write heads send RFID signals to the BL20 modular
remote I/O system. With the help of a special RFID disc,
the data is collected and transferred to a gateway that
carries out the local RFID communication, so that only
reference data has to be sent to the main computer via
Modbus TCP.
“Working with the system from Turck was very comfortable,” Bachmann adds. “It was not difficult to program
and I could rely on established standards, like Ethernet,
so that we could integrate the system into the machine
easily. Because of the modular concept, we also could
set up everything exactly as we wanted to.” N
The BL20 gateway is programmable with CoDeSys and carries out the RFID communication
more @
Turck's RFID-System is programmable with CoDeSys
and therefore creates the flexibility to
outsource complex
actions to the controls on-site. That is
how we unburden
the computer that
controls the test
Volker Bachmann,
24 A p p L I C AT I O n S _ S E N S O R
Toralf Märtin is the
Key Account
Manager for the
Volkswagen group
at Turck Germany
in Mülheim
Webcode | more21053e
After the coating,
the car body is
transferred from the
skid system to the
overhead monorail
Safe Transfer
Volkswagen AG in Wolfsburg relies on measuring light curtains and the BL67 I/O-system
from Turck for a flawless vehicle transfer from a lifter onto an overhead monorail
ans of track and field recognize the critical
moment when a baton is passed during a relay
race. Is the transfer successful or does the team
lose because the baton was not passed successfully?
Less spectacular, but much more expensive, are unsuccessful transfers for Volkswagen AG in their factory in
Wolfsburg, where coated car bodies are transferred
from a skid system to a power and free system on their
way from the paint finishing system to the final assembly. This transfer is executed with the help of four transfer lifters that lift the car body to a required position
so that the transport gear is able to use the openings
through the front and back window to lift the vehicle
onto an overhead monorail. The car bodies rest on
grapplers attached to the monorail and glide securely
to their next destination. The critical point in this process is the moment when the grapplers take the car
body from the skid system.
The position of the car bodies during the transfer
was originally diagnosed by a switch on the base of
more @
 Quick read
In the Volkswagen AG factory in Wolfsburg, Germany,
freshly coated car bodies are transferred by four transport lifters onto an overhead monorail. Because of the
tolerances that are inherent to the system and imprecise measuring, problems with the positioning of the car
bodies required an adjustment for the vehicles. With
the new EZ-Array measuring light curtains and BL67 I/O
system from Turck, the transfer lifters work without
26 A p p li C atio n S _ S E N S O R
All information at a glance: The measured data is displayed graphically on the control panel
a measuring system. Only 20 to 50 millimeters within
the overhead monorail and the car body, as well as
potentially unstable positions of the vehicles, led to a
margin of error that required costly adjustments during the transfers. The position of the transfer lifters and
the grapplers was based on operators visually monitoring the system, and the exact position of the vehicle
With the ModbusRTU protocol,
measured data
from the light
curtains is sent to
the IP67 rated I/O
system, BL67, from
Turck, where it is
transformed by
a programmable
gateway into the
Modbus-TCP format and is forwarded to the controls
wasn't safely identified since it couldn't be guaranteed
that the car body really was in the correct position.
New measuring system
To guarantee that the vehicles were transferred safely,
a new measuring system that would show the exact
 EZ-Array measuring light curtain
The EZ-Array light curtain has a resolution of five mm
and comes with two PNP or NPN switching outputs, as
well as two 0-10V or 4-20mA analog outputs. Due to
its anodized aluminum body, the light curtain may also
be used in extreme environments with temperatures
between -40 to 70 °C. The two-part light curtain allows
an easy startup: The body of the receiver contains the
electricity for analysis, which can be configured with
the help of six DIP-switches. An external controller is
not necessary. A three-figured display and a LED bar
graph show the status and the alignment of the sender
and the receiver. The adjustment of the receiver also
can be done via software with the use of the RS485
gateway, which is also used for the data transfer of the
Modbus-RTU protocol.
position of the lifters, grapplers and car bodies was
necessary. The company came to the conclusion that
the most efficient solution to their problem was measuring light curtains. After analyzing different models
and providers, the specialists at Volkswagen chose the
EZ-Array light curtains manufactured by Turck's optic
partner, Banner Engineering.
With a range of up to four meters between the
sender and the receiver and a resolution of five millimeters, the light curtains from Turck provided the necessary range required by Volkswagen. In addition to using
light curtains from Turck, Volkswagen chose to use
Turck's BL67 modular I/O system. This system incorporates a gateway that can be programmed with CoDeSys
and it sends the data to the controls via Modbus-TCP,
exactly as needed for the application.
Real-time measurement
Volkswagen is able to measure the exact position of
the vehicle during transfer, because the measuring
light curtains are placed in a horizontal position at the
transfer point on the overhead monorail. The concerns
related to spacial distances and human error are no
longer relevant.
In principle, the measuring light curtain consists
of numerous, parallel light barriers that send a signal
as soon as the ray of light is interrupted. Volkswagen
uses two EZ-Array pairs with 900 and 1,200 millimeter lengths for each transfer lifter. The light curtains
measure the exact position of the roof edge on the car
body and the position of the front and back grappler
in real time.
With the position of the edge of the roof of the car
body identified, the grapplers can be operated precisely. Even if the car bodies move during the procedure,
the measuring light curtains record the change of position reliably and the grapplers are repositioned accordingly. This allows a precise procedure and a safe transfer of car bodies with a drastically reduced possibility
of the cars being damaged. During the first month of
testing this system, Volkswagen noticed an explicit
improvement in the availability of the equipment, and
more @
The EZ-Array measuring light curtains record the position of the car body
and the grappler in real time
the transfer problems were reduced by 50 percent
within four weeks. In the meantime four transfer lifters
are working with the new measuring light curtains in
Wolfsburg – without any problems. N
28 A P P L I C AT I O N S _ S E N S O R
Cast Off
Updated level measurement system for the sea and domestic port in Papenburg uses
wireless data-transfer as a cost-saving alternative to complex cable laying
f the placid banks of the river Ems between Papenburg and Emden in the northwest of Germany are
as crowded as the Hockenheimring when Michael
Schumacher is driving a good race, then the time has
come: a cruise ship has arrived at the Meyer dockyard
and must be led through the tight waterway towards
the North Sea – an impressive spectacle that attracts
a lot of onlookers.
The first challenge for the ship captains comes
directly after the boat leaves the dockyard in the deep
water harbor, because of the locks located between
the dockyard and the river Ems. The first lock is responsible for making sure the tidal range of the river (about
three meters deep in the middle) doesn’t affect the
water level of the inner harbor. About 100 meters away
from the dock lock, a sea lock separates the industrial
harbor in Papenburg from the river Ems. No matter if it
is a dock lock or a sea lock, the most important factor
Hans-Peter Löer
is a sales specialist
at Turck Germany
in Mülheim
Webcode | more21054e
Modern radar sensors
replaced the mechanical measuring system
at the sea and domestic
port in Papenburg
for a safe sluice is a perfectly calculated water level in
front of and behind the lock gates.
For many years, the Papenburg port used a
mechanical measuring system to measure the water
levels at the locks. When the city decided this process
was no longer up to standard, it began searching for a
new way to measure and display the exact water level.
After a public tender offer, Josef Graupe GmbH & Co. KG
from the city Haren got the job to update the harbor.
The founder of the company, Josef Graupe, and his ten
employees are specialists for control and measurement
engineering on docks, bridges and weir systems in
Level measuring with radar sensors
At the Papenburg port, Graupe equipped the four
measuring points with radar sensors that measure
On the roof of the station, four radio
receivers are installed
At a glance: The display at the central station always shows the water level of the
Ems, the lock and both inner harbors
The waves of the radar sensors are reflected by the
water surface, the elapsed time defines the level
the water level by using electromagnetic waves. The
waves emitted by the radar sensors are reflected by the
water surface, and the elapsed time defines the water
level. While one of the sensors measures the level of
the river Ems continuously, the other sensors measure
the water level in the sea lock and the water level in
the harbor. At the central station of the sea lock, this
data is processed and displayed on four readouts and
a monitor.
Only a wireless radio-based system was considered
for sending the data from the four measuring points
 Quick read
To update the level measurement at the Papenburg
port, the old mechanical measuring system was replaced
with modern radar sensors. Turck’s wireless solution,
DX70, guarantees an efficient and reliable signal transfer
via radio.
more @
to the monitor, because of the distance involved and
the cost of laying new cables. To find the right wireless solution, Graupe checked systems from different
providers before choosing the DX70 solution, which
is developed and produced by Turck’s partner Banner Engineering. “Regarding the price-performance
ratio, Turck is unbeatable,” Graupe explains. “The DX70
devices are fantastic. I can install them everywhere and
quickly have a connection of more than hundreds of
meters. Also, the installation of the radio system was
done quickly; we only had to install the data line from
the sensors to the senders and the power supply system from a facility nearby.”
The analog radio signals are recorded at a central
station by four DX70 receivers and sent to Web based
displays that can be accessed from the internet. Plans
are being developed for a Smartphone version as well.
In this way, ship captains and other interested people
have the opportunity to check the current water level
in the Papenburg harbor with ease.
Radio solution for every application
Turck‘s DX70 is a point-to-point radio solution that –
as in this example – is mainly used for the transfer of
data from subsequent measurements. With the DX70gateways, up to eight binary inputs and four binary
outputs, or, alternatively, four analog signals can be
transferred. For more complex automation tasks, Turck
offers the DX80, a radio based network topology that
can handle a gateway and up to 99 remote nodes.
All DX radio systems work with a 2.4GHz frequency
band and use FHSS technology with TDMA as a protection against perturbation. The gateway and nodes are
IP67 rated type and work in temperatures between
-40 and 85 °C. N
Regarding the
ratio, Turck is
unbeatable. The
DX70-devices are
fantastic. I can
install them everywhere and quickly
have a connection
of more than
hundreds of
Josef Graupe,
Graupe Elektro
30 A P P L I C AT I O N S _ S E N S O R
Zukui Zhang is a
product manager
at Turck China
in Tianjin
Webcode | more21055e
Turck's uprox+ sensors
resist vibrations, heat,
water vapor and oil in
the hot rolling mill
Hot Iron
Inductive sensors from Turck's robust uprox+ family guarantee the reliable
operation of hot rolling mills from the Ningbo Iron & Steel Corporation in China
he Ningbo Iron & Steel Corporation is a subsidiary
of the Shanghai Baosteel Group Corporation and
produces about 4 million tons of iron and steel
products in China every year. Located at the south of the
Yangtze estuary, the company produces numerous metal sheets using the cold and hot rolling method.
The hot rolling method alone produces 9,000
tons of sheet metal every day. To improve the automation of the production and logistics, the hot rolling mill uses numerous inductive sensors from Turck
that measure the horizontal and vertical movements
of the plant components to obtain an exact measurement of the position. Employees from the Ningbo
Iron & Steel Corporation tried using products from
other manufacturers, but experienced negative results.
Because of the small sensing distances and installation restrictions, the sensors had to be installed
in close proximity to the moving metal blocks, and
were often destroyed by heavy vibrations or through
direct contact. Furthermore, the sensors could only
The robust
uprox+ sensors
meet all requirements of the
Ningbo Iron &
Steel Corporation
 Quick read
Because of repeated shutdowns caused by the malfunction of inductive sensors, the Ningbo Iron & Steel Co.
was looking for a reliable replacement – a sensor solution for the rough working conditions. These days the
robust factor 1 sensors of the uprox+ family from Turck
guarantee a safe operation of the plants.
be installed at the lower part of the plant, where they
were exposed to water, oil and dust.
To avoid a plant shutdown due to sensor malfunction, it was important to find more reliable sensors with
a larger sensing distance that could resist the extreme
conditions of the steel production. However, sensors
with a higher sensing distance create stronger magnetic fields that can cause two-way disturbances, therefore
it was also important to find sensors with a high resistance to electromagnetic interference.
Robust Factor 1 Sensors
After an intensive analysis of the sensors that currently
are offered on the market, the automation experts from
Ningbo Iron & Steel Co. decided on the robust uprox+
sensor from Turck. Thanks to their multi-coil technology, uprox+ factor 1 sensors recognize all metals
more @
without a reduction factor: they have the same rated
sensing distance for iron, special steel, copper, aluminum or brass. This fact means that only a few sensor
types are applicable to numerous applications, where
the user previously needed many different types of sensors. Compared to conventional ferrite core sensors,
uprox+ sensors measure the metal targets with considerable higher sensing distances – up to 50 mm. The
model NI30U-M30-AP6X-H1141, which is used in Ningbo, offers a rated switching distance of 30 mm.
Uprox+ sensors don’t contain a ferrite core and
are immune to magnetic fields so that two-way disturbances are not an issue. This feature also results in
installation options that protects against collisions.
Additionally, the high IP68 protection rating makes
the sensors resistant to the extreme environmental conditions of the hot rolling mill, like water vapor,
vibrations, oil or heat. N
32 A P P L I C AT I O N S _ F I E L D B U S
Water Treatment
Water treatment plants from WJP Solutions are used in many Australian buildings –
now they are working with DeviceNet fieldbus technology from Turck
s specialists for water treatment plants that
deal with waste water and water for domestic use, WJP Solutions, headquartered in Melbourne, Australia, has completed various large projects
in Victoria, New South Wales and Queensland. WJP Solutions' water treatment plants are mainly found in public
buildings, shopping malls, universities and golf courses.
With a team of approximately 25 employees, WJP Solutions is able to implement entire projects – from the
design stage all the way to installation, commissioning,
fine-tuning and maintaining of the complete system.
WJP Solutions' latest project was to design and
implement a waste water treatment plant at the
Christian Homoc
is the Product
Support Engineer
at Turck Australia
in Melbourne
Webcode | more21056e
WJP Solutions relies on
fieldbus technology
from Turck for their
new water treatments
South East Queensland Correctional Facility in Gatton.
This plant was first built in a modular fashion at WJP
Solutions site in Melbourne and then shipped to the
location in Queensland. To use the modular concept
efficiently, Petar Bijelac, the electrical automation manager of the company and his colleague, Aleksandar
Stanojevic, made the strategic decision to utilize fieldbus technology to replace the conventional methods
used in the design and implementation of their projects. Compared to the conventional methods, fieldbus
solutions cost less and are faster to install – especially
with regard to the modular installation during reconstruction on site.
The motor starters, which are connected with a BL20 DeviceNet gateway, are installed in no time at all
Comprehensive portfolio
After Bijelac and his team compared the current
products on the market, they decided on Turck. “We
assessed similar systems from other manufacturers and
we found the solution offered by Turck to be the best
in terms of ease of integration and cost. Support of the
product has played an important role in selecting Turck
as a supplier, as well,” says Bijelac. Since the beginning
of the project, Turck has provided support from software or CAD-data to specific device configurations. In
addition to the support Turck provides, the functionality, reliability and price-performance ratio Turck offers
with its robust IP67-rated components is exactly what
WJP Solutions needed for its project.
For the project in Gatton, Turck delivered 16 digital
and analog advanced I/O modules (AIM stations) and
27 motor starters for its BL20 distributed I/O system.
The motor starters can be easily installed next to each
other within the control cabinet, and are connected to
the plant via three BL20 DeviceNet gateways.
With the robust connection technology from
Turck, WJP Solutions was able to connect the pumps,
valves and numerous sensors, including the devices
that measure pH-value and chlorine, easily and reliably. WJP Solutions is also using Turck products for
a project at the Westfield Sydney City Shopping
Center. Turck is supplying this project with 16 AIM
stations, both digital and analog, as well as two BL67
distributed I/O systems with analog output modules.
Both systems utilize DeviceNet cables, splitters and
connectors from Turck.
DeviceNet on board
We assessed
similar systems
from other manufacturers and we
found the solution
offered by Turck
to be the best in
terms of ease of
integration and
cost. Support of
the product has
played an important role in selecting Turck as a supplier, as well.
Petar Bijelac,
WJP Solutions
Another advantage of the fieldbus solution from
Turck is the fact that each I/O station can be
connected directly to the DeviceNet network. The
systems are easily integrated into the network controlled by an Allen Bradley PLC with a DeviceNet
master. The alternative, a central DeviceNet station
where the sensors are connected in a star topology,
becomes superfluous. N
 Quick read
To support the modular concept of their water treatment plants, the Australian
company WJP Solutions replaced conventional wiring with fieldbus technology.
Their partner from the beginning was Turck, because of its comprehensive portfolio of compact and modular I/O systems for DeviceNet.
more @
34 A P P L I C AT I O N S _ F I E L D B U S
Peng Wang is a
product manager
for fieldbus technology at Turck
China in Tianjin
Webcode | more21057e
A modern shipping
plant for iron ore
was developed at the
Taicang Wugang Port
Let the Water Flow
In the port of Taicang, an extensive sprinkler system reduces the dust pollution that is
caused by shipping iron ore – Turck’s fieldbus modules support the system
hina has become the world's export champion.
To develop and keep this title, China generated
a huge need for resources. This need can only
be filled with the help of modern transportation solutions. Therefore, numerous shipment centers for coal,
minerals and iron ore, as well as computer terminals,
need to be expanded. China will form five large-scale,
intensive, modern port groups, such as the Bohai Sea,
the Yangtze River Delta and regions at the southeast
and southwest coast.
Taicang, located in the south bank of the Yangtze
River estuary, is the best intersection for river-and-sea
coordinated transport. In order to meet the growing
iron ore import demand and to provide efficient iron
ore transit services in the Yangtze region, the Ningbo
Port Group, the Wuhan Iron & Steel Group and the Sinotrans Group established the joint venture of the Taicang
Wugang Port Company Limited in 2003. Next to the
Ningbo Port, the Taicang Wugang Port will be the second biggest port for the local production of iron and
steel. If the port is completed, the annual throughput
will be up to 30 million tons.
Sprinkler system against dust
A huge bucket wheel for iron ore works at the bulk
material port of the Taicang Wugang Port. A large
amount of dust is produced during the shipping pro-
Each sprinkler is equipped with a control cabinet with a BL20 station
cess so the operating company decided to install a
sprinkler system to reduce the dust impact on the
environment. Twenty-one sprinklers on each column
are distributed over a length of 800 meters in order
to cover the entire area. There are two traditional
control methods for the sprinkler system. First, the
signals of each sprinkler will be transmitted through
cables to a central control unit. This option would
allow easy start-up and programming of the system, but laying the countless cables would lead to a
substantial increase in cost.
The second method is to equip each sprinkler with
a small SPS to achieve control. Although this method
could solve the cable problem, a large number of small
SPS's would increase the cost and manpower because
of the programming required. Also, these local solutions are not ideal for maintenance work. For the system integrator, Shanghai TGE Environment Equipment
& Engineering Co. Ltd., in charge of the control system’s
installation, programming and commissioning, only a
fieldbus solution came into consideration. All advantages of a central control can be used without having
the disadvantages of a complex wiring. All signals are
collected from I/O stations directly at the sprinklers and
are forwarded via Profibus to the controlers.
BL20 station and Profibus repeater
ules, which are configured for the different required signal types. The signals are forwarded from the gateway
to the main controls via Profibus-DP. Because of the
large distance within the plant, an additional Profibusrepeater from Turck was used to increase the maximum
distance from 1,200 to 2,400 meters.
Turck's I/O-assistant diagnostic software was
another reason for the BL20 becoming the product of
choice. The FDT/DTM based tool supports the user during design, start-up and maintenance of the network.
With the help of the I/O-assistant, each BL20 station can
be configured on-site – without having to be connected
to the main controls.
The BL20 system from Turck contains the features needed for use in the spacious Taicang Wugang Port. The
modular system is flexible and adapts to the requirements of the different stations. The system integrator
and users benefit from numerous possibilities to save
costs – not only through the reduction of the cables,
bridges, terminal blocks and control cabinets, but also
through the fast start-up and operation of the I/O network. Thanks to the extensive diagnostics function provided by I/O-assistant, network errors are located and
taken care of quickly. N
Flexible BL20 system
After comparing different products, the system integrator chose the BL20 Economy distributed I/O system
from Turck. With its modular concept, high signal density, small size and low price per channel, Turck’s fieldbus solution was the clear choice. "Because of the flexible structure and ability for expansion, the tailored I/O
system, BL20, from Turck is quite fit for our distributed
system," says Chunyang Zhong, manager of Shanghai
TGE Environment Equipment & Engineering Co. Every
fieldbus station consists of one gateway and I/O modmore @
 Quick read
The Taicang Wugang Port will be the second biggest
port for the local production of iron and steel in the
Yangtze-Region in China. To reduce the dust impact on
the environment that is caused by shipping iron ore, the
operating company decided to install a sprinkler system
that is controlled by a local SPS. BL20 I/O stations and
Profibus-repeaters from Turck guarantee a reliable Profibus communication between the SPS and the sprinklers.
Because of the
flexible structure
and ability for
expansion, the tailored I/O system,
BL20, from Turck
is quite fit for
our distributed
Chunyang Zhong,
Shanghai TGE
Equipment &
Engineering Co.
36 A P P L I C AT I O N S _ C O N N E C T I V I T Y
Facing the Winter
Using connectivity solutions by Turck, Cirus Controls creates deicing systems that clear
snow and ice from roads and lessen the environmental impact of sodium chloride
s the people in Minnesota know, winters can
be cruel. Residents there are all too familiar
with subzero temperatures that leave ice and
snow covered roadways for months on end. Snowplows
that clear the road and spread the ice-melting products
that make traveling less treacherous are a necessity for
people living in many northern climates. Even so, most
drivers don’t think about what happens to the deicing
material – usually sodium chloride (salt) – until they are
washing it off of their vehicles.
Though the salt effectively melts ice and snow off
the roadway, it also winds up in the ditches, marshes,
lakes and streams that surround the area of application.
Numerous studies have shown an increase in sodium
chloride levels in waterways that has been attributed to
the application of salt as a deicing material, which has
led many industry professionals to investigate ways to
reduce the salt on the road.
Paul Mortell, President of Cirus Controls in Brooklyn Park, Minnesota, and his team have been working
to design control systems used on the snowplows to
regulate the amount of salt being applied to roadways
since 2001. According to Mortell, without the use of
control systems, snowplow operators are relied upon to
use their best judgment about how much salt to apply
Eric Lavigne is
a sales specialist
with Turck's
representative Mtech
Minnesota in USA
Webcode | more21058e
Cirus customers
can reduce cost
of materials by
30 to 80 percent
to the roadway, and in an abundance of caution, are
oftentimes using too much.
How much is enough?
Imagine how difficult it would be to see the salt coming off of the rear of a snowplow during blowing snow
conditions using only your rearview mirrors. “When
our calibrated systems are used for the first time by an
experienced snowplow driver, they sometimes think
that there is very little salt coming off of the spreader.
This is because Cirus Controls’ systems are configured
to only apply as much salt as is needed to melt the ice,
which is usually far less than what is applied without
a calibrated system and is hard to see in the rearview
mirror,” explains Mortell. “Calibrated controls reduce the
driver’s requirement to constantly watch how much
salt is being spread and lessens the amount of salt that
ultimately winds up in the watershed. In addition, it
frees the operator’s attention to be more focused on
what is in front of him instead of the spreading going
on behind.”
The incentive for keeping salt on roadways to a
minimum is obvious: it’s better for the environment
and it helps reduce the deterioration of guard rails
The junction boxes and
cordsests from Turck are
well prepared for the tough
winter conditions
and vehicles. However, using control systems to manage salt application did not immediately become a
standard practice. Says Mortell, “The implementation
of electronics in the control system was slowed by
the lack of durable electrical connections for the environment that they must operate in. The revolution in
molded, shielded cables accelerated the introduction
and adoption of calibrated electronic controls.”
Electronic control systems
Where traditional systems rely on user expertise, electronic control systems are used to measure system
features that help regulate salt usage. Some of these
features include the ground speed of the truck used to
apply the salt, the temperature of the road, the pressure
of hydraulic system fluid, remaining amount of liquid
and granular de-icing material, and the GPS position of
the vehicle. This data is available to snowplow drivers
so that they can accurately gauge system performance.
In Cirus Controls’ electronic control systems, a
valve bank is mounted onto the truck frame and is connected to the controllers in the cab of the snowplow.
Finding a cable supplier with connectors that can hold
up in the cold, wet and abrasive conditions found on
a snowplow led Cirus to Turck. Depending upon the
configuration, Cirus uses Turck 4 and 8 port junction
boxes with either M8, M12, M23 or 1-1/8 inch molded
connectors to connect the devices in the valve bank.
Turck’s connector’s large size makes it easier for operators to connect the devices in the field, and integrated
LEDs improves field diagnostics by allowing the user to
visually see if the connection is operational.
“Outside the cab, electrical connections are
exposed to water, ice, salt, hydraulic fluid and other
materials so the connections must be IP68 rated or
better,” says Mortell. “It’s also important that the connectors can be easily applied in the field. Both of
these requirements were met by Turck junction boxes
and cordsets.”
Since Cirus Controls makes custom valve banks
per their customer’s requests, another benefit of using
Turck connectors is the company’s ability to customize
terminated valve connections for specific valve manufacturers. In this way, Cirus customers are ensured the
right connection for the valve back system they’ve
chosen to use.
Less salt equals less expense
Using Cirus systems has numerous benefits to the user
aside from the environmental impact, including having
to purchase less salt. A Cirus customer that retrofitted
25 snowplow systems was able to save over 30 percent
in material costs for a full season by using the control
system. Even more savings can be experienced when
using a closed loop system, where event and performance data is recorded and downloaded to provide
performance feedback to operators.
Among other features, this data allows users to see
exactly where the salt has been applied via a GPS system so that cities are better able to manage the deicing process. According to Mortell, users that move to a
closed loop system can experience a savings of up to 80
percent. In an example of true partnership, a city and a
watershed district authority partnered to purchase and
install this equipment and to share the deicing performance data, as well as the data regarding the amount
of chloride going into the watershed surrounding the
city, to accurately gauge the outcome. Quick read
Cirus Controls develops and produces deicing system for new snowplows or to those that are already in service. In order
to connect valve banks, sensors and controls reliably, the company, based in Brooklyn Park, Minnesota, decided to apply
Turck's junction boxes and cordsets, which are withstanding water, ice, salt, hydraulic fluid and other materials.
more @
The connections must be IP68
rated or better. It’s
also important that
the connectors can
be easily applied
in the field. Both of
these requirements
were met by Turck
junction boxes and
Paul Mortell,
Cirus Controls
S E R V I C E _ C O 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.
Trade Show
City, Country
26.01. - 28.01.2011
08.03. - 11.03.2011
17.03. - 20.03.2011
22.03. - 26.03.2011
29.03. - 01.04.2011
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
Automation World
WIN – World of Industry
Hannover Messe
Technical Fair
Assembly Technology Expo
Smart Automation
Pack Expo
Celje, Slovenia
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Las Vegas, USA
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Nuremberg, Germany
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the data record that you need in our
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export formats in 2D and 3D. This
service is absolutely free, registration is also not required.
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leads to your solution.
Turck on the Internet
Whether sensor, fieldbus, interface or connection technology, in the product
database on you will find the right solution to your needs at the touch
of a button. Three search functions will help you.
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.
Headquarters HANS TURCK GmbH & Co. KG
Witzlebenstraße 7 ı Mülheim an der Ruhr ı (+ 49) (0) 208 4952-0 ı [email protected]
Hans Turck GmbH & Co. KG
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45472 Mülheim an der Ruhr, Germany
Tel. +49 (0)208 4952-0
[email protected]
Editorial Staff
Klaus Albers (responsible)
[email protected]
Karen Keller
[email protected]
Contributors to this issue
André Brauers, Thorsten Evers, Christian Homoc,
Stefan Kappel, Eric Lavigne, Hans-Peter Löer,
Toralf Märtin, Angela Scheufler, Peng Wang,
Zukui Zhang
Art Direction / Graphic Design
Arno Kraemer, Britta Fehr (Art design)
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
 Webcodemore21080e
more @
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Witzlebenstraße 7
45472 Mülheim an der Ruhr
[email protected]
D900901 1110
Page 32
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Hans Turck GmbH & Co. KG
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