moreTURCK epaper en 2
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
Extended Offering
Oliver Merget: “Connectivity
is part of our integrated
automation strategy”
High-Speed Sensor
Arburg uses Turck's advanced
LI linear position sensor as a
motion control system
RFID Intrinsically Safe
WACKER uses BL ident RFID
solution to identify tumbler
screens in dust Ex-zone 22
Multi Language Talents
Turck presents the first multiprotocol gateways and block
I/O modules that can address three Ethernet protocols
02 E d i t o r i a l _ J ü r g e n
Focus on the Customer
When the automation sector meets once more in Nuremberg at the end of November, Turck will also be there at
hand to present our range of advanced solutions. The
following pages introduce the interesting new products
that we will be presenting together with the proven Turck
portfolio at Stand 351 in Hall 7. We warmly invite you to
visit us at the SPS IPC Drives fair in order to take a closer
look at our products and services. Apart from our range
of solutions, we will be pleased to show you what in our
view is the key factor for the success of our business: our
strong focus on the customer and his requirements.
From development to product management, right
through to sales and service, customer orientation is at
the center of all our activities. Ultimately, you as a user not only want
to pay for high-end technological products, but also for the fact that
they optimally fulfill your requirements. At Turck we therefore consider professional and direct communication with you as a customer
an essential element of our corporate philosophy.
In recent years we have worked hard at establishing a situation
where we can now offer you the support that you expect in all areas.
In addition to our sales specialists in the sales force, your project will
be supported if necessary by our colleagues in system sales, together with our in-house support and project management. For more
complex automation issues – particularly in all aspects of RFID and
image processing – our system partners, with their extensive sector
know-how, will ensure that your project is implemented with optimum efficiency.
One result of these activities is presented on page 18: The further
development of our inductive linear position sensors for the injection molding machine manufacturer Arburg, and in collaboration
with them, went so far that they even used it for regulating the
injection axis, making it the fastest inductive motion control linear
measuring system on the market. Through close collaboration, all
project partners could benefit. Arburg benefited from a non-contact
and maintenance-free measuring technology that is unique, and
Turck, from a high-speed sensor that is now available in the standard
product range with an SSi interface.
Our specialists in Nuremberg will be pleased to show you how you
too can benefit from Turck. We are looking forward to meeting you!
Yours sincerely
Jürgen Grabow, Vice President Sales Factory Automation
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Innovations for automation specialists
Cover story
FIELDBUS TECHNOLOGY: Multi Language Talents
Turck is presenting the first multiprotocol gateways and block modules that can
communicate in three different Ethernet protocols
INTERVIEW: „Part Of Our Integrated Automation Strategy“
C&A editor Inka Krischke spoke to Oliver Merget, Vice President Automation Systems,
about Turck‘s increased involvement with connectivity products TECHNOLOGY
SENSOR TECHNOLOGY: All Around Carefree Pack
Turck has developed its first 2x360° inclinometer that can be set individually by the
customer for any application
RFID: No More Trial and Error
A new simulation software based on the ray tracer algorithm enables Turck
to calculate and plan complex UHF-RFID applications
With the B2N-360-Q42, Turck is offering the world's first
3D inclinometer that offers a full 360° measuring range
on two axes. Page 14
SENSOR TECHNOLOGY: High-Speed Measuring
In conjunction with Arburg, Turck has further developed its LI inductive linear position
sensor into a genuine high-speed linear position measuring system for motion control
SENSOR TECHNOLOGY: Perfectly Assembled
The assembly systems with parallel arms from Möve-Metall are equipped with Turck‘s
inductive RI angle sensors to ensure that screws are inserted exactly to specifications
SENSOR TECHNOLOGY: All Around Protection Without Blind Zones
Intronyx protects robot cells with Banner Engineering EZ Screen safety light curtains
from the Turck range
A Chinese freight train uses Turck FCS flow sensors to monitor the air cooling in the
current converter cabinets
CONNECTIVITY: Good Connection
How Turck’s quick disconnect connectivity products helped the University of
Wisconsin-Madison’s Electric Ford F150 research vehicle come to life
RFID: Safe Screening
At its Burghausen site, WACKER is using Turck’s BL ident RFID system for reliable detection
in its tumbler screening systems in the dust Ex zone 22
FIELDBUS TECHNOLOGY: Tradition and Modern Ways
In the Irish Distillers whiskey distillery, Turck’s excom remote I/O proves that traditional
manufacturing processes can also benefit from state-of-the-art fieldbus communication
RFID: Protection for Cap Tip Dressers
Turck‘s BL ident RFID system enables the electrode cap tip dressers of AEG SVS
Schweisstechnik to reliably detect the correct cutting head for the electrode cap
CONTACT: Your Fastest Way to Turck
How, when and where to find us
CONTACT: Imprint
Intronyx protects robot cells for an automotive supplier
with Banner Engineering EZ Screen safety light curtains
from the Turck range.
Page 24
In an Irish distillery, Turck’s excom remote I/O proves
that traditional manufacturing processes can benefit
from state-of-the-art fieldbus communication. Page 33
04 N E W S _ I N N O VAT I O N S
Turck Expecting
430 Million Euro
 The Turck Group is expecting a consolidated total turnover of around
430 million euro for financial year
2012. According to Turck managing
director Christian Wolf, the automation specialist will thus exactly match
the levels of last year’s turnover figures.
Developments in the economy and
the market in 2012 have meant that
an increase in the total result was not
possible. However, the family-owned
enterprise was able to achieve a slight
increase in turnover of two percent in
the German market with almost 100
million euro. The number of employees
rose worldwide in 2012 from 3,000 to
3,200, with half of these employed by
the Turck Group at its German sites in
Beierfeld, Halver and Mülheim/Ruhr.
New Connectivity
 Turck has added its own connectivity portfolio to its range of products. The new product lines, TXL
and TEL, are available with angled or
straight M8 or M12 connectors. With
the different combinations of 3, 4 or
5-pin female and male connectors
and cable lengths from 30 cm to up
to 10 m, every user will find the right
cordset for their application. The connection and extension cordsets of
the TXL line are jacketed in specially
abrasion resistant polyurethane (PUR).
The PVC cables of the TEL series are
resistant to acids and alkalis, as well as
being flame retardant and cULus and
RoHS approved.
Active Passive
Junction Boxes
 Turck has extended its range of passive junction boxes. As well as standard
junction boxes with 4, 6 and 8 input connectors and a multi-pole cable output,
the customer will also be able to find two active IO-Link variants. The IO-Link junction boxes combine 16 switching status elements in a 16-bit IO-Link signal, thus
bringing 16 switching signals from the machine to the control cabinet via a single
standard cable. Instead of assigning each signal to the individual wire of an M23
master cable, terminating and routing them into the control cabinet with expensive multipole cables, the IO-Link junction box only requires a single standard M12
cable. The signals can come for example from proximity switches, pushbutton
actuators, optical switches or
also temperature sensors with
a switch output. The use of the
junction boxes is particularly
recommended when a large
number of signals have to be
routed from the machine to
the control cabinet. Like the
other standard passive junction boxes, the IO-Link junctions are provided with LEDs
that indicate the switching
status of each individual input.
Linear Position Sensor
for Motion Control
 For the first time Turck is entering the market for high-speed motion control with its further developed LI inductive linear position sensor. A new
electronics architecture increases the effective output rate of the sensor from 1
to 5 kHz. In conjunction with the
short signal run time (130 µs)
and the highly resolved SSi output, the inductive linear position sensors can thus achieve
the performance of potentiometers but without their disadvantages. Unlike potentiometers, the LI sensors offer permanent protection to IP67, provide
non-contact measuring and
are absolutely wear-free. The
magnetic field immune sensors
are therefore suitable for measuring axes with high-speed
controls such as is used in injection molding machines. Other
application areas include axis measurement in packaging machines, presses or
machine tools. With the high speed and precision of the sensor (system resolution of 1 µm), machine builders can keep the position error in motor control
more on page 18 
applications to a minimum.
V. P. Sales Factory
Magnetic Field Sensor for
Short Stroke Cylinders
 With the BIM-UNTK, Turck is offering the shortest magnetic field sensor for detecting
the piston position in compact pneumatic cylinders. The sensor comes with protection
to IP67 and is ideally suited with a length of only 19.7 mm for measuring particularly
short hydraulic cylinders, pneumatic power clamps and grippers. The user not only benefits from increased switch point accuracy but also from the extremely compact mounting form: The sensor disappears completely in the T groove and thus does not present a
target for any mechanical damage. An LED on the sensor enables the cylinder position
to be read directly in the field. The new BIM-UNTK can be fitted simply into the T groove
of a cylinder from above or from the side and can be secured with a hexagon socket
screw. The sensor can thus be fastened with one hand in the standard T groove without the need for any additional accessories. Turck offers suitable mounting accessories
for different cylinder and groove sizes for other cylinder types such as tie rod cylinders,
round cylinders or dovetail groove cylinders.
Multiprotocol Ethernet
Gateways and Block I/Os
 Turck is presenting at the SPS IPC Drives fair the first fieldbus gateways and block
I/O modules that communicate with Profinet IO, Modbus TCP or Ethernet/IP. The new
multiprotocol devices can be operated automatically in each of the three Ethernet
systems. The multiprotocol solutions help users of different Ethernet protocols to effectively reduce the range of device variants required. Multiprotocol devices also enable
the identical planning of machines and plant sections with different Ethernet protocols. Depending on the requirements of
the end customer, only the controller or
master have to be changed in order to
offer machines for three different protocols. Turck offers the devices for its modular BL20 series gateways for control
cabinet mounting and also for the BL67
series for field mounting. IP67 block I/O
modules including the space-saving BL
compact series are also available as mul
more on page 8 
tiprotocol devices.
 Jürgen Grabow has been appointed vice president sales factory automation of Turck. The graduate engineer
will thus direct and
be responsible for all
sales activities in the
field of factory automation worldwide.
The 49-year-old has
extensive experience
in international sales
management in the
industrial automation sector. Before
moving to Turck, Grabow worked for
several years in sales management
positions at Kontron AG – since 2006
as executive vice president sales for
the EMEA region. Jürgen Grabow studied electrical engineering at the RWTH
Aachen university and acquired his first
professional experience in the sale of
electronic measurement technology
and industrial computers. He is married
and has two daughters
Customized User
 Turck is expanding its
range of RFID handheld
devices with software
that can be specifically
tailored to the requirements of individual customers. This enables the
automation specialist to
offer a complete solution,
which, in addition to the
special handheld device,
includes a customized
user interface, RFID tags
and also stationary read/
write heads if required.
Write and read commands
can be executed via the
touch screen or keypad. The read information can be shown on the display
according to customer requirements.
The handheld readers are available for
both HF and UHF systems and can also
read barcodes or data matrix codes as
well as RFID tags. The handhelds can
communicate with mobile devices, PCs
or other systems via Bluetooth, WLAN or
a standard USB cable.
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06 N ews _ innovation S
 A software based on the ray tracer
algorithm enables Turck to simulate
the complex UHF applications of
customers and thus more reliably
estimate the accessibility of RFID tags
and read/write heads. Turck specialists
go through various scenarios in order
to determine the optimum operating parameters and ideal positions of
read/write heads and RFID tags. Read/
write heads on moving elements or
moving RFID tags can also be simulated. The simulation is particularly useful for applications where the expense
required for a test application is dis
proportionately high. more on page 16 
Powerful LED
Indicator Lights
 Turck introduces five new EZ-Light
high intensity indicators to provide
clear long-range visibility in intense
sunlight or brightly lighted indoor conditions. The Lights have been developed by Turck’s partner Banner Engineering. All use advanced LED technology to provide longer life and lower
energy consumption than fluorescent
or incandescent light sources.
Webcode more21210e
Wireless Sensor Series
 The first self-contained wireless photoelectric sensing solution for
multiple monitoring and control applications has been introduced by Turck’s
partner Banner Engineering. The new Wireless Q45 includes a sensor, radio and
internal battery power supply in a single compact and robust housing. A variety
of sensing modes are available in the new series, allowing for functions including presence/absence, alignment, position, counting, monitoring and detection. Battery life
is up to five years depending on
sensor model and application,
and the housing is IP67/NEMA
6 rated. Signals from the sensors are received at a wireless
network gateway that interfaces
with all common PLCs and other
industrial control systems. Basic
gateways control two and six
sensors, and the system can be
expanded for larger scale applications. Using a simple binding
procedure, new sensors can be
added to the network in minutes since there is no need to install any cabling.
The wireless sensors are designed for rapid, low-cost deployment and dependable operation in a wide range of situations. These include providing remote
input for dry relay contacts, replacing failed cable runs, adding sensors to
mobile applications, replacing complex cabling and connecting locations that
were previously impractical or impossible.
Fully Parameterizable
3D Inclinometers
 With the B2N-360-Q42, Turck is presenting a 3D inclinometer that can be
adapted extensively and precisely by the customer to the requirements of the
application via IO-Link. With a double 360° measuring range, the sensor is not
limited to a maximum ±85° – as with all comparable models. Users can not only
set individual vibration filters that precisely mask out the vibration frequency of
your machine, but also define the zero point, switch points or switch windows
– according to the mounting position and requirements at hand. As well as
vibrations, the sensor also suppresses potential error sources such as accelerations or shocks. The extensive range of assignable parameters and the maximum sensing range of 360° on
two axes enable the sensors
to be suitable for virtually any
application. It therefore reduces the number of variants that
need to be kept in stock to a single type. Turck offers two variants of the sensor: The industrial variant for the temperature
range from -25 to +75 °C and a
second variant according to the
e1 specification for use in utility vehicles and construction
more on page 14 
08 C O V E R
With its new
multiprotocol devices,
Turck is offering an
efficient way to utilize
the option of
Ethernet protocols
Webcode more21200e
Author Jörg Kuhlmann is the director product management factory automation systems
Multi Language Talents
Turck is presenting the first multiprotocol gateways and block modules that
communicate in three different Industrial Ethernet protocols
thernet-based bus systems like Profinet, Ethernet/IP or Modbus are becoming increasingly
more established compared to conventional
fieldbuses. For example, our Profinet devices can establish a physical point-to-point connection between two
stations in linear topologies. This minimizes the risk of
reciprocal interference between several stations. The
possibility to implement ring redundancy also increases communication efficiency compared to fieldbuses.
With Profinet, the Media Redundancy Protocol (MRP)
responsible ensures that the communication direction
is automatically changed in the event of a communication failure in the ring topology, in order to secure the
possibility of further communication.
All these benefits have contributed to the rise of
the Ethernet protocols in industrial automation. However, the hope that this transition from fieldbus to
Ethernet networks would solve the specific protocol
and connection requirements of different bus systems
has not been realized. Like their adherence to proprietary Ethernet protocols, controller manufacturers have
again developed proprietary installation guidelines for
cabling their networks. As a legacy of the fieldbus era,
the Ethernet era continues to be characterized by a
plethora of protocols.
Reducing complexity
The principles by which the controller manufacturers
are marking out and securing their claims are resulting
in a number of similar Ethernet protocols: the leaders
of the standard Industrial Ethernet protocols, Profinet,
Ethernet/IP and Modbus TCP, are sharing the majority
of the automation market between each other. Automation manufacturers on the one hand, and machine
and system builders on the other have to deal with this
diversity – both with fieldbuses and with Ethernet. One
trend therefore continues to characterize the industrial
automation sector: The range of standards and devices that fulfill similar tasks but which are nevertheless
based on different protocols continues to increase.
Turck has pursued a different approach which provides a solution for this challenge: The automation specialist is launching the first multiprotocol Ethernet gateways and block I/O modules in the world that can be
operated with the Profinet, Ethernet/IP or Modbus TCP
Ethernet protocols without any intervention required
by the user.
With its multiprotocol devices, Turck is not only
reducing the diversity of proprietary device types, but
also the number of customers that use different protocols in different parts of their production or in different
country-specific versions of their machines. In automotive production, for example, it often occurs that
body construction and final assembly are automated
using different protocols. In the future, all these users
only have to keep one gateway type in stock, regardless of the Ethernet protocol used. As purchasing and
stock-keeping are often centralized, this will enable the
costs and complexity of stock-keeping to be effectively
The multiprotocol devices make it possible to
implement machines and plants that can be planned
and constructed identically. They can also be provided
with different controllers or masters to meet specific
Different Ethernet protocols
in a production
line with Turck's
devices are no
longer a problem
 Quick read
With new multiprotocol gateways and block I/O modules, that support Profinet,
Ethernet/IP and Modbus at the same time, Turck is offering a new approach to
effectively managing the variety of protocols that had developed over time. With
no international vendor-neutral standards due in the foreseeable future, the
multiprotocol gateways take a first step towards reducing the complexity of protocols and devices used in the industry. Also, the lean architecture of the new
devices achieve by far the fastest startup times on the market.
more @
10 C O V E R
col is running on the cable by listening to the traffic in
the so-called snooping phase. The devices then automatically switch to the detected protocol and ignore
the telegrams of the other two. The implementation of
the protocols is in no way inferior to that of the single
protocol devices: In Profinet mode, topology detection
and address allocation are supported with LLDP, and
Ethernet/IP with QuickConnect and Device Level Ring
(DLR media redundancy).
Protocol detection and more
Turck FGEN Fast
Startup modules
achieve startup
times of less
than 150 ms
(Profinet) and 90
ms (Ethernet/IP)
customer specifications, enabling communication in
different protocols. Besides the benefits with regard to
spare parts management and procurement, the provision of multiprotocol devices from other automation
manufacturers will make it possible to create identical
installation plans for electrical designs which just have
to be duplicated.
Turck has added the new multiprotocol devices to
several Ethernet I/O product families: These include the
gateways of the modular BL20 series for control cabinet
mounting and BL67 for field mounting, as well as the
IP67 block I/O modules, including the space-saving BL
compact series for direct mounting on the machine. All
gateways feature internal switches that enable installation in line. The Ethernet IP, Modbus TCP and Profinet
protocols are combined in a single device firmware. In
spite of the gateways' slim design the protocol stacks
contain all the relevant protocols for this market.
The multiprotocol functionality is made possible
by an intelligent identification routine of the gateways.
During startup, they determine which Ethernet proto-
However, the multiprotocol talent is not the only source
of innovation on the new Turck gateways. The multiprotocol devices also have a turbo on board that enables
a high-speed startup. They support Fast Startup in Profibus mode and feature QuickConnect in Ethernet/IP
mode. Due to the extremely slim architecture of the
microprocessor and the operating system, they can
achieve startup times that were previously impossible.
The automotive industry in particular required
short startup times in order, for example, to increase
the cycle rate for a tool change on robots in body shell
construction. The faster the I/O module on the tool
changer returns to operational readiness, the faster
the cycle time for an operation. For the automotive
manufacturer, a shorter cycle time means either more
output per unit of time or fewer robots for a particular operation – both significant alternatives from an
economic standpoint.
The Profinet User Organization first of all streamlined the startup protocol in order to shorten the
startup times. The controller manufacturers added
prioritized startup to the Profinet protocol: If a station
was already logged in at the controller, both the station and the controller store all the necessary parameters. When a further login at the controller occurs,
the matching of these two parameter sets is quickly
checked. If they match, the station can continue with
the next step. This shortens the protracted information
ping pong between slave and master, which slowed
down the Ethernet protocols with a standard startup.
By accelerating the stack with the prioritized startup,
Profinet eliminated this brake on the startup procedure with its fast startup protocol, and Ethernet/IP with
Optimum fast-startup solution
Turck developed an optimized electronic architecture
for its Ethernet I/O modules that ensures that processors are operational considerably faster – largely
regardless of any protocol modifications – and speeds
up the startup times. The Turck block type fast startup
modules (FGEN series) now achieve startup times of
less than 150 milliseconds for Profinet and around 90
milliseconds for Ethernet-IP. Turck modules are thus
well within the requirements set by the automotive
industry, for which the maximum startup time is 500
milliseconds. There is currently no other supplier of fast
startup I/O modules that can even approach the times
of the FGEN series. N
12 I N S I D E _ I N T E R V I E W
Oliver Merget: “The
first two product lines
in Turck's corporate
design are the TEL
and the TXL line in
M8 and M12”
“Part Of Our Integrated
Automation Strategy”
C&A editor Inka Krischke spoke to Oliver Merget, vice president automation systems business
unit, about Turck's increased involvement with connectivity products
Mr. Merget, Turck is covering new
ground and for the first time is
manufacturing its own cordsets
and connectors for direct sale. Up
to now you always relied on your
partner company Escha for connectivity products – why are you now
developing them yourself?
The idea of in-house development isn't
entirely new – we have been producing
our connectors and cordsets in the USA
and in Mexico for over 20 years. At the
same time, we have been working worldwide in the connectivity sector for many
years with Escha, a renowned manufacturer. Today connector/connectivity products are a fundamental and strategic component of Turck's integrated automation
strategy. That is why we have now formalized our future long term collaboration
with Escha in a cooperation agreement:
An extensive technology cooperation and
a mutual technology transfer will enable
both parties in future to have full access
to the technology and the products of the
other company.
And what does this mean in real
The agreement makes it possible for Turck
to produce connectors on its own and
also to develop its own connector solutions – always in close cooperation and
technological exchange with Escha. Full
unrestricted access to all Escha products
– also under the Turck brand – is retained.
We will continue to work closely together
in the further development of standard
and special solutions.
What is the aim of this cooperation?
A key objective is the better development
of market potential in the target markets
of both companies. Turck will thus be able
to open up these markets faster, more
competitively and more dynamically with
Turck branded connector products, as is
the case in the USA. This enables Escha,
on the other hand, to develop additional
market potential worldwide under its
own name with its standard and niche
market strategy. In-house manufacturing
in our different factories will also enable
us to considerably improve our own
value creation depth, as well as improving logistics, thus ultimately offering our
customers greater flexibility and shorter
delivery times.
Which connectors and cordsets will
be affected by this?
The entire product range is going to be
included in the Turck portfolio and will
be manufactured by us. In this way, every
Turck sensor and every further module
can be connected with the company's
own cable. The corporate design – the
black grip with the yellow ring – will naturally play a significant role in terms of
brand recognition. In a first step we have
launched this year two product lines – the
Economy Line and Extended Line. Most
applications can be served with the stan-
dard connection and extension cordsets
in M12 and M8.
Which regional markets are you
In the North American market Turck's market leadership includes the connectivity
sector. We now also want to achieve this
success in Europe, South America and Asia
– in this case, particularly in China where
we are represented by our own subsidiary
in Tianjin. For this we are using standard
connector solutions on the one hand, but
also customized solutions on the other.
How do the requirements of the
markets differ?
The key differences are in the individual
regulations and standards such as UL, CCC
or Goost. In Europe, for example, the socalled PUR cable (polyurethane) is often
used, while in the USA TPE cables (thermoplastic elastomer) are used for similar
applications. These are flame-retardant
but do emit toxic fumes. In Asia on the
other hand, certified cables or even the
characteristics of the connector solutions only play a secondary role – the key
requirement is rather for the function to
be fulfilled at an attractive price.
How is it possible to stand out from
the competition in the connectivity
By offering a comprehensive portfolio
from M8 standard to M40 power connectors. This hardly sounds spectacular
but is not offered in this way by any of
our competitors. And naturally with short
delivery times – not only with standard
solutions but also with special customer
solutions. What we have learned and practiced in the USA market, we now want
to implement worldwide. We will also
expand the customized business for our
What kind of innovations are there
in the new connectivity product
line from Turck?
In this range, the innovations primarily
focus at present on the optimization of
production processes and the producibility of the individual assemblies and
finished parts. However, we are currently
working on the development of our own
molded connectors and the associated
accessories such as junction boxes and
integral connectors in the Power range up
to M40 for 600 V/40 A, which are suitable
for use in logistics and conveying systems,
as well as for mobile automation. N
Today connector/connectivity
products are a fundamental and
strategic element of Turck's integrated automation strategy.
Oliver Merget
What we have learned and practiced in the USA market, we now
want to implement worldwide.
Oliver Merget
Author Inka Krischke is an editor for
the technical journal Computer &
Webcode more21230e
more @
14 T E C H N O LO G Y _ S E N S O R T E C H N O LO G Y
All Around Carefree Pack
Turck has developed its first 2 x 360° inclinometer that can be set individually by the
customer for any application
he operating principle of an inclinometer is
based on the detection of all acceleration
forces acting upon it. This measuring principle is like dropping a weight on the end of a string,
by which a mass is aligned according to the gravitational field. This can involve the use of a mechanical pendulum, a bending beam or a liquid – as is the
case with a bubble level. However, like when dropping a weight on a string, the pendulum not only
reacts to accelerations but also to vibrations and
shock. These factors interfere with the inclination
Interference factors
The physical principles at play in the process, i.e. the
inertia of the pendulum, are the reason why acceleration and vibrations can affect the measuring result. In
order to eliminate this error source, filters are used to
mask out particular frequencies. The disadvantage of
these preset filters is the fact that they can restrict the
application range of a sensor. Different inclinometers
are required for the different vibration frequencies of
plants or vehicles, which complicates procurement and
Even the zero setting of the sensor at the factory is
often unsuitable in many applications if the sensor cannot be fitted on a 0° plane. In such cases, the customers
have to order specific zero settings of 10°, 20°, -10°, -20°
etc. or find a mechanical solution to adjust the sensor
into the 0° position.
Individual parameterization on site
Turck has developed the B2N-360-Q42 inclinometer, for
which the customer can set every relevant parameter
New freedom: Unlike all
comparable solutions,
Turck's 3D inclinometer
is not restricted to
a maximum measuring
range of ±85°
Webcode more21270e
Author André Brauers is product manager for linear and rotary position sensors at Turck
on site: this includes zero point, switch points, switch
window, output signal, as well as vibration, acceleration or shock filters. In order, for example, to mask
out machine vibrations, the vibration frequency of a
machine is measured with the inclinometer, and the
filter is then set specifically for this frequency. This filter is then used to output a cleaned inclination signal.
Accelerations and shock can be calculated from the signal in the same way. The user sets their own zero point
in similar fashion. The customer mounts the sensor in
a way permitted by the application and then sets the
zero point accordingly.
3D MEMS technology
The new inclinometers from Turck are based on 3D
MEMS technology, with MEMS standing for “microelectro-mechanical systems”. The core of the design is
a micromechanical capacitive sensor element consisting of several adjacently positioned plate capacitors
with a fixed and moving plate. If the sensor is moved
or brought out of the perpendicular position, the plate
moves and the capacitance changes.
The sensors operate on spring mass systems, the
springs are made from silicon elements only a few
micrometers wide. The mass is also manufactured from
silicon. Any deflection caused by movement or tilt
between the spring-loaded elements and the stationary reference electrodes produces a change in the electrical capacitance measured.
360° on two axes
Besides the parameterization function, the B2N360-Q42 offers the user another benefit: It is the first
sensor ever that enables full 360° detection in two axes.
Although this is actually only required in a few applications, it can also be used in applications where sensing
up to ±90° is required on two axes. Traditional MEMS
inclinometers offer at most ±85°. The measuring range
can be set to the specific requirements via the IO-Link
interface, enabling an output signal with a higher resolution. Even if not every application requires the full
functionality, the B2N-360-Q42 gives the customer a
sensor model that allows inclinometer measurements
to be implemented in a wide range of application fields.
Tunneling machines represent a typical application, in which precise information about the position
of the machine is required. The greatest problems with
these machines stem from the vibrations and the fact
that in many cases the sensor cannot be mounted horizontally. With the B2N-360-Q42, the customer measures
the machine vibration and then masks out this frequency precisely. The sensor can be mounted in almost any
position. As it has a full detection range of 360° on two
axes, the zero point is set after mounting.
Apart from the specific application-related benefits, the
sensor is particularly useful for customers who have
to use different models of inclinometers for different
applications. Thanks to its IP69K protection, the new
Turck sensor is ideal for virtually every application. This
simplifies logistics and maintenance. In the event of a
sensor failure, a device can be replaced in an instant
since the parameters are stored in the controller. These
parameters can be copied directly to the new device
via IO-Link.
Two variants
example of a tunneling machine:
The B2N-360-Q42
measures the
vibration of the
machine and then
masks out this frequency precisely
Turck offers two variants of the B2N-360-Q42: In addition to the industrial variant for the temperature range
from -25 to +75 °C, which is suitable, for example, for
inclination measuring on solar panels or robots, a variant is also available for utility vehicles and construction
machinery, which was developed to e1 specifications.
This sensor is run with the standard vehicle on board
power supply of 8…30 V and is resistant to extreme
temperatures from -40…+85 °C, as well as other stresses involved with the use on utility vehicles. The output
signals of both sensor variants can be defined individually as required within the standard signal ranges of
0…10 V or 4…20 mA. All parameter settings are made
via the IO-Link interface. N
 Quick read
With the B2N-360-Q42, Turck is offering the world's first 3D inclinometer that
offers a full 360° measuring range on two axes. The sensor can be parameterized
individually in the field via IO-Link, from the 0° position to the measuring ranges
to the output signals. The new sensor solution enables customers to not only go
beyond the ±85° range limit of existing solutions, but also to cover virtually any
application field with a single model.
more @
16 T R E N D _ R F I D
Simulation example of a
car body: Starting from
the UHF read/write head
(indicated by the green
dot), the colors orange
and red show the areas
in which reliable
communication with
tags is ensured
Webcode more21205e
Author Dr.-Ing. Patrick Bosselmann, RFID product management, Turck
No More
Trial and Error
A new simulation software based on the ray tracer algorithm enables Turck
to calculate and plan complex UHF-RFID applications
ne of the greatest challenges in planning
and installing RFID solutions in the UHF frequency band (860…960 MHz) is finding the
ideal locations and operating parameters for the read/
write heads. As the ranges in this frequency band are
considerably higher than the HF band, interference in
the immediate surroundings may cause the tags to be
read incorrectly. The actual range of a UHF read/write
head in a specific customer application may therefore differ considerably from what is achievable in
a laboratory setup.
In reality, the propagation of the radio waves
depends on how they are reflected or shielded by
walls, ceilings and other objects. Metals reflect particularly strongly, which may lead to superimposed waves
(interference) – depending on the application. This
interference can have a positive or negative effect on
the accessibility of a tag. During an application process, ambient conditions may also have an effect on
RFID performance, resulting in tags that may suddenly
become inaccessible or are accidentally addressed
due to the stronger or weaker reflection behavior.
If several read/write heads are used simultaneously
in a UHF application, such as along an assembly line,
the probability of interference is also increased due
to the unsynchronized parallel operation of these
transmission sources. In short: Most industrial applications are too complex to precisely predict whether
a UHF-RFID tag will be addressable in read or write
mode all the time.
Simulation instead of gut feeling
Present day prediction techniques for UHF-RFID applications are based on estimates, empirical values and, to
some degree, gut feeling. System planners ultimately
have to examine their assessment of a UHF installation
with a test system in the specific application. In order to
make a reliable prediction, production processes have
to be interrupted, antennas installed and, if necessary,
measuring devices have to be positioned. The tests also
require a great deal of time and expense. If the results
are negative and tags can not be read (no reads), or
are reached incorrectly (false positive reads), often a
tedious trial and error search for the perfect location
and the optimum operating parameters of the UHF
antenna has to be carried out.
By making calculations for UHF-RFID applications with ray tracer software, Turck can eliminate this
uncertainty for customers. The software calculates the
propagation of UHF radio waves taking complex environmental conditions into account. It is based on the
“ray tracing” algorithm, which is derived from the calculation of virtual, spatial scenes for graphics tasks. The
radio wave simulation provides information about the
supply of passive RFID tags with electromagnetic power in a predefined spatial environment.
All relevant operating parameters are taken into
account in a ray tracer simulation. The most important
elements are the size of the building concerned, with
precise consideration given to its rooms, gates, walls
and other objects such as conveyor belts, fork lift trucks,
machines or shelves. Besides the geometry of the room
and the arrangement of its essential objects, its material properties must also be known in order to make an
exact calculation and define reflection and transmission values. Other geometric factors include the positions of the RFID read/write heads and the areas of the
tags to be detected. Electrical operating parameters
such as transmission power, antennas used and polarization properties are also defined.
In this way, it is possible to create and simulate an
entire UHF application in a three-dimensional model. All
the physical effects of the ray optical propagation, such
as attenuation, reflection and polarization flow into the
calculation. The transmission paths found between
UHF-RFID read/write head and tags are then added
together in phase (superimposed) in order to produce
a realistic interference pattern. The finished calculation
makes it possible to determine the strength of the RF
output received by each RFID tag in the application
from the UHF antenna, whether this output is sufficient
for operating the tag, and whether its return signal will
also reach the read/write head without any interference. The result of the simulation is a two-dimensional,
colored and scaled representation of the UHF-RFID link
between the read/write head and the tags. This directly
indicates the areas where tags can be reached with a
radio frequency, taking all the critical constraints of the
application into account.
The simulation result provides answers to questions that could previously only be answered with the
time consuming installation of a test application: Where
in the room is the best location for a read/write head?
How can the reading of tags from other areas in the
installation be prevented? What effects do objects that
move like fork lift trucks have inside the application?
The measuring of the
environment for a
UHF-RFID application
including the materials
in place is the basis
for simulation with
the highest possible
The image shows the
distribution of radio
waves at the height of
the read/write head
fitted on the left-hand
door frame; UHF-RFID
communication with
the tag is possible
from around -15 dBm
Predictions create customer benefits
These questions can be answered faster with the help
of a computer than completing the appropriate tests
live on site. Answers to these questions and the visualization of radio wave propagation for UHF-RFID applications are the central benefit for Turck customers
planning a UHF-RFID system. This increases planning
security within the scope of the system evaluation and
feasibility analysis.
Although the work required for the ray tracer
modeling and the simulations cannot be ignored, the
benefits they offer, particularly with complex installations, far outweigh the effort required, since different
plant installations can be examined with greater flexibility and speed. During the subsequent application
field tests it is usually possible to determine the almost
final operating mode already with the first attempt
thanks to the ray tracer results gained beforehand.
This reduces the time and effort required for the live
test phase and minimizes the trial and error interventions in existing processes on site. The ray tracer therefore considerably speeds up the planning of complex
UHF-RFID applications. N
 Quick read
The simulation software enables Turck to calculate the range of UHF antennas in specific industrial applications and
provide better advice than before to its customers in the installation of a UHF application. The simulation results
quickly determine the ideal location for UHF-RFID read/write heads in order to exclude both “no reads” and also
“false positive reads”.
more @
18 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
High-Speed Measuring
In conjunction with Arburg, Turck has further developed its LI inductive linear position
sensor into a genuine high-speed linear position measuring system for motion control
hen Karl Hehl developed the first injection
molding machine for his own use in 1954,
he could not have guessed that, together
with his brother Eugen Hehl, he would develop the
Arburg company for the next 60 years into one of the
leading suppliers worldwide of plastic injection molding machines. Today, more than 1,800 employees in
the Swabian town of Lossburg produce the world
renowned “Allrounder”, machines that are tailored individually with different drive concepts for the customer
application at hand. Besides hydraulic machines, the
Turck's inductive
linear position sensors
with a signal run
time of 130 µs are
now also suitable for
the high-speed axes
of Arburg machines
Webcode more21250e | User
Author Holger Spies is a project manager at Turck
family-run business also offers electrical machines and
hybrid variants that combine both drive concepts.
At Arburg, the optimization of injection molding
machines at critical points in step with actual practice
has always been understood. The company was always
able to generate new ideas to ensure the long term
development of injection molding worldwide. One
example of this is the Allrounder Edrive series, which
Arburg offers as an entry model for electrical injection
molding applications. The main axes for injection and
metering, as well as for opening and closing the mold,
are driven in the machine with servo-electric drives
instead of hydraulically. This not only makes the axis
movements completely independent of each other
but also makes them more precise than in hydraulic
Arburg uses the real-time Ethernet Varan bus for
communication in the Edrive. “Our customer wants a
robust and reliable machine. By changing to the realtime Ethernet system, we are able to further improve
the maintainability of the machine,” Werner Faulhaber, head of electrical engineering development at
Arburg, explains the approach.
Conventional solutions are
not enough
Another aspect of Faulhaber's approach to the development of the machines applies to the sensors.
Although the magnetostrictive linear position sensors primarily used on the electrical axes offer noncontact and wear-free measuring, “the performance
of magnetostrictive sensors is not fast enough for
the dynamic axes of the Arburg machines,” Faulhaber
explains. As the magnetostrictive measuring principle
is based on the run times of structure-borne sound,
the sensors have a comparably long signal run time.
Today, magnetostrictive sensors with optimized run
times and short lengths can reach an output rate of
up to 4 kHz. Normally however, this is more likely to
be 1 kHz. The propagation speed of the torsional wave
of the waveguide is around 3,000 m/s, which means
that the wave needs more than 300 µs for a measuring length of 1,000 mm. The latency time of the electronic circuit then has to be added to this time. The
run time and the output rate therefore depend on the
measuring distance and the electronics – the greater
the distance, the longer the signal run time of magnetostrictive sensors.
Some magnetostrictive sensors try to avoid the
long signal run time with a prediction mode. They predict future measured values that occur between real
measurements and can achieve output rates of 10 kHz
at the interface. However, these types of systems only
make sense on axes with an almost constant speed.
The injection axis of the injection molding machine
in particular requires a very dynamic position control.
This axis has the most demanding control requirements as it is responsible for forming the molded part
and therefore the quality of the final product. Magnetostrictive sensors, even with a prediction of the measured values, are out of the question for the injection
axis of Arburg machines.
Today Arburg also uses a potentiometric linear
position sensor in its hydraulic injection molding
machines. The measuring principle enables short
signal run times and offers the resolution required to
measure very fast axis movements in real time. The
speed of the potentiometric linear position sensors is
only limited by the mechanical design and the signal
processor. As with all analog systems, however, the
resolution depends on the length. In addition to this
is the fact that potentiometers are wear parts: “After
millions of cycles, the original degree of protection to
IP54 of the potentiometers is no longer ensured. This
means that water is likely to penetrate the sensor during a tool change, if for example a pressurized cooling
tube is pulled out,” Faulhaber qualifies.
“For a long time I had been in search of a noncontact and wear-free system that would achieve
the performance that is possible today with a potentiometer. I haven't found any other system than the
LI inductive system from Turck, as its accuracy and
resolution are totally independent of the measuring
length. Although there are other inductive sensors on
the market, the resolution on these sensors depends
on the length. As they are purely analog systems,
these sensors are also unsuitable for conversion to a
digital interface.”
Inductive measuring offers a solution
During the course of this search, Faulhaber drew up
specifications that defined the requirements for a linear position sensor for use on the high-speed axes of
the machines. Five requirements in particular had top
priority: The sensor has to achieve a real output rate of
at least 5 kHz, it must be contact-less, robust and wear
free, and must be able to communicate via the Varan
real-time bus. During the search for a supplier, Turck's
LI inductive linear position sensor drew the attention
of the Arburg specialists. With its non-contact and
magnet-free resonator measuring principle, the IP67
sensor combines the performance and magnetic field
immunity of a potentiometer with the robustness and
wear-free design of a magnetostrictive sensor. Due to
its operating principle, the LI is immune to external
magnetic fields.
However, the output rate at that time of 1 kH was
insufficient for measuring the high-speed injection
axis of the Arburg machine. “The physical measuring
principle did not, however, prevent this,” Faulhaber
noted. “The Turck sensor has the potential to output
the measured value faster. Unlike a magnetostrictive sensor, it is not limited by the measuring principle but only by the electronics.” Besides precise and
highly resolved measured values, motion control also
requires extremely fast measured value calculations
and corresponding output rates. In short: The most
accurate measurement only has any value if the measured value can be provided fast enough at the sensor
output. The LI sensors were not originally designed for
closed-loop control tasks. However after an inquiry
For a long time I
had been in search
of a non-contact and
wear-free system that
would achieve the
performance that is
possible today with
a potentiometer. I
haven't found any
other system than the
LI inductive system
from Turck as its accuracy and resolution
are totally independent of the measuring length.
Werner Faulhaber,
 Quick read
As a world-renowned specialist for plastic injection molding, Arburg has always
understood how to further optimize injection molding machines at the critical
points in step with actual practice. This is also the case with position measuring.
As conventional position sensors could no longer meet the demanding requirements, new solutions were needed that guaranteed a constantly high resolution
regardless of measuring length. In Turck's LI inductive linear position sensor, the
specialists at Arburg found a solution that today can meet all their requirements.
more @
20 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
The injection axis
of the injection
molding machine
requires a very
dynamic position control – the
performance of
sensors is not
sufficient for this
from Arburg, Turk decided to use the potential of its
measuring principle and make the LI series fit enough
for high-speed positioning. The new high-speed linear position sensor, that could meet the demanding
requirements of the customer, was developed in a
16-month pilot project involving the close collaboration between the developers at Turck and the Arburg
The Turck inductive linear position sensors have a
signal run time of 130 µs, which is considerably shorter
than the 200 µs required by Arburg. The challenge was
to enable the signal processor to achieve an output
rate of 5 kHz. For this Turck uses a new and more powerful generation of signal processors. A close adaptation of the front end of Turck's sensor to the Varan
interface of Arburg allows a particularly slimline architecture of the entire system. Signal linearization and
 Reducing contouring error
The delay caused by slow sensors in high-speed applications is known to machine builders as “contouring
error”. If a moved object reaches a defined setpoint, the
sensor detects it and outputs a corresponding signal.
The object continues to move in the time between
the detection and the signal output, and this results
in contouring error. As result, the faster a body moves,
the greater the contouring error. Conversely, the faster
a sensor outputs the measured value, the smaller the
contouring error. The important manipulated variables
to minimize contouring error are therefore the output
rate and the signal run time of a sensor. The output rate
is the frequency at which a sensor can output a measured value. The signal run time is the time it requires to
calculate a new measured value. It makes no sense to
output a measured value before a new one could be
calculated, and so the signal run time should be less
than the output rate of a sensor.
synchronization, as well as device profile and interface
definition, were fully implemented in an FPGA module
(Field Programmable Gate Array). “The working collaboration with Turck was excellent and was definitely
anything other than ordinary,” Faulhaber emphasizes.
As the new LI sensor is now fit for motion control tasks, Arburg is using it on the high-speed axes
of the electrical machines. However, the sensor could
also be used for distance measurement on hydraulic
axes. The design engineers benefit from the absolute
magnetic field immunity of the sensor. Magnetostrictive sensors frequently used on hydraulic axes have to
be fastened with aluminum components. They also
have to be protected from nearby electromagnetic
fields which corrupt the measuring result. “The Turck
linear position sensors with the inductive measuring
principle can be fitted without any problem close to
strong fields or electromechanically actuated valves
and valve coils,” Faulhaber explains and also appreciates the compact design of the LI: “The low housing
style with extremely short excess lengths is very convenient for our designers.”
Standard variant with SSi interface
It wasn't just the technical aspect of the collaboration
that worked well. “A key factor in the success of the
project was also the active engagement of Turck sales
specialists who seriously promoted the project in
their own company,” Faulhaber says. Turck recognized
early on that there were no solutions on the market
for motion control applications and therefore pushed
this project vigorously. And so this collaboration not
only produced the customized solution for Arburg.
The use of the resulting synergies also produced a
standard product with an SSI interface for series production. Turck's LI inductive linear position sensor is
therefore an attractive solution for a wide range of
motion control applications. N
w w w. r f i d- ready.d e | www. r f id -r e a d y. com
Your Source for RFID Technology News
22 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
Perfectly Assembled
The assembly systems with parallel arms from Möve-Metall are equipped with Turck's
inductive RI angle sensors to ensure that screws are inserted exactly to specifications
oka Yoke is a Japanese concept that stands for
“mistake-proofing” or “avoiding inadvertent
errors”. The term describes the ongoing production trend of excluding errors already in the production
process, instead of looking for them after assembly
through the implementation of complex quality controls. With the poka yoke principle, faults are prevented
by making it as difficult as possible for the production
worker to carry out their working steps incorrectly.
The US car parts supplier, Johnson Controls, a leading company worldwide in the supply of car seats, roof
lining systems, door panels, dashboards and electronics
for vehicle interiors, also follows this principle in its production processes. With car seat production, for example, this involves the following specific requirements: it
must be ensured that each component is fitted to the
The contactless
RI angle sensors
from Turck supply a
4…20 mA signal to
the controller from
which it calculates the
exact arm position
Webcode more21251e | User
Author Evelyn Märtin is a sales specialist at Turck
seat in the correct order, with the correct screw or rivet,
the correct tool and with the correct amount of force.
This requirement is implemented using assembly
devices with parallel arms or other so-called reaction
arms supplied by Möve-Metall, in Mühlhausen. The
company based in Thuringia, Germany, was formed
out of the former VEB Möve Factory, has 50 employees
and develops, designs and produces special machines,
equipment, plants and, in particular, assembly and testing equipment for car parts suppliers. Möve-Metall
developed a parallel arm with position detection for
use in assembly processes. This enables the position
measuring of the screw and rivet processes and reliably
prevents incorrectly assembled parts.
“In order to screw in components, the car seat is
fixed in positioning elements,” Michael Zimmermann,
With a resolution of 0.09°, Turck's RI sensors provide
more than sufficient accuracy
technical manager of the company, explains the principle. “A screwdriver device is clamped on the parallel
arm. The operation is based on the principle of the parallelogram and ensures the precise and repeatable positioning of the screwdriver.” The position monitoring at
the three joints of the parallel arm is provided by Turck
inductive angle sensors. A beneficial spin-off of this
is the fact that the forces involved with the assembly
processes can be measured as well. This eliminates the
effect of reaction torques on the user. If positions closely situated together have to be identified, the inductive
RI angle sensors are located at all three joints of the
arm. If positions far apart from each other have to be
identified, a single angle sensor on the swing arm of the
parallel arm is enough.
The parameters for each screw set are stored
in the controller. If the operator wishes to screw in
the first screw, he guides the arm to the appropriate position. The controller registers the correct position and releases the power or the compressed air for
the screwdriver (first OK). The operator screws in the
screw until the controller has registered the required
number of screwdriver rotations (second OK) and the
required torque has been reached (third OK), which
guarantees that the screw is seated correctly. Only
when these three OKs have been registered by the
controller can the next screw be fitted: If the sequence
was programmed beforehand, it is only possible
to fit the screw that was stored in the controller as
the second screw.
Tolerant sensors
“The torque monitoring has been implemented here
for a long time,” Zimmermann explains, “but the position monitoring is relatively new. This offers an addi-
tional level of safety for the assembly process and
is also easy to implement with the inductive angle
sensor. A great benefit of the Turck sensor is its noncontact operation, thus requiring no mechanical
connection to the positioning element. The four millimeter tolerance for the offset of the positioning element helps us considerably with the assembly process: we no longer have to fit so precisely and protect
the sensor from contact, since slight impacts do not
impair measuring.”
Another benefit of the RI angle sensor is its immunity to magnetic fields and metal environments. The
majority of other sensors on the market either have a
mechanical connection between the rotary encoder
and the sensor, or are susceptible to magnetic environments produced by large motors or welding equipment. The immunity of the sensor is based on its innovative resonant circuit measuring principle which eliminates the need for a magnetic positioning element. The
resonator measuring principle from Turck uses instead
an oscillation circuit that is formed by the sensor and
the positioning element. The principle combines maximum precision with an excellent level of interference
immunity and vibration resistance.
Another benefit of the sensors is their ease of
adjustment and the setting of positions using a program developed by Möve. Zimmermann shows on
the display of the Siemens controller how the mounting points are programmed. With the controller in
Teach mode, he guides the parallel arm to the required
mounting point and taps on the display. The controller defines the position and accepts the actual values
of the three angle sensors as x, y and z coordinates of
mounting point 1. Depending on how exact the position has to be defined, and the distance from the next
mounting point, the user can define a tolerance window around the point.
A great benefit
of the Turck sensor is
its non-contact operation, thus requiring no
mechanical connection to the positioning
Michael Zimmermann,
“Considerable benefit”
“Our assembly device is simple and reliable to use
for today's customers. For us also, the use of Turck
angle sensors is a considerable benefit. We previously
designed the parallel arm with an optical length sensor
between the two arms in order to also detect the arm
position. However, the optical sensor was considerably
heavier to fit and was more susceptible to faults during
operation,” Zimmermann summarizes. N
 Quick read
With their assembly and testing devices, Möve-Metall
GmbH in Mühlhausen primarily supports the car parts
suppliers in fault-free production. Wherever a manufacturing process requires manual interventions, the
machines and devices from Thuringia in Germany
ensure precise assembly conditions. This also includes
the screwing in of car seats using various assembly
devices with parallel arms, for which the arm positions
are detected with Turck's inductive RI angle sensors.
more @
24 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
All Around Protection
Without Blind Zones
Intronyx protects robot cells with EZ Screen safety light curtains from Banner
ntronyx GmbH & Co. KG is a company based in
Neutraubling, Germany, that offers tailored complete solutions for industrial automation. The
portfolio on offer ranges from consulting and design
to engineering and implementation, right through
to commissioning and onsite optimization. The small
and yet successful company includes several wellknown car parts suppliers, machine builders and food
“Since the founding of the company in 2003, we
have guaranteed a fast and flexible response to our
customers' requirements based on our technical closeness,” Alfred Kautzki, one of the three managing directors and responsible for the technical area, reveals
The three-sided protection provided by
EZ Screen safety light
curtains enables the
Intronyx robot cells to
be loaded from the
front and from the side
Webcode more21252e | User
Author Achim Weber is sales specialist at Turck
the secret of the company's success. “We offer a wide
range of solutions for all aspects of machine engineering, with a focus on machine and plant optimization
including programming,” Kautzki explains.
One of the last orders completed by the eight-man
team was the design and turn-key implementation of
four robot cells for a leading car parts supplier. The
order required adhesive to be applied in the production process automatically and as efficiently as possible. The cells were used for bonding door components
from pressed wood chip material with reinforcements.
Intronyx designed, produced and fully programmed
the robot cells in order to ensure the application had a
defined amount of adhesive. The cells have been given
a flexible design so that they can also be used to process larger parts when necessary. In the production
process, the parts are first placed manually in the holder. A slide containing the part is then moved into the
cell where the robot applies the adhesive. In the next
step the part is removed and transferred to a jointing
unit where all of the components are pressed together
until the adhesive has hardened.
Protection on three sides
While these types of cells are normally loaded from
the front, in this case the customer wanted the possibility to insert and remove parts from the side. This
prevented the possibility of a mechanical guard for the
sides so that safe shutdown of these cells could only
be ensured through the use of several light curtains
that cover all three open sides. In order to guarantee
full protection, also on the corner areas, light curtains
were needed that have small blind zones and could
therefore be mounted as closely as possible to each
other in the corners.
“We ran through several different solutions that
also cover the area over the corners. Only the EZ
Screen safety light curtain from Turck could really make
Gerhard Korunka was looking for protection right
into the corners without any dangerous protrusions
an impression. With all other systems we would have
had to install overlapping and therefore longer light
grids,” Kautzki explains. The high resolution safety light
curtains from the SLPCP25 series were developed and
produced by Turck's optical sensor partner Banner and
consist of an emitter and receiver that operate without
any blind zone. As the system is optically synchronized,
no wiring is required between the emitter and receiver unit. The safety switching outputs of the receiver
are directly connected to a load relay and trigger the
immediate stop of a dangerous machine cycle. With
two-channel monitoring of the switching device and
the diversely redundant design with mutual processor
control, the light curtains guarantee personnel safety
category PLe acc. to ISO 13849-1.
Cables instead of connectors
For Gerhard Korunka, managing director responsible
for software and hardware, the EZ Screen models also
offer another unbeatable benefit: “Even the cable outlet is optimally designed. Other systems mostly have
a plug connector terminal that sticks out at the end.
This is not a problem with vertical mounting since the
connector can be mounted upwards. If the light curtains are mounted horizontally, however, you have a
protrusion with the connector that has to be mechanically protected. With the direct cable outlet on the EZ
Screen models this is implemented considerably better. Here I can route the cable directly to the side and
mount devices absolutely flush. Nothing sticks out that
requires mechanical protection later.”
As well as the direct cable output, the light curtains also stood out on account of their simple mounting options: “The very compact light curtains and the
small, well-designed brackets made our design work
much easier,” Korunka explains. “They are very easy to
mount and adjust. As we don't have to terminate any
connectors, the mounting of the light curtains was
done in next to no time.”
Although the Turck light curtains were not originally listed in the list of approved suppliers, Intronyx
was able to convince its customers of this solution's
capabilities and “win approval”. Ultimately the fact that
the entire cell could be designed more compactly with
the EZ screen safety light curtains was also a factor.
Korunka adds: “As we scan all light curtains simultaneously unlike with cascade solutions, we are able to
achieve faster response times. The systems can thus be
built smaller because the minimum clearance does not
have to be so large.” N
We ran through
several different
solutions that also
cover the area
over the corners.
Only the EZ Screen
safety light curtain
could really make an
Alfred Kautzki,
 Quick read
Well thought-out concept: No blind zones, integrated cable outlet and variable compact holders
Intronyx was given the task of designing and implementing robot cells for the
bonding of car door components for a well-known car parts supplier. In order to
ensure the safe loading of the cells from the front and from the sides, the company used the EZ Screen safety light curtains from Banner Engineering. The light
curtains of Turck's optical sensor partner are unique on the market and could
meet all requirements.
more @
26 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
The inverters of the
electrically driven
freight train Harmony
D2 produce a lot of
heat that has to
be removed in a
controlled way
Webcode more21255e
Author Zukui Zhang, marketing engineering department at Turck China
Train Watch Out!
A Chinese freight train uses Turck FCS flow sensors to monitor the air cooling in the current
converter cabinets
he expansion of the Chinese rail network has
been advanced ever since the founding of the
Peoples' Republic of China in 1949. In spite of all
the improvements, the rail network and the trains continue to be in need of further expansion. In this respect,
powerful freight trains are at the top of the wish list.
As in other areas, Chinese manufacturers are building
on the proven technology of foreign partners and are
developing this further for their own market. This also
applies to a manufacturer of electric rail vehicles that
is a leading developer in China of state-of-the-art drive
The manufacturer recently developed a freight
locomotive based on the Prima BB 43700 freight train
of its cooperation partner Alstom. Harmony D2 is the
name of the 8-axle Chinese version of the freight locomotive with a high performance AC drive. The loco-
motive is a showcase project for the modernization
of the Chinese rail traffic. Besides the microcomputer
control system, the Harmony D2 also shares the high
performance range of its European example. With
its high shaft output and good traction, the Harmony D2 also offers a broad application range. The low
operating costs of the locomotive are due in part to
its ease of maintenance. Turck has contributed here
with a flow sensor that monitors the reliable cooling of
the converter cabinets.
Heat dissipation in the converter
The drive power of the high performance AC locomotive is provided by a traction converter. This is a traction
current converter, which is installed in the main conver-
 Quick read
A Chinese locomotive manufacturer relies on Turck flow sensors for a freight
locomotive. The flow sensors for gaseous media monitor the air flow in the converter cabinets for the supply of the ancillary units. Turck was able to impress
the customer with a compact sensor with a male thread, which could correctly
measure the flow speed even when the medium changes temperature.
often supplied incorrect measuring results. The specialists building the locomotive therefore went in search
of a sensor solution that provided a steady output
signal when the flow was constant, irrespective of any
temperature changes. It also required a solution that
could be installed in the restricted space of the converter cabinet without any problems.
Turck solution: Aligned fitting
The compact Turck sensors
even fit in the restricted space
of the converter cabinets
ter cabinet. The locomotive is also equipped with two
independent auxiliary power converter cabinets. The
auxiliary power converters supply power to the ancillary units such as cooling fan, water and oil pump, air
conditioning unit, main compressor as well as battery
chargers, heating units and other additional equipment. The auxiliary power converters are operated redundantly: one converter in normal operation and one
in standby mode. With such a large number of connected loads, the fault-free operation of the locomotive largely depends on the function of the converters and the
cabinets in which they are installed.
The temperature in the control cabinet rises the
longer the converters are in operation. The cabinets are
therefore equipped with an active air cooling system in
order to remove the resulting heat. The air circulation
must be monitored constantly in order to ensure that
permanent cooling continues without interruption.
Problems had occurred several times with the flow
sensors of another manufacturer that the customer had
installed for this purpose. The sensors were not only
insensitive but were also not able to compensate the
frequent temperature changes that took place inside
the cabinets. The sensors had misinterpreted temperature changes as a drop in the air flow and therefore
Turck's M18 flow sensors for gaseous media proved to
be the sensor solution that could meet all the locomotive manufacturer's requirements. The FCS-M18-LIX
is a compact flow sensor in a cylindrical housing with
a male thread that enables it to be mounted even in
restricted spaces. Although the calorimetric measuring principle used here is susceptible to temperature
changes, the Turck sensor compensates for this with
its special sensor design and a so-called aligned fitting: The measuring resistor and the heatable measuring resistor have to be positioned parallel to the flow
direction. The aligned fitting enables the full precision
potential of the sensors to be used. If the sensor was
incorrectly fitted, the heated air could also cause the
measurement to be incorrectly interpreted as a change
in flow. With aligned fitting on the other hand, the sensor cannot be affected by temperature changes of the
passing air current.
Once the FCS-M18-LIX, specially designed for
gaseous media, is correctly aligned, it can fully utilize
its potential. It now reliably monitors the flow with the
electric locomotives in continuous operation – even
when the temperature increases. The Turck sensor
therefore also helps to keep the maintenance times of
the locomotive to a minimum and to improve its efficiency. Turck's flow sensor also fulfills the second customer requirement on account of its compact design
which combines sensor, probe and processing unit in
a single housing. Sensors with a larger housing style or
with separate processor units could not be installed in
the conditions at hand. N
When the fitting
of the FCS-M18LIX is aligned, it
can compensate
for any temperature fluctuations
more @
28 A P P L I C AT I O N S _ CO N N E C T I V I T Y
Good Connection
How Turck’s quick disconnect connectivity products helped the University of
Wisconsin-Madison’s Electric Ford F150 research vehicle come to life
hillip Kollmeyer has long been interested in
building a research vehicle. He wrote his master‘s thesis on the electromechanical modeling
of a Corbin Sparrow, a red, three-wheeled single seater electric car manufactured in California a few years
ago in 2001.
For his doctoral thesis at the University of Wisconsin-Madison Kollmeyer took it one step further: he strived to build a state of the art electric research vehicle,
with a modern battery pack, electric motor, and motor
drive. Kollmeyer‘s dream vehicle included technology
on par to commercialized vehicles along with a hefty
Turck‘s quickdisconnect connectivity products allowed
the quick and reliable
connection and disconnection of several parts
Webcode more21253e | User
Author Paul Gilbertson is a technical communicator at Turck USA
budget for advanced sensing and control hardware.
The electrical engineer found support for his ambitious
project at Orchid International, a metal stamping and
manufacturing company, Orchid had been involved in
building a prototype electric motor for a startup electric vehicle (EV) company, and expressed an interest in
sponsoring a project with the university.
Orchid provided the foundation for the project
– it designed and built a prototype electric motor,
mounted the drivetrain, and also helped provide
funds to ensure the extensive list of parts that were
needed could be secured.
Benefits of electric
One goal of electrifying a Ford F150 was to be able to
better quantify the benefits of utilizing an electric powertrain versus the stock F150 powertrain.
The electrified vehicle has zero emissions; lower
energy costs from about $0.22 per mile to $0.07 per
mile, offers similar power to the stock vehicle while
requiring a simpler, more efficient two speed gear box,
and reduces brake wear through regenerative breaking. If those benefits aren’t enough, it is also exceptionally quiet, with the only noise coming from the battery,
motor, and radiator cooling fans. As the project continues, modeling, control, and design projects will continue to explore further opportunities to improve the
efficiency and reliability of the vehicle, as well as lower
the cost of individual components.
Strong support
Although Orchid provided strong support the postgraduate also took the project as an opportunity to
collaborate with others. As Kollmeyer explained, “As
the detailed plans were coming together, I realized
I needed to find a way to connect all these systems
together. At that time I remembered that Turck‘s range
includes cabling“
Kollmeyer got in touch with Larry Jacob, Sr. Sales
Engineer for Turck representative MTech, who was a key
to the cabling and connectivity success of the project.
As Kollmeyer describes, “I started out with an abstract
block diagram of the whole vehicle, with lines connecting all the different components. Larry Jacob helped
me get from the block diagram, to an actual specification for each cable in the vehicle. I really started out
unfamiliar to the world of industrial cabling, and Mr.
Jacobs met me personally, suggesting specific specialty
cables for certain applications including Ethernet cable
and power cables where they fit. Then I spent a long
time with the big Turck connectivity catalog, and ended
up with 34 cables providing interconnection between
more than a dozen vehicle systems.”
Quick disconnect
One of the most convenient features of Turck’s cables
is their quick disconnect feature – basically a few minutes is all that is needed to disconnect or reconnect a
set of cables. With the research vehicle continuously
having components and different systems worked
on, there is a need to constantly remove and reinstall
parts of the system. Turck’s quick disconnect connectors made what would otherwise be a major undertaking, one which for a vehicle typically involves a maze
of hand assembled wire harnesses and comparatively
fragile automotive connectors, a painless and easy part
of the process.
Kollmeyer has taken full advantage of this feature
to minimize the hours needed to complete the project. He explained the benefits as follows: “Many of the
connections in our research vehicle are sensitive signal
level cables, requiring shielded cabling. If I had to build
Research vehicle: With support from Orchid and Turck Phillip Kollmeyer
developed an Electric Ford F150
all these cables by hand, it would have taken weeks,
and I wouldn‘t be nearly as confident in their performance. And a further benefit of the Turck solution is
the receptacles, which are populated with color coded
flying leads making populating connectors quick and
easy compared to traditional methods.”
With the exception of the high current battery cable,
Turck provided all the cabling in the vehicle. Compared to a production electric vehicle there is an exorbitant amount of cabling, which is due to one of the
research features of the vehicle – extensive measurements of component efficiency and power consumption. As Kollmeyer puts it, “Turck‘s quick disconnect
connectors really made it possible for me to develop
a reliable, water proof, prototype electric vehicle.” The
vehicle is now being shown at events across the country, including the 26th annual International Electric
Vehicle Symposium in Los Angeles and the 1st annual
International Transportation Electrification Conference
in Detroit. Each show requires the vehicle to be in show
worthy condition, which means many long days leading up to the show preparing the vehicle for tech savvy
crowds eager to see the vehicle which Kollmeyer is
proud to show. N
Turck‘s quick disconnect connectors
really made it possible
for me to develop a
reliable, water proof,
prototype electric
Phillip Kollmeyer,
University of
 Quick read
For his doctoral thesis in electrical engineering at the University of Wisconsin-Madison Phillip Kollmeyer developed
and built an electric research vehicle. The postgraduate
equipped a Ford F-150 with a modern battery pack, electric motor, and motor drive – including quick disconnect
connectivity from Turck.
more @
30 A P P L I C AT I O N S _ R F I D
WACKER has equipped
several tumbler
screens at the
Burghausen site with
Turck‘s RFID solution
for the dust Ex zone
Webcode more21256e | User
Author Holger Anders is a key account manager process automation at Turck
At its Burghausen site, WACKER is using
Turck’s BL ident RFID system for reliable
detection in its tumbler screening systems
in the dust Ex zone 22
f screed is flowing well and tile adhesive is particularly flexible, it’s highly likely that a WACKER product
has something to do with it. The globally operating
chemical company with around 17,200 employees has
25 production facilities, 20 technical centers of excellence and 53 sales offices worldwide.
The most important production site for WACKER
is the plant in Burghausen, idyllically situated on the
Austrian border, in the so-called ‘Bavarian chemical
triangle’. The chemical plant, covering a two kilometer
area, employs 10,000 people in around 150 facilities,
and produces thousands of different products. These
products also include dispersion powders that are added to tile adhesives, plaster, screeds and other building
materials so that they are given particular properties.
To produce the end product, a liquid is dried in a drying tower at the end of the production process. The
resulting powder then has to be vibrated through a
screen before it can be packaged. This ensures that the
product concerned has the required grain size.
In order to increase transparency and traceability
in the production of dispersion powder, the production
plant expressed the wish for the automatic detection
of the screen size used in the tumbler screens. “The
correct screen size was previously measured manually by colleagues in the plant,” Michael Holzapfel, plant
engineer responsible for electrical engineering in the
Construction Polymers division, explains. “In order to
exclude the possibility of human error, the screen used
for each batch now has to be measured automatically.
This enables us to not only guarantee the 100% quality
of the ongoing process, but also to have a retrospective
record of the correct screening process.”
Continuous vibration requires
a wireless solution
Holzapfel soon discarded his original idea of using a
coating in conjunction with inductive sensors: “The
 Quick read
Depending on the application, dispersion powder must be manufactured in different grain sizes. To ensure and document this process, WACKER in Burghausen
has for the past year been identifying the mesh width of its tumbler screens with
Turck’s BL ident RFID system, which is also approved for use in dust hazardous
areas. As a result of its good experience with this system, the company is also now
equipping the first coupling stations with it.
more @
32 A P P L I C AT I O N S _ R F I D
The Turck RFID
system works so
well in the tumbler
screens, so that we
are now expanding
the system for use
in our coupling
stations, as dust-Ex
approval is also
required here.
Michael Holzapfel,
Wacker Chemie AG
screen is continuously vibrating, over almost the entire
year, and so cable-based solutions are not feasible. We
already have first-hand experience of this. Every month
we have to replace the grounding cables of the screens
in order to ensure that they don’t break, even though
highly flexible cables are used.”
We therefore gradually came to the idea of using
an RFID solution. Due to the particular environmental
conditions at Burghausen, the solution nevertheless
had to be approved for use in the dust Ex zone. “Turck
was the only manufacturer that could offer us an RFID
system that is Ex-approved for zone 22 dust,” Holzapfel
describes the original reason for choosing the system
of the Mülheim automation specialist.
Up to now, WACKER has fitted four tumbler screens
with a type TNLR-Q80-H1147-Ex read/write head that is
approved for use in Ex zones 2 and 22. All the screens
used there were fitted with a TW-R50-B128-Ex tag on
which the mesh width is stored. The disk-shaped tag is
fitted at the edge of the screen, directly under a strap
with the optical marking of the mesh width. The read/
write head reads the mesh width and passes on the
data to the process control system via Profibus using
one of three BL20 I/O stations.
During the course of the installation yet one other
hurdle had to be overcome: “The function block supplied with the RFID system is programmed for a Siemens
S7 PLC and not for a Siemens PCS7 process control system like we use here,” Holzapfel explains. “However, our
software specialists worked in close collaboration with
Turck Support to quickly adapt the S7 function block so
that it can now also run on the PCS7.”
An Ex read/write head reads out the mesh width of
the screen from the tag on the screen (left)
The screen data reaches the PCS7 process control
system via Profibus and Turck’s BL20 I/O system
New project: coupling station
The system has been in operation at WACKER for the past
year to the customer’s complete satisfaction. Due to the
good experience he has had with his supplier, Holzapfel
has already started to tackle the next project. “The Turck
RFID system works so well in the tumbler screens, so that
we are now expanding the system for use in our coupling stations, as dust-Ex approval is also required here,”
the plant engineer describes the next step. Around 20
targets and nine sources are to be recorded via RFID in
order to guarantee the transparency of the process. For
this purpose, each of the 20 DN80 hoses will be provided
with a tag containing the individual hose number. Each
target is fitted with a compact read/write head. When
a hose is connected, the system reads the appropriate
number and enables operation if it is connected correctly. Via its subsidiary mechatec, Turck is supplying
the coupling station project with a ready-to-connect
solution which is provided with a customized male
connector and is fully encapsulated. N
Mick McCarthy monitors
whiskey production with
up-to-date plant data
transferred to the control
system via Turck‘s excom
remote I/O system
Webcode more21254e | User
Author Frank Urell is the managing director of Turck‘s irish agency Tektron
Tradition and Modern Ways
In the Irish Distillers whiskey distillery, Turck’s excom remote I/O proves that traditional
manufacturing processes can also benefit from state-of-the-art fieldbus communication
he art of making Whiskey is believed to have
been brought to Europe through Irish missionary monks. Production of ‘Uisce Beatha‘, meaning ‘water of life‘ in Gaelic, began over 800 years ago
The knowledge of distilling spread through the Church
and eventually reached beyond the monastery walls.
The Old Midleton Distillery was founded in the
early seventeenth century by brothers James and
Jeremiah Murphy when they bought and converted
an old woolen mill. The distillery is located in the town
of Midleton approximately 20 kilometres east of Cork
 Quick read
According to legend, Midleton is the birthplace of Irish whiskey. Even today,
the heart of the Irish whiskey industry is still beating in this small town south
of Cork. Close to the historical Old Distillery, which still serves today as a museum, the Irish Distillers Limited (IDL) produces the most famous distillates of the
Irish Republic, including Jameson, Paddy and Powers. The traditional manufacturing process has since recently been supported by the latest I/O technology:
Twelve excom remote I/O stations from Turck ensure the safe and transparent
communication between the control system and field devices in Ex zone 1.
more @
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
The high signal
density of the MT18
module rack was one
of the reasons we
chose excom. The
hot swap functionality also impressed
us, as we can now
remove and fit all
modules during
ongoing operation –
without having to
interrupt fieldbus
Mick McCarthy,
Irish Distillers Limited
High channel density:
As well as the redundant power supply,
the excom module
rack can take up to
128 binary or 64 analog inputs/outputs
City in the south of Ireland. The Irish whiskey industry
was booming at the time and the distillery soon had
200 people employed and produced 1.5 million litres
of whiskey a year. The world’s largest pot still is in this
distillery holding 32,000 gallons.
In 1975, production at the Old Midleton Distillery
was moved to the New Midleton Distillery which was
built right next to the original one. The new distillery
was built by the newly formed Irish Distillers Group.
In 1988, Irish Distillers group was bought by PernodRicard, and with access to their global marketing and
distribution network sales for Irish Whiskey grew, with
Jameson Irish Whiskey now the fastest growing international whiskey in the world.
As a result, production at the distillery in Midleton
is being maximized, with expansion plans in place to
increase the output potential of the plant. It is planned
in the coming years to double the output production
capacity of the plant. Part of these expansion plans was
a full upgrade of the VAT House automation system,
which has recently been completed.
Profibus for the VAT House
The old automation system in the VAT house consisted
of three ITT PLC systems, with conventional wiring via
barriers to the hazardous area. Irish Distillers have previous experience of utilizing fieldbus with Profibus DP
and PA networks installed elsewhere on the site, so it
was not surprising that it was decided to utilize Fieldbus in this upgrade.
DeviceNet was selected for use with Motor Control Stations, and Profibus DP for communication of all
field automation signals. Irish Distillers selected Turck’s
Excom Profibus DP for zone 1 hazardous areas as the
best solution for the interface of the automation signals. Turck excom systems were supplied by Turck’s Irish
Distributors Tektron, based in Cork, Ireland, who also
provided technical advice to the project.
High channel density and hot swap
Mick McCarthy, IDL E&I Manager for this project, selected excom over other hazardous area remote I/O vendors, “due to the high density that can be achieved in
the MT18 module rack. The hot swap functionality also
impressed us, as we can now remove and fit all modules during ongoing operation – without having to
interrupt fieldbus communication.” Another benefit: the
automatic adjustment of power from the DO40Ex digital output card regardless of the voltage and current
enabled IDL to use this single type of I/O card for all
Digital Output cards thereby reducing specification and
design engineering.
The ease of implementing full communication
and power redundancy was an obvious factor. IDL
chose to utilize communications redundancy from
the outset. However, they have not implemented
power redundancy for the present and see that it is a
big advantage that they can implement power redundancy simply by fitting an additional power supply to
the MT18 rack. LED indication for every device on the
rack was another feature which led to excom being
selected. The Turck stainless steel field panels have
a viewing window to allow the operator or maintenance engineer see the status of a card or channel
without opening the door. IDL has taken this a step
further by fitting a printed matrix to each door, which
details the card and channel number, identifying the
relative instrument tag number.
The project size was in the region of 800 I/O, with the
integration works carried out by Rockwell Engineering,
Cork, using an Allen Bradley PLC. The Project required
12 new excom remote I/O stations (MT18). To ensure
the maximum speed available (1.5 MBaud) could be
achieved, four Turck SC12Ex segment couplers were
used, providing four sets of redundant intrinsically safe
Profibus segments in the field, which allowed the design
engineers ensure that the maximum Profibus DP cable
length was less than 200 m. The Remote I/O panel locations were selected to ensure good distribution and that
instrument cable lengths were kept to a minimum.
The VAT house is an important part of the distillery
process. It was critical that as much of the installation
work and in-fact testing and commissioning be carried
out before disconnecting the existing system. This was
easier to implement due to the use of excom remote
I/O panels as the new automation cabling could be
installed without obstructing production.
cedures which will assist in increasing the efficiency
and the production from this part of the plant.
Once the project was complete, and the VAT House
returned to full production, the task of stripping out
the redundant tray work, cabling and panels associated with the old system could began. Four large rubbish skips of cabling alone were removed from the site.
Areas where it had been impossible to gain access due
to large cable trays, were now accessible, making the
building a more efficient working environment, assisting in the overall drive to increase efficiency, reduce
downtime and increase production. N
IDL has fitted all
twelve excom cabinets with a terminal
layout, showing the
allocation of
each output to
a field device
Irish Distillers now have the capability to utilize the
diagnostic tools available to them over the Profibus
Network. Channel, Module and Panel diagnostics are
now available via the Allen Bradley Master and can be
visualized in the new control room. The operators and
maintenance staff now have a more efficient plant, and
will be able to implement predictive maintenance pro-
Mick McCarthy is delighted with the support provided
by Tektron sales specialist Adrian O’Mahony (r.)
more @
36 A P P L I C AT I O N S _ R F I D
Protection for
Cap Tip Dressers
Turck's BL ident RFID system enables the electrode cap tip dressers of AEG SVS
Schweisstechnik to reliably detect the correct cutting head for the electrode cap
n spite of all the progress made in bonding and
joining technology, spot welding continues to be
the most cost-efficient joining process for stressed
connections, particularly in industrial mass production such as in the automotive industry. The welding
tongs operating in the fully-automated assembly lines
use electrodes to exert pressure and heat on the sheet
metal parts to be connected.
After a specific amount of time, known as the
tool life, the working surfaces of the electrodes widen
and collect impurities. This prevents the reproducibility of the individual welding results, and the quality of
the welded joint is impaired. In order to ensure absolute process reliability and the reproducibility of the
welding result, the electrodes have to be reworked
according to empirically calculated values by using
a dresser to restore the original tip geometry of
the electrode cap.
Test setup: Andres
Bäker designed an
RFID-based cutting
head monitoring
system for electrode
cap tip dressers
as part of his
engineering studies
Webcode more21257e | User
Author Lars Franke is a sales specialist at Turck
Challenging cutter identification
AEG SVS Schweisstechnik from Mülheim produces
the electrode cap tip dressers required for this process, as well as electrode caps and around 200 different cutting heads. If a dresser is fitted with the wrong
cutting head, this can lead to critical faults in the
production process.
As the cutting heads are very difficult to identify visually, AEG Schweisstechnik in 2010 looked for a
method of automating the identification process. The
aim was also to create a test application in order to
determine the optimum settings for the cutting parameters for speed, number of cutting strokes and pressure.
The company approached the Mönchengladbach College for Technology and Media with these questions.
Andres Bäker, who at that time was completing the last
stages of his engineering studies, was keen to take on
the challenge together with two fellow students as a
final course project.
Bäker and his team first examined the possibility
of optical barcode identification directly at the cutting
head or cap tip dresser. However, the idea of optical
identification was quickly discarded since metal swarf
can cover or scratch the barcode and lubricant grease
could restrict legibility. The team then focused instead
on wireless identification using RFID.
Support from Turck
Supported by Turck, the budding engineers used the
BL ident RFID system to develop a solution that detects
the cutting head during fitting. A read/write head with
an 18 millimeter diameter is fitted diagonally above the
cutting head. It does not prevent the cutting process
and is nevertheless close enough to the tag to ensure
identification in spite of the fast rotation. The engineers
have integrated the tag directly in the cutting head. The
mini tags used are only 1 millimeter high and 7.5 milli­
meters in diameter. The 128 byte memory is entirely
sufficient for basic identification tasks. It is only necessary to write the eight-digit identification number on
the tag so that it can be identified uniquely.
The read/write head is connected to a BL ident I/O
slice module on Turck's BL20 I/O system. The Codesysprogrammable BL20 gateway implements the control
of the entire application. In addition to identification
tasks, the engineers also developed a solution for
detecting the speed and rotation direction of the cutting head. For this, they fitted two inductive sensors in
the swarf extraction system, which detect two recesses in the cutting head. An appropriate control logic is
used to determine the rotation direction and the speed
of the cutting head from the switch pulse of the rotating disc. If the incorrect cutting head is fitted, a yellow
LED signal is output and the plant is prevented from
starting up.
The test plant can display all cutting parameters
via the Codesys user interface: speed, pressure and
number of cutting strokes can be defined individually
via the controller in order to test the optimum configuration for cutting on different caps. “The result of the
engineering study project is more than satisfactory
for us since we can include the RFID solution directly
in our product portfolio nearly without any additional
requirements,” Jürgen Rosendahl, product manager at
AEG SVS Schweisstechnik, explains. “The engineering
study was always of a high technical standard. I also
found the collaboration with Turck to be very productive since they took the prospective engineers under
their wing and left none of the students' questions
For Andres Bäker contact with Turck has also
proved to be worthwhile after the successful project
work was completed. He now works as an engineer
in the RFID support area at Turck in Mülheim. If AEG
The result of the
engineering study
project is more than
satisfactory for us
since we can include
the RFID solution
directly in our
product portfolio
nearly without
any additional
Jürgen Rosendahl,
AEG SVS Schweisstechnik
The integrated compact tag could be well protected
in the cutting head (right)
SVS wants to develop its idea to market maturity,
Rosendahl knows who to turn to: “We are particularly pleased that Andres Bäker was able to join Turck
directly after his engineering studies were completed
successfully.” N
 Quick read
The yellow read/write head reads the tag in the
cutting head during rotation
As specialists for welding system accessories, AEG SVS Schweisstechnik from
Mülheim primarily produces electrode caps, electrode cap tip dressers and
the associated cutting heads. In order to ensure that the correct cutting heads
are used for the corresponding welding cap geometry, the company searched
for a reliable identification solution, which Andres Bäker developed with two
students as part of the final project work of their engineering course – with
excellent support from Turck.
more @
38 S e r v ic 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.
Date Trade Show
21.01. – 24.01.2013
30.01. – 31.01.2013Euro Expo Industrimesse
30.01. – 01.02.2013
01.02. – 03.02.2013
12.02. – 14.02.2013
Automation Technology West
13.03. – 16.03.2013
19.03. – 22.03.2012
19.03. – 22.03.2013
21.03. – 24.03.2013
WIN Automation
10.04. – 12.04.2013
08.04. – 12.04.2013
Hannover Messe
17.04. – 18.04.2013
ISA 24.04. – 26.04.2013
17.06. – 21.06.2013Exponor
03.09. – 06.09.2013
10.09. – 12.09.2013
Assembly Tech Expo
23.09. – 25.09.2013
Pack Expo
15.10. – 18.10.2013EloSys
23.10. – 25.10.2013
18.11. – 21.11.2013
19.11. – 21.11.2013Electron
26.11. – 28.11.2013
SPS IPC Drives
City, Country
Chicago, IL, USA
Trondheim, Norway
Celje, Slovenia
Mumbai, India
Anaheim, CA, USA
Seoul, Korea
Brno, Czech Republic
Warsaw, Poland
Istanbul, Turkey
Bogotá, Colombia
Hanover, Germany
Calgary, Canada
Kortrijk, Belgium
Antofagasta, Chile
Herning, Denmark
Chicago, IL, USA
Las Vegas, NV, USA
Trenčín, Slovakia
Miskolc-Lillafüred, Hungary
Chicago, IL, USA
Prague, Czech Republic
Nuremberg, Germany
Turck on the Web
In the product database on you will
find all relevant infomation on Turck products and solutions,
from data sheets to CAD data in many export formats.
 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.
Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
Tel. +49 208 4952-0
[email protected]
 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.
Editorial staff
Klaus Albers (responsible)
[email protected]
Simon Dames
[email protected]
Paul Gilbertson
[email protected]
 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.
Contributors to this issue
Holger Anders, Dr. Patrick Bosselmann, André Brauers,
Lars Franke, Paul Gilbertson, Inka Krischke, Jörg Kuhlmann,
Evelyn Märtin, Holger Spies, Frank Urell, Achim Weber,
Zukui Zhang
 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.
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
Webcode more21280e
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 + 49 208 4952-0 ı [email protected]
(+54) (11) 47561251 ı [email protected]
AUSTRALIA ı TURCK Australia Pty. Ltd.
(+61) 3 95609066 ı [email protected]
(+43) (1) 4861587 ı [email protected]
(+973) 13 638288 ı [email protected]
(+375) (17) 2102189 ı [email protected]
BELGIUM ı Multiprox N. V. (TURCK)
(+32) (53) 766566 ı [email protected]
BOLIVIA ı Control Experto
(+591) 4 4315262 ı [email protected]
BRAZIL ı TURCK do Brasil Ltda.
(+55) (11) 26712464 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]
CHILE ı Intech Analytica E.I.R.L.
(+56) (2) 2037700 ı [email protected]
CHINA ı TURCK (Tianjin) Sensor Co. Ltd.
(+86) (22) 83988188 ı [email protected]
COLOMBIA ı Dakora S.A.S.
(+571) 8630669 ı [email protected]
(+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]
(+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]
(+33) (1) 60436070 ı [email protected]
(+44) (1268) 578888 ı [email protected]
GREECE ı Athanassios Greg. Manias
(+30) (210) 9349903 ı [email protected]
(+502) 2268-2800 ı [email protected]
(+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]
(+352) 5678939 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]
(+39) 2 90364291 ı [email protected]
LJAPAN ı TURCK Japan Office
(+81) (3) 57722820 ı [email protected]
JORDAN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
(+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) 67718678 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]
(+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]
(+52) 844 4116650 ı [email protected]
LNEW ZEALAND ı CSE-W Arthur Fisher Ltd.
(+64) (9) 2713810 ı [email protected]
(+31) (38) 4227750 ı [email protected]
NIGERIA ı Milat Nigeria Ltd.
(+234) (80) 37236262 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]
(+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]
(+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]
(+7) ( 495) 2342661 ı [email protected]
(+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) 10 4471600 ı [email protected]
(+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 TURCK Otomasyon Tic. Ltd. Ști.
(+90) (216) 5722177 ı [email protected]
L Ukraine ı SKIF Control Ltd.
(+380) (44) 5685237 ı [email protected]
(+973) 13 638288 ı [email protected]
URUGUAY ı Dreghal S.A.
(+598) (2) 9031616 ı [email protected]
(+1) (763) 553-7300 ı [email protected]
(+58) (241) 8345667 ı [email protected]
VIETNAM ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
more @
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Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
[email protected] |
*D900901 1112*
D900901 1112
Hans Turck GmbH & Co. KG
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