moreTURCK 2 11 EN
Issue 02
2011
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T h e M a g a z i n e f o r C u s t o m e r s o f t h e Tu r c k G r o u p
Edison’s Heritage
Robust LED machine and workplace illuminations conquer
industrial applications
P. 14
Waterproof
RWW monitors more than 100
well covers with wireless sensor
solution
P. 18
Process Greening
SAS Automotive optimizes the
installation of VW cockpit modules
with a pick-to-light system P. 22
Flow Under Control
With sensors, signal processors and know-how Turck offers
flexible solutions for efficient flow surveillance
02 E d i t o r i a l _ U l r i c h
tUrck
Expectations exceeded
dear readers, it is that time of the year again. We have
finished the preparations for the large annual fall event of
our sector, the SPS/iPC/driVES and now we are looking
forward to those three days in Nuremberg. traditionally
this is also the time to take a look back at last year.
With joy we look back at the past eleven months. after
the successful year 2010, in which turck could compensate the year of the crisis 2009 almost completely with a
sales increase of 30 percent, we again managed to grow
above average. at the end of this year, our sales growth
will be about 25 percent which exceeds our expectations
by far. With that the turck group makes its largest turnover in the history of the company.
i want to thank you, our customers, for your trust in turck. i also want
to thank our more than 3.000 employees worldwide, which made
our success possible with their outstanding commitment. obviously
we are on the right way with our approach to be the solution partner for your automation requirements. We work intensively on walking this path together with you to exceed your expectations too.
that is why we invest into new production capacities in Halver and
Minneapolis as well as in our fieldbus development at our location
in detmold. and if required, we also walk the path together with
partners, as the rFid cooperation with the UHF specialist deister
Electronic proves.
You will find more information in this issue of your customer magazine [email protected] on the following pages we inform you about
our new portfolio and numerous interesting automation solutions. if you want to meet us personally, come and visit us at the
SPS/IPC/Drives at our booth 351 in hall 7.
Be our guest, we are looking forward to meeting you!
Sincerely, yours
Ulrich Turck, Managing Partner
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c o n t en t _ 2 _ 2 0 1 1
News
Innovations for Automation Specialists
Coverstory
SENSOR TECHNOLOGY: Flow Under Control With sensors and IO-Link capable signal processors Turck offers a comprehensive
portfolio for the efficient flow surveillance of gases and liquids
INSIDE
INTERVIEW: “On the Right Way” Andrea Gillhuber, editor of the trade journal, Elektronik, talked to Turck‘s
managing director Christian Wolf about markets, crises and partnership
TREND
INDUSTRIAL LIGHTING: Edison’s Heritage Whether signal light, pick-to-light system, workplace or machine illumination –
LED lights conquer more and more industrial fields of application
APPLICATIONS
04
08
12
LED lights are robust, durable and energy-efficient and
therefore ideal for the industrial use as machine and
workplace illumination. Page 14
14
SENSOR/WIRELESS TECHNOLOGY: Waterproof The RWW Rheinisch-Westfälische Wasserwerksgesellschaft in Mülheim an der Ruhr secures
more than 100 well covers with Turcks uprox-sensors and the wireless system DX80
18
SENSOR/FIELDBUS TECHNOLOGY: Process Greening At its factory in Zwickau, automobile supplier SAS Automotive Systems optimizes
the production of cockpit modules with a pick-to-light system
22
SENSOR/FIELDBUS TECHNOLOGY: Open Air Stadiums Uni-Systems moves stadium roofs, video cubes and much more with sensor,
fieldbus and connection technology from Turck
26
FIELDBUS TECHNOLOGY: Field Transparency Uhde Services relies on Turck‘s Foundation Fieldbus portfolio with diagnostic
functions for the modernization of their fertilizer complex Abu Qir II in Egypt
30
RFID: Tracking Bearings Bicycle supplier Thun automates the control and surveillance of their inner bearings
production with the RFID system from Turck
33
RFID: A Clean Thing The Austrian wastewater treatment plant designer Ness-Schneider automates
washing stations for animal transporters with the RFID system BL ident from Turck
36
RFID: Transparency Enhancer RFID system BL ident guarantees efficiency for a Chinese food manufacturer during
the production of sodium glutamate
40
SERVICE
CONTACT: Your Fastest Way to Turck How, when and where to find us
42
CONTACT: Imprint
43
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03
Uni-Systems relies on sensor and fieldbus technology
from Turck when it comes to solutions for retractable
stadium roofs and comparable projects. Page 30
The manufacturer of bottom brackets for bicycles, Thun,
optimized his production process with Turck‘s BL ident
system to make it transparent and retraceable. Page 33
04 N e w s _ i n n o vat i o n S
Highest Sales
Turnover
 Turck looks to conclude the current
financial year with the highest sales
turnover in company history. As Christian Wolf, Turck’s Managing Director said
at the annual press conference in Neuss
(Germany), the family-owned company expects a consolidated total turnover of more than 430 million euro,
of which 100 million will be in Germany. After a 30% increase in turnover
last year, Turck will grow about 25%
this year. The number of employees
has also grown with the sales turnover:
Currently, the company employs more
than 3,000 people worldwide, of which
1,530 work at German sites in Beierfeld,
Halver and Mülheim an der Ruhr. “Based
on our current assessments, this year
we will well exceed our ambitious target of 400 million euro annual turnover,”
says Wolf. “This is due to the favourable
economic trend in our target markets,
as well as our implementation of growth
strategies. This year, Turck has invested
in markets and production capacities
and has founded new subsidiaries in
Brasil and Turkey. About 15 million euro
have been invested in the expansion of
18,500 square meters of manufacturing capacities in Halver (Germany) and
about 6 million US dollars into 4,000
square meters of manufacturing capacities in Minneapolis (USA).
Info
You can find more information on
the reports or product presentation
in [email protected] under www.turck.
com. Simply enter the Webcode that
you find at the end of each article in
the search field. The following article
page takes you directly to the product database or you can download or
send the article as a PDF.
Application-Optimized
RFID-Components
 Turck’s RFID-system BL ident has been expanded with application-specific
read/write heads and with data-carriers (tags) for the meat industry. A tag designed
for high-temperature applications rounds out the product offering. The new read/
write head TNSLR-Q42TWD with its associated tag was developed especially for
applications in wet environments with an increased range-requirement,
where UHF-technology won’t work. The head is based on the proven 13,56MHzHF-technology, but triples the usual range. In connection with Turcks 12mmtags, maximum distances of 35 mm can be achieved instead of the usual 10 to
15 mm. This technology allows the functionality of read/write processes for the reliable identification of meat
hooks during the operation
of conveyor belts. Furthermore, Turck equips the RFIDsystem BL ident with robust,
high temperature proof tags
with a protection category
IP68. The data carriers TWQ51-HT-B128 are suitable
for ambient temperatures
of -25 up to 85 °C. The temperature of the tag itself can
reach -55 and 240 °C.
excom Remote I/O
with New Functions
 Turck optimized its zone 1 remote I/O system excom for use in zone 2
applications. We also expanded the system functions with new firmware and a
new DTM (Device Type Manager). Because of the smaller power supplies in the
modular design and a compact as well as a backplane, the system can be installed
with even less space requirements. With the help of the new firmware and DTM,
the excom-system along with connected field instrumentation can be put into
operation without prior connection to the process control system, PCS. This
allows a validated operation and connection between the field installation and
control technology and eliminates
potential sources of error from the
beginning. Even during operation
the user is able to add new measuring points or modules and test
and operate them in the run up,
without having to consider changes in the PCS. This guarantees that
only validated system expansions
are connected to the PCS. The
new firmware enables updates via
communication interface, so new
functions can be implemented
without downtime.
05
new Managing
Director
24 v Switching Power
Supplies
 with four new switching power supplies added to the series IM82-24 Turck completes
its interface technology program. The power supplies provide safety extra-low voltage (SELv) according to eN 60950 and are suitable for the 24 V supply of equipment, as
well as for interface modules in the series IM, IMe, IMB, IMs and IMC. Due to their widerange input – 90 to 370 VAC – the IM84-24 can be used in numerous supply networks
worldwide. Depending on the type, output current of 2.5, 5, 10 or 20 A are available.
Using a potentiometer the output voltage can be adjusted from 22.5 up to 28.5 VDC – or
respectively 24 up to 28 VDC. The IM82-24-series are IP20 rated and were developed to
guarantee a reliable DC supply in the industrial environment. The power supply units
provide high efficiency, the possibility for parallel connection and an overload protection of up to 150 percent. A power-good-relay guarantees a reliable functional check,
meaning that in the case of irregularities the power supply-sided cause or a wire breakage can be excluded. The device bypasses power failures up to 30 ms automatically.
Linear Position Sensors
for Hydraulic Cylinders
 with the new magnetostrictive LTX-linear position sensors in rod design, Turck
promises optimized position detection in hydraulic cylinders. Additionally,
level detection can be achieved with the help of float magnet accessories. Due
to their high shock- and vibration resistance the sensors can also be used in
construction machines and other harsh applications. The series completes the
inductive linear position sensor portfolio of solutions for applications where a
magnetic locator is needed. The LTX-series meets IP68 standards and is resistant against many chemicals and oils. The rod is made of high-quality stainless
steel and offers optimal protection against aggressive media. The wear-free LTXsensors provide precise measuring signals with a high degree of linearity and
repeatability. They are available with analog output (4…20 mA, 0…10
VDC) or with a high-resolution digital ssI-output. A three-colored
LeD
D at the sensor output shows the current deviceand signal status at anytime. The low power
input (1 watt type)
ype) enables the direct connection to display-, control- and interface modules.
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 Guido Frohnhaus has been
appointed managing director of
the werner Turck
GmbH & Co. KG
in Halver. within
the management
board the 41-year
old engineer takes
charge of technical
management and
is also responsible
for development
and production. with the retirement
of company co-founder werner Turck,
a change of structure and youth was
needed. The werner Turck GmbH &
Co. KG with headquarters in Halver is
responsible for development and production, and the Hans Turck GmbH &
Co. KG headquartered in Mülheim is
responsible for sales and marketing
of the Turck group. each are managed by a member of the founding
families and an additional managing
director. In Halver, Guido Frohnhaus
and Markus Turck lead the company,
in Mülheim Christian wolf and Ulrich
Turck, son of co-founder Hans Turck,
manage the family enterprise.
turck acquires
MtX interest
 Turck has acquired eaton Automation Holding’s 50-percent interest in the joint venture MT elektroniX GmbH (MTX) in Detmold. Turck
now owns 100 percent of the shares.
In 2002, Turck acquired 50 percent
of the shares in Moeller electronix
GmbH from eaton – at the time still
under the name Moeller GmbH. The
two companies jointly founded MTX
to develop automation components, in particular I/O modules and
fieldbus gateways.
06 N e w s _ i n n o vat i o n S
Increased Focus
on RFID
 Turck increases its activities for the
HF/UHF-RFID-system BL ident,
which is now available for the longrange UHF (Ultra High Frequency).
The automation specialist arranged a
technology and marketing cooperation with its partner Deister Electronic,
who manages a long-term technology
and knowledge transfer in UHF-RFIDtechnology. According to the cooperation contract, Turck is now allowed
to develop, produce and market the
Deister-UHF-technology in the field
of automation. In other fields, Deister
will still market the technology on its
own. “This cooperation is a milestone
in corporate development of both
partners and the customers are going
to benefit from this.” Turck’s managing director Christian Wolf comments,
“With our application know-how in
the field of industrial automation and
based on the elaborate UHF-technology from Deister, we will be able
to develop it further. Our customers
always find the applicable read/write
head for their requirements, whether
in the established HF – or in the long
range UHF-band.” “Users increasingly
expect custom-fit system solutions
that are coordinated with one another,” says Anatoli Stobbe, managing
partner of Deister Electronic.
Training
 Turck now offers training courses
about its products, technologies and
systems for interested customers. The
training will teach the customers how
to implement and operate the solutions from Turck fast and reliably. More
information and registration online:
www.turck.de/training
 Webcodemore21110e

Voltage Surge Protection
for PMC-Circles
 With new voltage surge protection devices for PMC (Process Measurement &
Control) interface modules, Turck expands its position as a complete provider
of interface components. The six new modules of the IMSP series (interfacemodule surge-protection) are installed ahead of the regarding interface modules and offer reliable protection against overvoltage. The devices in protection
category IP20 can be used in explosion proof or non explosion proof zones.
Despite their small width of 6.2 mm the modules are available in two,
three and four wire technology. The modules are mounted over
the standard top-hat rail or onto an assembly plate. For
analog signals in two wire technology, or with
analog data separator – modules with
one (IMSP-1x2-24) or two signal circuits (IMSP-2x2-24) are available.
Binary signals of switches, inductive or capacitive sensors are
processed via floating signal
wires of the modules IMSP-2-12
and IMSP-2-24. With the modules IMSP-4-12 and IMSP-4-24
temperature amplifiers can be
connected with voltage surge
protection.
Wireless Connection
of Modbus Nodes
 The new Multi-Hop Data Radio from Turck’s partner Banner Engineering extends
the reach of the Banner’s SureCross wireless systems by repeating transmissions in
3 km ‘hops’. Multiple units can be placed, allowing signals to pass over hills and other
obstacles that would block a single wireless hop. The Multi-Hop Data Radio can be
used to connect a wide variety of field devices directly, including PLC’s, Controllers,
HMI’s, DCS’s, transmitters, level, pressure and temperature sensors. It allows extension of the widely used Modbus communication protocol to many applications
where wiring is impractical because of distance or accessibility. The large wireless
networks enabled by the
new radio provide previously unavailable information to users in a wide
range of industries. In Irrigation, soil moisture can
be measured, zone valves
can be operated and flow
rate measured. In automated parking applications, thousands of parking spots city-wide can
be monitored. More traditional applications include
tank level, pressure, flow
and temperature monitoring in a variety of markets.
07
LED Work Lights for
Industrial Use
New Automation
Systems VP
 Turck extends its lighting
technology range with energysaving LED work lights of protection categories up to IP67/IP69K.
The robust design and a life-span
of 100,000 hours allow their use
in a wide range of applications,
where a reliable, bright source
of illumination is needed under
rough environmental conditions. The color temperature in
daylight range between 5,000
and 10,000 Kelvin. The work
lights can be connected either
via a standardized M12x1-plug
connection or directly via open
wire ends. The power-on/-off is
carried out either over the connection with the supply voltage
(10...30 VDC) or – when there is a constant power supply – over the integrated switch
directly at the LED work light, which is incorporated in some versions. The lights are
available in three different construction groups: As compact spot lights, as line light
rails and as square LED lights for flat illuminations. Every work area can be illuminated
more on page 14 

optimal with luminous flux of 65 up to 1,800 lumen.
 Oliver Merget is the new vice
president of Turck’s automation systems business unit. The 41-year old
engineer is responsible for all product
management activities in the areas of
fieldbus techn o l o g y, H M I
and RFID worldwide. Merget
is the successor of Norbert
Gemmeke, who
recently left the
company. Oliver Merget has
many years of
experience in the areas of sales, product management and engineering.
Before joining Turck, he worked in factory and process automation for Siemens for 12 years, before he took over
the responsibility for sales process
automation Germany at ABB. With
his extensive experience, the automation specialist is well prepared for
his new role.
FF and Profibus-PA
Portfolio Expanded
 With a new multi-barrier and firmware for the Diagnostic Power Conditioner
(DPC), Turck expands its portfolio for process automation. The new multi-barrier
MBD40 in protection category IP20 is a compact 4- and 8-channel solution for the
connection of intrinsically safe electric circuits to Foundation-Fieldbus- or ProfibusPA-networks. The multibarrier can be operated reliably in temperature ranges
between -40 °C (optional
-55 °C) and 70 °C. Using
housings made of stainless
steel or plastic, user specific applications like 12- or
16-channel types can be
achieved in a small space.
With the new multi-barrier,
the 4-channel derivative in
a die-cast aluminum housing is available as 8-channel type. With the new
firmware, Turcks Diagnostic Power Conditioner DPC-HSEFD for Foundation Fieldbus
has expanded functions such as an integrated web-server, which offers the same
possibilities for parameterization and configuration as the DTM-based solution. An
internal diagnostic buffer memorizes detected alarms from the monitored FF-segments, so that a constant surveillance through an external DTM-based software is
no longer necessary.
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Compact Temperature Sensors
 Turck has introduced a new series
of compact temperature sensors
with processing electronics integrated
into the M12x1-connector. The miniature series TTM uses Pt1000 measuring elements for precise temperature
measurement in small spaces. Being
only 25 mm longer and 1.5 mm wider
than a standard M12x1 connector,
the fully encapsulated TTM sensors,
not needing additional processing
devices, provide an output signal of
4…20 mA in 2-wire technology.
Despite the compact design, the
user still benefits from the flexibility
of Turck temperature sensors. Like TP
sensors, the miniature transmitters work with mineral insulated probes and the
probe length is
selectable.
08 C O V E R S T O R Y _ S E N S O R
T E C H N O LO G Y
Author
Raphael Scholzen is
a product specialist
for fluid sensors at
Turck Germany
in Mülheim
Webcode | more21100e
The Turck portfolio
offers numerous inline
and immersion solutions
for flow monitoring,
starting with simple
sensors to IO-Link
capable monitoring
systems with FM
signal processors
Flow Under Control
With sensors and IO-Link capable signal processors Turck offers a comprehensive
portfolio for the efficient flow surveillance of gases and liquids
S
tanding still means taking a step backwards!
This short worldly wisdom can also be applied
to cooling circuits in industrial plants and
machines. An interruption, too little of the cooling
medium, or the wrong temperature can have exten-
sive and serious consequences. Additionally, security
issues, downtime, quality loss, and machine or product damages can be caused through irregularities in
the cooling circuit. Plant operators and mechanical
engineers have to install a continuous and precise
09
monitoring device to the cooling circuit. This allows
a considerable optimization of the energy balance
in energy intensive applications. Thanks to real time
measurement, cooling systems don’t have to run at
maximum rate permanently, but can be operated to
match the needs of the cooling demand. Therefore,
continuous flow monitoring of cooling circuits provides great benefit. This solution is recommended
where energy efficiency and reliability of a plant are
first priority.
Turck offers a wide range of inline and immersion sensors as well as fitting signal procedures for
monitoring the flow of gases and liquids. This broad
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range of products provide efficient and reliable cost
saving solutions with a high degree of reproducibility
in their results.

 Quick read
For the smooth operation of numerous machines and plants, the reliable monitoring of cooling circuits is indispensable. Turck offers a complete
range of solutions for this, from the simple flow monitoring in cooling circuits, over comprehensive flow and temperature data collection up to the
device parameterization via IO-Link.
10 C O V E R S T O R Y _ S E N S O R
T E C H N O LO G Y
heated measuring
resonator
measuring resonator
The FM signal
processors are,
as FMX modules, also available for use
in hazardous
areas with IOLink or HART
interface
The calorimetric measuring principle is based on the different heat dissipation at different flow speed
Calorimetric measuring principle
The classic flow sensor works following the calorimetric principle which is based on the laws of thermodynamics. The sensor creates heat energy at its tip that is
higher than the temperature of the medium surrounding the sensor. The different temperatures of the sensor
and the medium lead to an increasing temperature of
the medium directly at the tip of the sensor.
If the flow rate increases, the sensor loses heat
energy through the streaming medium. The tip of the
sensor cools down, which is
called heat dissipation. The
temperature at the tip of the
sensor is measured and compared to the temperature of
the medium. The temperature difference indicates the
flow rate. With compact sensors, the processing of the
measured information takes
place over the sensor integrated electronics.
Flow sensors that work
on the calorimetric principle are available as inline
or immersion sensors. In the
inline sensor, the heated and
the non-heated measuring resistor face each other in the inside of
the pipe. With the immersion sensor,
the tip of the sensor is immersed into
the flowing medium. For liquid media, the
heated and the unheated measuring resistor of the immersion sensors are together in
one sensor tip. For gas media they are usually separated
in two tips because of the low thermal conductivity
and higher temperature of gaseous media.
Calorimetric sensors are a reliable, robust and costsaving solution for many applications. The advantages
include their ability to be placed independently from
applicative influences such as vibrations or pressure
fluctuations. Even temperature fluctuations up to
4 K/s are no problem for modern calorimetric sensors. Furthermore they are almost maintenance and
wear-free, because they don’t have any moving parts
which extend into the flow channel. Calorimetric flow
sensors also measure the temperature of the medium.
Separate temperature measurements therefore aren’t
necessary which reduces the cost for installation,
wiring and maintenance.
Challenges for the calorimetric system include processes with fast temperature changes of the cooling
medium. Also, the monitoring of poor heat conducting media, like specific oils or liquids with a high solid
content, require a special construction of the sensor as
well as a careful installation. If the sensor has only one
measuring point, data could be misinterpreted. Not
only a change of the flow speed, but also a change in
the temerature can cause an output change. This is an
error source that has to be eliminated, especially with
cooling applications. To suppress this effect, the flow
sensor has a second measuring point, a compensation element that is specifically placed in the tip of the
sensor so that its heating can only be caused by the
medium itself.
Calorimetric flow sensors are very reliable, because
of their high repeat accuracy and long-term stability
over the whole temperature range. If the speed that
is going to be monitored is set up once, it will stay on
the same level, even if there is a repeated overtravel or
underrun. For the user and the operator of the plant,
the high long-term stability also has an effect on the
availability of the plant: it extends the time period in
which another review of the set switching point is due.
If the application requires classical switching
points, they can be freely assigned within the measuring range of the sensor. The switching output
11
The FCS immersion sensor can
be adjusted
onsite with the
help of the LED
display and the
potentiometer
changes its status depending whether the appointed
flow is overtravelled or underrun. An alternative to
the switching point is the use of a standardized analog signal of 4...20 mA (or 20…4 mA) for the coverage. Depending on the requirements of the application, the display spectrum can be expanded to gain
a better detail level. The mapping of the desired flow
speed to the analog signals occurs via a simple teach
procedure. Temperature data and signals of the flow
speed are available to higher levels.
Additional value through
IO-Link integration
Everyone who wants efficient flow monitoring ends up
with a standard that prevails for a reason, which is IOlink. The protocol enables the sensor system to communicate and therefore makes the conventional analog output needless. With the FM/FMX (Flow Module)
series, Turck offers signal processors for flow sensors,
enabling users to benefit from the advantages of IOLink over standard flow sensors. The FMX devices can
even be used in hazardous areas.
The IO-Link advantage is that the “virtual analog” process value is submitted digitally and therefore is less susceptible to faults. It also allows the use
of unshielded sensor cables which reduces the costs
for storage considerably. IO-Link also allows software
supported device parameterization. For example, the
parameterization can be realized over the FDT-based
engineering tool Pactware in connection with device
drivers like DTM (Device Type Manager) or IODD (IO
Device Description). For the controls the parameterization can be realized in different ways. Either as startup-initialization during PLC booting via GSD (DeviceMaster Data) or acyclic during running operation via
ORDO (On-Request Data Objects) in connection with
IEC61131-3 functional modules.
Due to the ability to transmit process data cyclically
and parameter data acyclically on-request, numerous evaluation options are available to the higher
level controls that go beyond classic flow monitoring.
For example, it allows the continuous visualization of
process data such as temperature or flow profiles and
tendencies. This is far beyond the simple switching
information “flow ok/not ok.” The follow up and review
of the flow allows diagnostic functions, which wouldn’t
be possible otherwise.
Long-term measuring and cross references
between flow speed, medium temperature and other process data allow analyses that make cooling
problems detectable before they even occur. Flow
monitoring of the second generation doesn’t just
protect from machine-, product-, and image damages, it also allows an insight into industrial plants
that enhances their transparency and maximizes the
availability of the plant. N

 Aligned fitting prevents measurement errors
To eliminate misinterpretation, immersion sensors need to be aligned
properly when it comes to rapid temperature changes of the medium. That means that the measuring resistor and the heated measuring resistor have to be aligned parallel to the flow direction. This
isn’t necessary for inline sensors because the measuring and heat
elements are aligned this way by design.
Through the aligned fitting the full precision potential of the
sensors can be used. This is relevant for resistance spot welding in
automobile manufacturing. The quality of the welding depends
on the welding temperature and therefore the precise configuration of the cooling process is of great importance. The cooling
medium is lead over different parallel cooling circles to the welding robot (welding transformer, robot arm etc.). In the backflow the
heated cooling medium has to pass flow control sensors shortly
after the welding procedure.
Rapid temperature changes of the cooling medium are normal
here. That is why the aligned fitting of the flow sensors is so important for this application. The heated cooling medium otherwise
would cause the sensor to report a flow change or hold-up which
could cause a complete standstill of the robot in turn. With the use
of the aligned fitting however, the sensor works safely even when
the adjusted flow is underrun.
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12 I n s I d e _ I n T E R V I E W
After a 30 percent growth
in sales in 2010 Turck‘s
managing director,
Christian Wolf, is
expecting almost 25
percent for this year
“On the Right Path”
Andrea Gillhuber, editor of the German trade journal‚ Elektronik, talked to Turck’s managing
director Christian Wolf about markets, crises and partnership
Turck is expecting record sales in
2011. Are automation systems or
automation products responsible
for the growth?
Both business units are impor tant
although there is slightly bigger growth
in automation systems than in automa-
tion products. As you can see, our solution orientated business works for us. For
the whole Turck group we expect to see a
growth of 25 percent in 2011.
What region had the best sales
numbers?
Regarding the overall sales numbers, the
region with the strongest growth was
north America with a relative growth of
about 28 percent. With the high total volume, north America is on top of the rankings with overall numbers. The biggest
percentage increase we have is in eastern
13
europe, specifically Russia. They have had
the biggest growth over the last two years.
Why is Russia growing so rapidly?
The Russian market is driven by process
automation, mainly because of the large
deposits of raw material. The oil- and gas
business is going well. Raw materials dominate the market and are the economic
power of Russia. If you look at factory
automation in this region, you see that the
degree of automation is remarkably lower
than elsewhere.
You describe Turkey as a region
with an enormous potential. What
is your strategy there?
Turkey is strong in factory automation and
has a good machine building industry.
The automobile, packaging machine and
food industries are anchored there. Many
companies located in Turkey are also functioning worldwide. Fundamentally Turkey
has a national economy and an industrial
environment that is similar to the conditions in Germany, although on a different
level. Turkey is the sixth largest machine
builder in europe and therefore already
shows enormous potential. Turck already
does business with partners there but
now we founded our own subsidiary and
we expect a growth of 50 percent anually
over the next three years.
Turck is still growing. How do you
manage the order situation?
That isn‘t very easy, especially in production. Of course after two years with high
growth we have reached the capacity limits of our organization. On the other hand
it is getting a little quieter. That isn‘t bad
for us because we have time to recover,
recruit new employees and put new buildings into operation. If everything runs
smoothly, we can think about increasing
our growth rates again in about one or
two years. But it is a challenge for every
company to work at the pace we have
worked over the last two years.
How do you assess the European
crisis and its impacts?
It is difficult for an industrial company
to assess the situation. We try to work
separately from this. But I think that
as long as there is a financial security
umbrella and cooperation of the european countries with the federal governments, we can expect stability. It is a
psychological effect: If there is insecurity, the investment behavior changes.
That is how we look back at 2009 – not
more @
2_2011
as an industrial crisis but as barriers to
investment and insecurity based on the
collapsing markets.
Turck cooperates with Deister Electronic. What does this partnership
look like?
deister has great expertise in the area
of ultra high frequency (UHF) and that is
what our partnership is about. deister
provides us with UHF-technology for our
markets and Turck can develop targeted
automation products based on this. The
advantages for deister lie mainly in sales
and distribution: the company is quite
diversified but does not have the distribution assets for potential market‘s like factory and process automation. The most
important thing about this partnership is
that you collaborate based on technology
on the one hand but stay independent in
your own business on the other hand.
Are there any other partnerships
planned for the future?
Of course this is always an option. The
Turck group is diversified and we always
ask ourselves if we can reduce complexity by producing something ourselves
or if we use a partner‘s expertise. It is a
question of identifying the right partner. They have to have the same standard regarding a partnership; it has to fit
technologically but also on a personal
level. For us it means strengthening the
development of our core competencies
on the one hand and at the same time
looking at how we can approach the market faster. We are also always looking for
other core competences that we could
integrate profitably.
How is the transition into a solution provider going?
As the numbers, the takeover of the MTX
and the cooperation with deister show, it
is proceeding very well. The growth rates
prove that we are on the right path. This
is a never ending process. What is defined
today as a solution and system provider
will be defined differently by our customers in about 10 - 15 years. Perhaps
next we have to engage more in areas
such as IT and web. Then, for example
with a continuous information and data
flow into the eRP system of the customer. We have to observe precisely where
the users are going. That is essential to
adapting to the changing requirements
and that is how we can be measured as a
solution provider. N
“
Regarding the overall sales numbers, the region with the strongest
growth was north America with a
relative growth of about 28 percent.
With the high total volume, north
America is on top of the rankings
with overall numbers.
„
Christian Wolf
“
What is defined today as a solution and system provider will be
defined differently by our customers
in about 10 - 15 years. Perhaps next
we have to engage more in areas
such as IT and web. Then, for example with a continuous information
and data flow into the eRP system of
the customer.
„
Christian Wolf
Author
Andrea Gillhuber
is an editor of the German
trade magazine elektronik
www.elektroniknet.de
Webcode |
more21130e
14 T R E N D _ I N D U S T R I A L
LIGHTING
Edison’s Heritage
Whether signal light, pick-to-light system, workplace or machine illumination – LED lights
conquer more and more industrial fields of application
W
ith the EG-regulation 244/2009, the European Union started to phase out the classical light bulb. This has generated the need
to replace these bulbs with alternative light sources.
The latest step of the regulation occurred in September 2011; since then luminous elements above 60 Watt
have to meet the energy efficiency class C, accordingly
60 Watt bulb must meet class E standards. Basically it
means light bulbs with more than 40 Watt will not be
used much longer.
Everyday users are not happy about this, wanting
the old light bulbs back, complimenting their warm
light and complaining about the disadvantages of
Author
Markus Bregulla is
the product manager for opto- and
ultrasonic sensors
at Turck Germany
in Mülheim
Webcode | more21105e
Robust, energyefficient and longlasting: LED workplace
lights are ideal for
the industrial use
the energy saving lamp. Some of the disadvantages
include complicated disposal and the delay in reaching
the full luminous intensity. Despite the genius inven-

 Quick read
LED lights are more robust, energy efficient and longlasting than other illuminants. That is reason enough
for automation specialist Turck to expand their portfolio
about LED machine and workplace lights that are connectable to the controls or Fieldbus junction boxes via
M12 connectors.
15
tor of the classic light bulb, Thomas Edison, the functionality of the classic bulb is very archaic. The design
allows electricity through an electric conductor until
it heats up and begins to glow, radiating light – rather
bright but not very energy efficient. The ratio of visible
light is only up to five percent from the total energy
consumption.
Because of the new energy savings, LED lights
are quickly taking the place of the classic light bulb.
The LED technology from Edison’s heirs is so well
engineered that it is already established in niche
areas and conquering more and more shares in the
market. LED’s are already being used in traffic lights,
street lights and medical engineering applications, as
well as mainstream applications including flashlights
and bicycle lamps. Each of the specific characteristics of LED is an advantage for those areas of application: the energy efficiency, the precise light color and
the long life span of about 100,000 hours are features
that outmatch other illuminators.
In the industrial environment, the LED technology has already been used for status and signal lights
for a some time. The difference between traditional
bulbs is that the light emitting diodes is that they are
not thermal emitters. LED’s emit almost monochrome
light in a limited spectral range. That is why they are
so efficient compared to other illuminants, where color filters have to filter a large part of the spectrum to
reach monochrome color characteristics. Next to these
advantages the LED also thrives in rough environmental conditions because it is very robust and highly
resistant to vibrations.
Robust lighting portfolio
Turck uses the advantages of the LED for a comprehensive LED lighting technology portfolio; in addition to traditional uses, users also can find LED industrial lamps for machines and workplaces. Most LED
lights come from Turck’s partner Banner Engineering, but the machine lights are being developed and
produced by Turck.
Signal lights are usually used for displaying the
status of systems, machines or process stages. For such
start and stop signals or traffic light signals, the high
light intensity of the LED pays off and bright signal
lights can be seen in a minimum amount of space. One
type of signal light is the pick-to-light system where
Turck is one of the market leaders. Pick-to-light solutions show the installation sequence in manual production and packing processes. The LED light shows the
assembler the specific product configuration with light
signals at the output trays. The assembler simply takes a
component from the illuminated tray and installs it. The
signal light has an integrated light sensor that confirms
the removal of a component automatically. The signal
lights are connected via Turcks I/O systems BL20 or
BL67 and controlled with the integrated CoDeSys-programmable gateway or by the superior SPS. To connect
the system to the automation structure of the user, the
I/O system offers numerous gateways for the common
fieldbus and ethernet solutions.
more @
2_2011
LED machine lighting
LED isn’t only suitable as a
signal light for industrial
environments, it also has
its advantages as a light
source. For this reason
LED machine and workplace light fixtures complete the Turck portfolio.
The housing materials
and the construction prinWorkplace lights
ciple are the same as sensors. The lamps
are available as
are moulded and resistant from common solid
square, longitudinal and
cooling lubricants such as oils and aggressive cleans- spot lights (picture)
ing materials. This technology provides a decrease in
susceptibility to malfunctioning and allows longer
life spans.
LED machine lights can be connected directly with
a M12 connector to a standard SPS output, a fieldbus
station or a passive junction. They are supplied with 24
VDC and have a power consumption of less than 0,5
A. Over an SPS or a programmable fieldbus gateway
from Turck, the illumination can be controlled externally depending on other control variables. This option
makes the installation easier and offers new possibilities to save energy. Instead of using a permanent illumination of 100 percent, individual illumination scenarios regarding production step, product, needed
brightness and other parameters are programmable.
The reduced wiring effort of the M12 connector is an
additional bonus. The machine lights are available as
built-in longitudinal light as well as surface mount, and
beacon and cube light, with or without a gooseneck for
easier alignment.
The LED lights from the pick-to-light system show the assembler from
which output tray he has to pick the next component
16 T R E N D _ I N D U S T R I A L
LIGHTING
Application
example
machine center:
LED machine
lights guarantee
sufficient brightness to monitor
the drilling procedure through
an inspection
window
LED workplace illumination
If you want to abstain from expensive protective housings, LED lights are often the only
option for illumination in close proximity to machines where they are exposed
to dirt, dust, steam or aggressive cleansing
materials. The use of LED in the production environment is possible because they
are robust (protection category IP67) and shock
resistant. The color temperature of the LED in the
daylight areas is between 5,000 and 10,000 Kelvin.
The luminous flux lies between 65 and 1,800 lumen,
depending on the type. As a comparison a 100-Watt
light bulb has a luminous flux of about 1,400 lumen,
a 60-Watt light bulb about 700. The switching on/off
of the lights happens over the connection with the
needed supply voltage (10...30 VDC) or – when there is
a constant power supply – over the integrated switch
at the LED light.
The lights are available in three types: As compact spot light, as longitudinal light and as square
LED light for extensive light requirements. Each
work area can be illuminated optimal with luminous
flux of 65 up to 1,800 lumen. The spot lights with six
LED’s are available with or without a switch. The longitudinal lights are offered in eight different versions
The machine light from Turck in a round case
can be aligned easily due to the gooseneck
of three up to 24 LED’s, with or without a
switch. For the extensive illumination of
large work areas Turck offers four square
LED lamps with twelve up to 48 LED’s.
Conclusion
With their life span of about 100,000
hours, LED lights increase the availability of
machines and reduce maintenance costs.
Design engineers and plant designers will
prefer the installation of LED lights in the
future, especially with illuminants that are difficult to access. The LED light will also be established for private use soon. Design, light color,
purchase price and most of all the power consumption will be the main factors for its use.
In 2016, the last step of the EG-regulation
will be carried out: all lamps (with the exception
of a few halogen lights) have to meet the energy
efficiency class B. Common light bulbs and normal
halogen lamps will then be completely phased out.
Next to the energy efficient lamps, a broad spectrum of LED lights will be available and established
as the superior technology. It remains to be seen
if the scenarios of illuminated walls with the use
of OLEDs (Organic Light Emitting Diodes) will turn
into reality or not. With OLED and its organic luminous material the circle will be complete as the filament of Edison’s improved light bulb from 1880
was made of charred bamboo fibers. N
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18 A P P L I C AT I O N S _ S E N S O R / W I R E L E S S T E C H N O LO G Y
Author
Lars Franke is
a sales specialist
at Turck Germany
in Mülheim
Webcode | more21152e
Numerous wells
from RWW are
located directly
at the Ruhr river
User www.rww.de
Waterproof
RWW Rheinisch-Westfälische Wasserwerksgesellschaft(Water Works Company) in Mülheim
secures more than 100 well covers with Turcks Uprox-sensors and the wireless-system DX80
T
he water works: anyone who bought that space
on the board game Monopoly hoping for large
profits was usually disappointed. Other players
seldom land on this space and if it were to happen, the
profit wasn’t even enough for a night on Baltic Avenue.
With increasing frequency, copper pipes, power supply lines, brass components or railway tracks are being
stolen by raw material thieves who are interested in
real, but illegal, incomes.
The RWW Rheinisch-Westfälische Wasserwerke in Mülheim has been faced with the challenge of trying to
make the theft of copper and the brass parts of well
covers almost impossible. Within their supply area
which covers a large part of the German state NorthRhine-Westfalia, RWW supplies about 825,000 people
as well as numerous businesses with drinking water. In
2010, that included 84.5 Million cubic meters in all. In
their water plants in Mülheim and Essen, RWW stores
19
Turck supplies prefabricated systems in a stainless
steel box, that has to be mounted to the well covers
by RWW electrician Klaus Bitter
processed water from the Ruhr river in underground
reservoirs. If requested, the water gets pumped into the
numerous wells that are located on the premises and
fed into the supply network. The nationwide increase
of raw material theft led the management of RWW to
question how to best secure the well covers. The loss
of material would cause an enormous financial loss
but the damage that could be caused by open wells
is even worse. Next to the danger of accidents there is
also the risk that the drinking water gets contaminated
or even poisoned.
Danger foreseen – danger averted
Until recently, the existing fences with barbed wire
were sufficient but now a constant monitoring of the
well covers was needed. In 2010 the supplier from
more @
2_2011

 Quick read
To guarantee the safety of the water supply, RWW has to
ensure sure that the numerous well covers of the water
reservoirs aren‘t opened unauthorized or even get stolen. While looking for the most efficient solution, Turck
was able to convince the specialists from RWW with a
pre-converted IP67 system consisting of sensors and a
wireless radio connection. Today the system monitors
more than 50 wells, 90 more are about to be equipped
with the system soon.
Mülheim decided to constantly monitor the well covers to ensure they were closed correctly. With several
hundred wells to be monitored, a classic wiring system
was impossible because the earthwork would have
20 A P P L I C AT I O N S _ S E N S O R / W I R E L E S S T E C H N O LO G Y
In the case of an
alarm, the service
technician in the
control room is able
to see immediately
which well is
concerned

 Pre-finished IP67-solution of Turck mechatec
To make the installation of the monitoring system as easy as possible for the customer, Turck delivers the whole system consisting of sender, battery and sensor already
wired in a water proof switchbox made of stainless steel. The employees of RWW
only have to mount the switchbox to the well cover and attach the vandal resistant
antenna. The whole assembly and the technical installation of the system within the
switchbox have been carried out by Turck mechatec in advance. The Turck subsidiary
is specialized on the construction of switchboxes including the system installation.
Turck mechatec offers customer orientated electromechanical complete solutions
for all areas of the industrial automation technology.
been extremely expensive. The only alternative was a
wireless solution with battery operation. Although antitheft systems and alarm installations aren’t exactly the
core business of an automation specialist, Turck could
fulfill the requirements from RWW and deliver a wireless fallback system for the well covers. “The fallback
system had to reliably and wirelessly monitor and
report the opening of a well cover to the control center,” says Frank Siepmann, responsible for electronics
maintenance at RWW. “The further details were about
to be worked out individually by the requested companies. Since we already had good experiences with
Turck in the field of sensor and interface technology, we
also requested them this time.” After a selection process
during the summer of 2010, the management of RWW
decided upon the solution from Turck, which the automation specialist had developed in close cooperation
with the responsible employees from RWW. “The individual solution, the good support from Turck, and last
but not least the provision of a sophisticated test system on our premises convinced us,” Siepmann explains
as the reasoning for their decision.
Today RWW uses a Turck system that currently captures the status of more than 50 wells and transfers it
to the central controls of the water plant. The unnoticed opening of a well and therefore the risk of a contamination is now impossible. An additional 90 wells
are currently being equipped at other locations. The
next expansion is planned for the upcoming spring, as
soon as the system has proved its reliable performance
under winter conditions.
Uprox-sensor monitors cover closure
In principle, Turcks monitoring solution is as easy as it
is well thought out: An inductive proximity sensor is
located at the outer edge of the well cover and captures the metal edge of the well while closed. If the well
cover is removed, the sensor doesn’t “see” the cover any
longer and changes its signal. Because the well cover
edges are made of different kinds of metal (i.e. Aluminum) Turck uses a Uprox factor-1 sensor, which has the
same sensing distance for all metals.
21
The antenna on the roof of the filter hall receives the
signals of all 55 connected wells
The DX80 gateway processes the
radio signals and
forwards them to
the control room
onsite and to the
superior controls
via Modbus RTU
The IP67 components of the DX80 system including sensors are installed in a switchbox
The battery operated wireless-sender of signals, the
DX80- series from Turcks Partner Banner Engineering,
sends the sensor signal over the 2,4GHz-band via radio
to the DX80 gateway in the filter hall where the signal is
forwarded via Modbus RTU to the control room in the
filter hall, and onto the central control room. There, the
status of all well covers is visualized on an HMI, so that
problems are recognizable at once. The DX80-series
allows the connection between a gateway and up to
48 senders (nodes) with two digital or analog sensors
each. The RWW system could be expanded by adding
sensors to the nodes. These sensors could measure the
level of the well and transmit the data to the controls
for example.
Next to the digital switching signal that shows
the status of the well cover, the DX80 also transmits
a status that confirms that the data transfer is working correctly. If this status fails to appear, the receiver
gateway sends a notification to the superior controls. This distinguishes the opening of a well from a
data transfer problem through power failure or other
errors. The communication between node and gateway works bidirectionally; the nodes are senders and
receivers at the same time. The battery pack supplies
the node as well as the connected sensor. An intelligent power management operates the system so
that it is able to transmit for more than two years with
only one battery.
more @
2_2011
Wireless challenge
A wireless transmission path is installed easily but there
are possible pitfalls. Sometimes the transmission of single
wells is faulty and leads to a faulty notification. The suspected cause for this is trees or high grass interrupting
the transmission between sender and gateway for a short
time. Turck has a solution for this problem; single nodes
can be linked to a subnetwork, where signals are sent over
a DX80 data radio to the gateway. This is how sensors can
be installed where connection to the central antenna
can be problematic.
Turck works in close cooperation with RWW for a
solution to this problem. From previous experiences
with Turck, Frank Siepmann is optimistic that the problems will be solved shortly. “We had initial difficulties
during the implementation of the transmission path
but all of the problems have been solved in a very short
time. If that continues and the system works well during the winter, we are going to equip further wells with
the Turck solution in 2012,” Frank Siepmann explains.
Thanks to the smart radio solution and the successful partnership between Turck and RWW, the company is well prepared for the challenge of securing
their raw material. And the next time someone tries to
open a well cover in Mülheim unauthorized, this could
mean: Go to jail. Go directly to jail. Do not pass go,
do not collect $200! N
“
The individual
solution, the good
support from
Turck and last but
not least the provision of a sophisticated test system
on our premises
convinced us.
”
Frank Siepmann,
RWW
22 A P P L I C AT I O N S _ S E N S O R / F I E L D B U S T E C H N O LO G Y
Author
Evelyn Märtin is a
sales specialist
at Turck Germany
in Mülheim
Webcode | more21153e
Pick-to-light systems
optimize manual
production processes
and reduce the error
rate remarkably
User: www.sas-automotive.com
23
A diffuse mode
sensor integrated
into the signal light
acknowledges
the removal
automatically
Process Greening
At its factory in Zwickau, automobile supplier SAS Automotive Systems optimizes
the production of cockpit modules with a pick-to-light system
S
AS Automotive Systems produces cockpit
modules for the automobile industry at four
locations in Germany. In 2010 the SAS Group
produced about four million cockpits. At the location
in Zwickau they were looking for new ways to reduce
sources of error during the production and composition of the cockpits. SAS Zwickau produces cockpits
for the Volkswagen vehicle plant next door. Oliver Graf,
jointly responsible for the plant design, describes the
process: “About 2.5 hours before delivery time we get
the demand requirements and then have to produce
and deliver the cockpits in the allotted time.“ To be able
to produce a number of up to 1,300 cockpits a day, one
cockpit has to be completed every minute. The mounting time at each of the 40 stations of the line is short.
If quality control discovers an error at the end of
the production chain, it has to be corrected manually,
which is time consuming. Therefore, the easiest way
for flawless production is an integrated quality control during the installation process. Before the pick-tolight system was introduced, the assemblers read the
respective configuration of the cockpit from an order
slip and equipped the cockpit accordingly. Mistakes,
especially at the types with rare components, couldn’t
be completely avoided.
Less mistakes with pick-to-light
With the recently installed pick-to-light system from
Turck and Banner, SAS could reduce the mistakes during cockpit mounting remarkably. The system translates the specific configuration of a cockpit into light
signals, which show the assembler the needed components in the right order. All output trays were equipped
with a signal light and the assembler simply takes a
component from the illuminated tray and installs it into
the cockpit. The signal light has an integrated light sensor that acknowledges the removal of a component
automatically. The system monitors the progress and
sends the information to the product line controls; this
captures the order completion and releases the light
signal for the next order.

 Quick read
SAS Automotive Systems produces cockpits for the automobile industry, individually mounted and just-in-time.
For the assembler at SAS in Zwickau, Germany, that means, that one module has to be finalized every minute. To
improve this work, a pick-to-light system now indicates exactly what component has to be installed in which order.
Turcks pick-to-light solution could convince the SAS specialist because of the comprehensive approach consisting of
sensors, I/O system and fieldbus gateway, as well as its easy integration into the production line.
more @
2_2011
24 A P P L I C AT I O N S _ S E N S O R / F I E L D B U S T E C H N O LO G Y
Turcks modular I/O
system BL20 guarantees a reliable
communication to
the plant controls
via Modbus TCP
“
With other providers you usually have
to find your own solution for connecting
the production line
controls, but Turck
provided a complete
solution, including
I/O system.
„
Oliver Graf,
SAS Automotive Systems
An unwanted activation of the light sensor is impossible
because of the background suppression set at 100 mm.
In addition, the system provides another protection level
so if the assembler picks something from the wrong tray,
a red light signal indicates the mistake immediately.
The effect of the pick-to-light system is remarkable.
Next to the reduction of mistakes, pick-to-light makes
the installation process faster; and the assemblers are
able to concentrate on the quick assembly instead of
having to identify the right components first.
trol. Because of the good experiences of the Cologne
crew, the optimization process in Zwickau could
be implemented confidently.
After the pick-to-light system was connected perfectly in Zwickau, the SAS employees responsible for
the plant in Saarlouis now are convinced of this process optimization and shortly the system is going to
minimize the error rate during the cockpit assembly
at their location too. N
Competitive advantage:
system approach
SAS decided to use the solution from Turck for various reasons. One of the main requirements was the
automated acknowledgment through a light barrier
or alternative sensors. Turck was not the only provider
that offered this solution, but what convinced the
customer in the end was the fact that the automation
specialist from Mülheim offered a solution and also
provided the needed hardware for the connection
to the production line.
During normal operation, 20 mounting stations
got equipped with the pick-to-light system and a K50
signal light was implemented into all relevant trays of
the mounting stations. A BL20 I/O system, which was
connected over a fieldbus gateway via Modbus TCP
to the line control of SAS, is responsible for the signal
transfer between lights and controls. Only minor adaptations regarding the software were necessary.
On the way to standard
The SAS plant in Cologne has been using the pick-to
light-system for five years now without any problems.
As a result, the people in Zwickau knew that the system would blend in perfectly with the utilized line con-
The light signal marks the box with the component
that is next to install
Discover
the new
website
s
www.ien.eu
26 A P P L I C AT I O N S _ S E N S O R / F I E L D B U S T E C H N O LO G Y
Author
Jay Silverberg is a
sales represetative
for Mtech, the Turck
Inc representative
in Minneapolis
Webcode | more21154e
Turck solutions are
used to retract
the scoreboard
at the Dallas
Cowboys stadium
User www.uni-systems.com Integrator www.powermation.com
Open Air Stadiums
Uni-Systems utilizes Turck solutions to bring the outdoors in to structures
around the world
W
hat do drawbridges and retractable stadium
roofs have in common? They are both examples of a trend called “Kinetic Architecture”.
While it wasn’t called a trend in the times of drawbridges, today the combination of functionality and form is
based on this trend. Kinetic architecture is construction
that reacts to changing environmental conditions and
requirements by changing architectural form. A sta-
dium roof can be opened or closed, theater buildings
can set up to accommodate different audience sizes
and performing acts, or whole buildings can be aligned
according to the position of the sun.
Uni-Systems is an industry leading designer of
kinetic architecture, having designed and developed
moving structures for applications in aerospace, military, construction, entertainment, and sports. The
27
University of Phoenix stadium’s entire playing field is retractable
company has designed, fabricated and installed the
mechanization components for five of the last seven
retractable sports-stadium roofs built in North America. Minneapolis based Uni-Systems works closely with
designers and architects around the world to produce cutting-edge structures that push the boundaries of traditional engineering. Their projects include
the Lucas Oil Stadium in Indianapolis, the University
of Phoenix Stadium in Arizona, Minute Maid Park Stadium in Houston and the Cowboys Stadium in Dallas,
just to name a few.
When it comes to architectural innovation, UniSystems is not limited to retractable roofs; the University of Phoenix Stadiums entire playing field is retractable. Other stadiums boast “home-run” features like a
steam locomotive that whistles through Minute Maid
Park, a retractable pitcher’s mound at RFK Stadium,
and an apple that rises out of Citi Field’s center field
to celebrate a New York Mets home run. Uni-Systems
also designed the system that retracts the enormous
scoreboard in the Cowboys Stadium so that it can
serve its original purpose during football games, along
with doubling as a backdrop for concerts that take
place off-season.
Transitioning a vision into an actual structure is a
complex and dynamic process. Each roof mechanization system that Uni-Systems designs includes a specific number of roof panels attached to rails that, together,
create the entire roof structure. If the roof is sloped, a
cable drum or rack and pinion system may be used to
retract the roof panels, while a traction drive is typically
used on a flat surface. Aside from the mechanical challenges of moving and controlling multi-ton structures,
there is the control aspect that must incorporate simplicity, reliability, safety and redundancy. Uni-Systems
specifies industrial controls of the highest quality into
its designs, including those from Turck.
more @
2_2011
A complex process
A Uni-Systems’ roof mechanization project typically
involves several different motor control applications.
In addition to moving the roof, motors are also used
in jack screws to open and close rail clamps that lock
the roof firmly onto the drive rails. Turck proximity sensors are placed at each end of each jack screw’s travel
to ensure that the travel is complete and the clamp is
holding, as well as to protect the motor and gear reducer from damage caused by over travel. On the Lucas Oil
Stadium project, small lift doors were placed at the end
of each of the ten drive rails (five per roof panel). These
doors were also operated by electrical jack screws,
monitored by Turck proximity sensors.
In addition to auxiliary roof systems, the primary
motion is also monitored by Turck sensors. One proximity sensor per rail signaled the motor VFDs (variable
frequency drives) to slow the motors down at the fully
open and fully closed position. At the same time, the
sensor provided the roof’s PLC with a fixed reference
point. This is used to check the validity of the encoder position provided by the Kübler by Turck absolute
encoder, which provides a precise location for each
roof transporter (wheel and motor assembly).

 Quick read
The US company Uni-Systems, a specialist for kinetic
architecture, relies on sensor, fieldbus and connection
technology from Turck when it comes to solutions for
retractable stadium roofs and many other objects like
XXL video cubes. The solutions from Turck make sure
that the large structures can be precisely and safely
moved and controlled.
“
Powermation
always provides
extremely good
service, and Turck
stands behind
its products if
something goes
wrong.
„
Lennart Nielsen,
Uni-Systems
28 A P P L I C AT I O N S _ S E N S O R / F I E L D B U S T E C H N O LO G Y
IP20-rated distributed I/O systems collect all of the signals from a local area
Installation and
maintenance is fast
and simple with
plug-and-play cordsets
Cordsets connect
everything from
proximity sensor and
encoders to motors
and brakes
Custom-molded Turck
motor cables for
VFD-controlled motors
On projects using cable drums, such as the Lucas Oil Stadium and University of Phoenix Stadium projects, there
are two measuring applications: one to measure the
roof’s actual position and a second to measure the cable
paid out by an individual cable drum. Depending on the
roof construction and degree of slope, many drums may
be used, and it is extremely important to know that all
drums are working together and paying out at the same
rate. Uni-Systems typically uses Kübler by Turck incremental encoders to measure the progress of the cable while
using absolute encoders to measure the roof position.
The reasons for this difference are the small inaccuracies
in cable payout measurements caused by temperatureinduced cable stretch as well as long-term cable stretch.
This requires the encoders to be reset periodically, which
is simpler with incremental encoders, and the position can
always be confirmed by the main absolute encoders.
In applications such as the Cowboys scoreboard project, there is no feedback from any other source, so absolute encoders are deployed on all of the 24 cable drums
holding the scoreboard. On the main 16 lifting drums
there is one encoder per drum, since adjacent cables take
the same path as long as the VFDs report equal load. Two
absolute encoders are used to verify the position of the
eight stay drums that control two cables per corner of the
board all radiating out in different directions.
Diagnostics make maintenance simpler
All of the signals from these devices must be brought
over the large geography of a stadium back to the main
controlling PLC for processing. To make design, construction and maintenance simpler and less expensive, these
systems are designed with many smaller motor control
“cells” where typically four to eight motors are controlled
from each motor control center. Uni-Systems uses Profibus as the preferred network to transmit the signals and
Turck BL20, IP20-rated distributed rack I/O systems to collect all of the signals from a local area. In some installations, Uni-Systems use Namur input modules and Namur
rated Turck proximity sensors to take advantage of the
detailed point-level diagnostics (open-wire and shorted
wire) these BL20 modules offer. “In such widely distributed projects, it is very beneficial to know if a device has
been left unplugged by maintenance personnel, rather
than simply being an open contact,” says Lennart Nielsen,
Electrical Engineering Manager with Uni-Systems.
To make installation and maintenance fast and simple,
Uni-Systems uses plug-and-play pre-molded cordsets from
Turck throughout the projects for connecting everything
from proximity sensors and encoders to motors and brakes.
The motors and brakes are pre-wired with Turck receptacles in their wire boxes, which makes exchanges fast and
simple and removes possibilities for wiring errors. For VFDcontrolled motors, Uni-Systems uses custom-molded Turck
motor cables using VFD-rated shielded cables.
The strong partnership that exists between Uni-Systems and Turck is a direct result of the credence of Turck’s
St. Paul-based distributor, Powermation. According to
Nielsen, “Powermation always provides extremely good
service, and Turck stands behind its products if something goes wrong.” N
30 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
Author
Stefan Kappel
is director key
account management process
automation at
Turck in Mülheim
Webcode | more21155e
In Abu-Qir, 60 DPC49-4RMB diagnostic
power conditioner
systems supply and
monitor the 220
Foundation Fieldbus
segments
User www.abuqir.com Integrator www.uhdeservices.com
Field Transparency
Uhde Services relies on Turck’s Foundation Fieldbus portfolio with diagnostic
functions for the modernization of the fertilizer complex Abu Qir II in Egypt
31
T
he Abu Qir Fertilizers and Chemical Industries
Company (AFC) in Alexandria, Egypt, is one of
the leading manufacturers of nitrogenous fertilizers in Egypt, Africa and the Middle East. The company has more than 3,300 employees and relies on
international standards during production and quality
management, including ISO 9001/2000. To guarantee
environmentally friendly and efficient production, the
plants in Alexandria are continuously being upgraded
and optimized. The use of modern automation solutions for ammonia plants is critical in the fertilizer
industry because it provides increases in production
and energy savings.
“With the Abu-Qir-revamp-project, a large fertilizer plant in North Africa is being converted into an
ultra-modern automation solution for the first time”,
says Dr. Bernd Jordan, Head of Electrical and Instrumentation at Uhde Services. The service provider
Uhde, a fully owned subsidiary of ThyssenKrupp AG,
develops individual concepts for industrial plants
worldwide for modernization and increased production, for maintenance, compliance with environmental standards, and increased cost and performance
efficiency. The focus of Uhde lies with the power plant
technology, mineral oil processing, chemical, as well
as the petrochemical industry.
High requirements
Because of the geographical position of the fertilizer
complex, the Foundation Fieldbus wiring as well as the
Foundation Fieldbus system components must meet
very high standards. The ambient temperature usually
lies between 3° and 45 °C and the surface temperature
can rise up to 75 °C in direct sunlight. A relative humidity of about 85 percent as well as the chemical and the
mechanical demands through urea, ammonium nitrate,
dust and sand complete the profile of requirements.
The revamp-project can be divided into two parts:
Foundation Fieldbus loops for measurements and
process control as well as ESD-loops for fail-safe plant
monitoring. All in all, 350 devices in hazardous classified areas and 1,050 devices in unclassified areas had to
be connected via Foundation Fieldbus, divided into 220
segments – 60 each in the ammonia plant, the nitric
acid plant and the utilities and factory services, plus 40
more for the visualization. After a search for a suitable
solutions partner for the Foundation Fieldbus installations in Abu Qir, the general contractor Uhde Services
and the operator of the plant selected Turck, the sensor,
fieldbus, and interface specialist. “Turck wasn’t just able
to provide us with an extensive Foundation Fieldbus
portfolio, but also with detailed diagnostic functions
that make a new Foundation Fieldbus installation all
the more efficient”, says Markus Mahlandt, Project Engineer E&IC Engineering, Uhde Services.
Universal Foundation Fieldbus Portfolio
To supply and monitor all 220 segments, Turck delivered 60 preconfigured diagnostic-power-conditionersystems (DPC) in control cabinets. The DPC-systems
more @
2_2011
165 eight channel JBBS-49SC-T815 junction boxes from Turck guarantee a
safe connection between the field devices and the DPC-systems
supply FF H1-segments with power and offer comprehensive diagnostic capabilities for monitoring, which
allow a plant-wide asset management. The start-up of
a fieldbus plant is already supported by the DPC-system. During operation, the solution even recognizes
gradual changes within single fieldbus segments over
an extended period of time. So disturbances or failures
that develop slowly can be prevented.
One DPC-system can supply up to 16 segments
redundantly with up to 800 mA output current and 30
VDC output voltage. It consists of one or more DPC-494RMB module racks with up to eight DPC-49-IPS1 power supply modules and one DPC-49-ADU diagnostic

 Quick read
To update their fertilizer production in Alexandria, Egypt, the Abu Qir Fertilizers
and Chemical Industries Company (AFC) assigned the revamping of their existing plants to Uhde Services. In cooperation with Honeywell Process Solutions as
supplier for control systems and physical-layer-specialist Turck, Uhde Services
converted the complex to Foundation Fieldbus, including detailed diagnostic
functions for a comprehensive asset management system.
module. Per module rack, up to four H1-segments can
be operated and monitored redundantly. The diagnostic data from the H1-segments can be transferred via a
FF-HSE-field device DPC-49-HSEFD/24VDC to a higher
level asset-management-application – in this case an
Experion PKS from Honeywell.
165 JBBS junction boxes and 110 multi-barriers
from Turck are responsible for the safe and secure
32 A P P L I C AT I O N S _ F I E L D B U S T E C H N O LO G Y
“
Turck wasn’t just
able to provide us
with an extensive
Foundation Fieldbus
portfolio, but also with
detailed diagnostic
functions that make
a new Foundation
Fieldbus installation
more efficient.
”
Markus Mahlandt,
Uhde Services
connection of the field devices to the DPC-systems
in Abu Qir. The eight channel JBBS junction boxes are
equipped with an adjustable short circuit limit (30, 35,
45 and 60 mA). Common shielding concepts can be
realized with the help of two switches on the circuit
board, and a terminating resistor for the bus can be
switched on. The enclosure is IP67 rated and made of
powder coated aluminum with a breather to prevent
internal condensation. Despite their high ingress protection rating, Turck placed the junction-boxes in additional protective housings to ensure their ability to defy
the harsh ambient conditions.
Multi-barriers MBD49-T415/Ex are applied for connection to field devices in hazardous classified areas.
The multi-barriers increase the maximum number of
fieldbus nodes per segment up to 32. The number of
nodes is extended by the explosion protected fieldbus
supply which can be daisy chained from multi-barrier
to multi-barrier in Zone 1. Each fieldbus node in Zone
0 and Zone 1 is supplied by one of the four intrinsically safe and galvanically isolated outputs of each
multi-barrier. Galvanic isolation exists between the
Because of the special ambient conditions in the ammonia facility, Turck
placed the IP67-fieldbus components into additional protective housings
trunk line and the output circuits as well as between
the four output circuits themselves. For the customer,
the use of multi-barriers has clear cost advantages.
All field devices in a single fieldbus segment can be
operated in the hazardous classified area; there are no
costs for additional bus couplers, or a new segment
card with its integration and parameterization. There
is no need for additional supply wiring as the power
supply of the multi-barriers takes place over the bus
with the support of Turck.
Local support
Even with the complete package from Turck, there
were a few obstacles to overcome at the beginning of
the project, which contained 200 kilometers of fieldbus lines. “It is normal that some problems arise when
it comes to a project of this size”, Dr. Jordan explains.
But ultimately the first two reconstruction phases were
completed on time and to the satisfaction of the operator. Today AFC operates one of the world’s most modern and most efficient fertilizer plants. N
In hazardous areas, multi-barriers MBD49-T415/Ex with
four intrinsically safe and isolated outputs are used
R F I D _ A P P L I C AT I O N S
33
Author
Bert Kinzius is a
sales specialist at
Turck Germany
in Mülheim
Webcode | more21156e
The HF read/write head
reliably reads the RFID
data carrier at the transport boxes, despite the
metal environment
User www.thun.de Integrator www.at-wg.de
Tracking Bearings
Bicycle supplier Thun automates the control and surveillance of their inner
bearings production with the RFID system from Turck
I
f we want to produce results with reliability and
repeatability, we need to implement an automated system with RFID that requires little operator
involvement,“ explains Heinz Ehmann, EDV manager
and controller at Alfred Thun GmbH & Co. KG in Ennepetal. During the 43 years Ehmann has worked for the traditional family company, he witnessed a few attempts
to install a manual batch and production surveillance
system. Because of the high effort of manual solutions
more @
2_2011

 Quick read
Alfred Thun GmbH & Co. KG from Ennepetal is one of
eight manufacturers of bicycle bottom brackets worldwide. With the help of system integrator Weingärtner
Automatisierung and Turcks RFID components Thun
optimized large areas of its production processes and
made them retraceable and transparent.
34 A P P L I C AT I O N S _ R F I D
“
With their broad
portfolio, Turck could
fulfill most of the
requirements, even
though some additional requirements
only arose during the
project. The good
support from Turck
also convinced me.
„
Matthias Weingärtner,
Weingärtner
Automatisierung
this was never a viable option. Today, RFID technology
allows a new opportunity to implement an automated
and transparent production chain and batch surveillance system. With a solution like this, the family could
expand the company, and maintain a leading market
position in all of their product segments.
Thun supplies the bicycle industry worldwide with
inner bearings for city, trekking, children and mountain
bikes. In addition, they provide complete system components for Pedelecs, which are bicycles with electrical auxiliary drives that have become popular. With 60
employees the company provides about one million
inner bearings to the bicycle industry each year. With a
market share of 60 % Thun is one of the market leaders
in Europe in their market segments.
Requirements
In 2009 the company decided to modernize their production chain. The intention was to implement a reliable batch surveillance system over the whole production chain using RFID. The first step in the process
involved the assembly of the bottom brackets being controlled via RFID. The next step was the reception of supplied goods to be recorded by RFID. Last but not least the
refinement and electroplating of shafts and prefabricated
products would be optimized. However, during the process more and more automation options appeared that
would be included in the project.
The first solution considered was UHF due to the
longer range and flexibility. But in the production environment of Thun, the tags with the UHF technology
couldn’t be read reliably due to the metal housings the
data carriers were attached to. Thun decided to use
an alternative solution, which was suggested by the
system integrator Weingärtner Automatisierung from
Oberhausen in Germany. This solution worked with
the RFID system BL ident from Turck. “Mister Weingärtner directly understood our situation and showed vast
experience and a deep knowledge about the details of
implementation. His knowledge convinced us and it
proved to be useful during the process.”
With Turcks BL ident solution, Matthias Weingärtner
found a comprehensive and versatile RFID package that
met all of the projects requirements: “With their broad
portfolio, Turck could fulfill most of the requirements,
even though some additional requirements only arose
during the project. The good support from Turck also
convinced me.”
The RFID system from Turck allows the use of both
UHF and HF components. The first phase used HF
technology which functions at 13,56 MHz. HF reduces
potential disturbances, thus is a reliable and precise
outcome could be reached. Weingärtner and Turck
convinced the customer to use the system and RFID
tags by doing a successful test in electroplating baths.
The high temperatures and the acidic electroplating
environment didn’t harm the IP67 tags. One challenge
was the tuning of the communication between the
fieldbus components which also had to be adapted to
the ERP system Navision.
Registration at goods received
The identification solution at Thun starts when the
goods are received. If the delivery note is equipped
with a data matrix code, the components from the suppliers are scanned. The data gets into the ERP system
and is connected with the UID of the RFID tag to the
corresponding transport box.
All data is collected in a central SQL data base that
is read and written by the Middleware Visam. The registration of the stock can be retrieved on an up to the
minute basis over the ERP system. Here, Thun optimized
the process by letting the supplier keep the stock at a
minimum level. The current stock and the required
quantity can be retrieved from the ERP system via online
access at any time.
The system demonstrates its biggest advantage
through the integration of the RFID surveillance into
the process stages refinement and assembly. On the
way to the finalized bearing, the batch purity has to
be guaranteed at any step in the process. Through the
RFID combined head, the machine knows at any time
Turck’s I/O system
BL67 captures the
RFID and sensor
signals directly at
the machine and
forwards the date
via Modbus TCP
to the controls
The read/write head at the feeding recognizes if the
right batch is supplied to the blasting machine
35
The RFID tags are
attached to the
metal boxes reliably with a spacer
what batch is being processed. A K50 light shows the
employee if the procedure is being carried out correctly or not, and if a red light appears, there is an error.
During implementation, another issue was identified and resolved with the help of Weingärtner: The
blasting plant only had capacity for 80 kilogram of
shafts, and a transport box was double that. In the past,
the weights for the blasting process had to be identified
with a scale and entered manually; today an integrated
scale unit automatically carries out this step. Thanks to
the RFID surveillance, all shafts from one transport box
can easily be assigned to a batch. With an inclination
sensor, the emptying of the box is measured, so it can
be released again automatically for a new filling.
This option is highly valued by Thun because if
a full transport box is reintroduced into the process
it causes a delay. “As much automation as possible,” is
the motto of Ehmann, because “even the most reliable
employee can make a mistake now and then and that
disturbs the automation process.”
emptied correctly. “This process saves a lot of time and
we are even more flexible and reliable now,” Ehmann
says. The data of the combined heads and the inclination sensors are collected directly at the machines with
Turck’s I/O system BL67 and are send with the CoDeSys
programmable fieldbus gateway via Modbus TCP to the
Middleware Visam.
Outlook
The company from Ennepetal is confidant they have
created additional value for their customers through
the surveillance and the traceability of their batches
via RFID because the new transparency allows a more
flexible production without additional costs. Through
automation, Thun also created a competitive advantage, especially if the system is optimizedc ontinously.
The next phase will include the connectivity to other
systems like quality assurance and checking facilities. N
Side effect quality assurance
The next phase involved the automated assembly
machines, which make machine mount bottom brackets. “We have many types of bottom brackets. Previously the employees entered the specific configuration via a display into the machine. Unfortunately this
led to mistakes,” Ehmann describes. Today the order is
entered centrally over the ERP system and forwarded
to the machine directly, then an employee accepts the
order and starts the process. The machine now reads
all relevant data, including the machine settings and
the components, from the data base and programs
the right configuration immediately.
At the feedings of the assembly machines an RFID
head reads the transport boxes tag to ensure that the
right components for the current order are installed.
Turck’s inclination sensors measure if the boxes are
more @
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The inclination sensor at the feeding gives a signal
when the box is emptied
36 A P P L I C AT I O N S _ R F I D
Author
Thomas Reznicek
is chief editor
of the Austrian
trade journal
Austromatisierung
Webcode | more21150e
Truck washing
station by NessSchneider: Only
when there is a successful notification
via RFID chip the door
lock of the hose box
(in the back of the
picture) opens and the
cleaning process
can begin
User www.ness-schneider.at
A Clean Thing
The Austrian wastewater treatment plant designer Ness-Schneider automates washing
stations for animal transporters with the RFID system BL ident from Turck
W
hether ski lift tickets, hotel room keycards
or admission cards in a thermal bath – RFID
is very prevalent in everyday life. The convenient identification technology is also used in more
and more applications in the industrial area. For this
reason, Turck developed a modular system that can be
linked to almost all control systems, independent from
the PLC manufacturer. In one such system, the Austrian
wastewater treatment plant designer Ness-Schneider
uses the new flexible design.
To complete its portfolio of wastewater treatment
solutions for the food industry, the company also offers
washing stations for the cleaning of animal transport
vehicles. The identification of the transporters and
the registration of the exact duration of the cleaning
process takes place automatically via RFID-Key. Only
when the chip is recognized as “legitimate” the system
enables control of the water pump.
The company Ness-Schneider, located in Vienna
and Grünau/Austria, has been founded 1994. Originally
it was a trading company for wastewater treatment
components but over the years it developed into a producer as well. In 2004 the company was taken over by
NTA, New Technology Anlagenbau, a plant manufacturer that specializes in the food industry. Since then the
business is privately owned by the Steinmaurer family.
37
Today Ness-Schneider is a research orientated company
and offers plants for drinking water supply, environmental compact systems and components for the cleaning
of industrial wastewater.
The customers are mainly from the food industry.
“We offer the whole range of wastewater treatment
plant design – from biological process technology to
project management, development and construction,
the actual machine- and plant design up to the installation and start-up onsite. During the process we act
as general contractors. Only for building processes, like
concrete work, do we hire a partner, but everything else
comes from us,” managing partner Walter Steinmaurer
explains, and emphasizes, “we rarely build wastewater
treatment plants for communities – we are more specialized on industrial wastewater.”
Robust ID system wanted
It is our daily business to fulfill individual customer
requests. This often results into solutions that are later
more @
2_2011

 Quick read
To run his washing stations for animal transporters fully automated, the Austrian
plant designer Ness-Schneider uses Turcks RFID system BL ident. After the authorization with a RFID tag, the robust ID solution allows the driver to use the high
pressure washing station and reliably registers water consumption, use of cleaning agents and duration.
included into our standard portfolio. “We often face
applications where it would make sense to take over
identification tasks as well,” Steinmaurer says. “That is
why we were looking for a suitable identification system, that is already offered as a matured solution and
that is being expanded as well. After all we strive for
good and long lasting partnerships with our suppliers.”
The company finally found Turck. For many years
the plant designer had purchased various components
for measuring and control technology from the automation specialist located in Mülheim. After an intense
38 A P P L I C AT I O N S _ R F I D
“
We deliver our
plants worldwide, so
we have to be very
flexible regarding
the used control
hardware. The Turck
system can be connected to numerous
controls of different
manufacturers
without problems,
either over a
standard fieldbus
or via Ethernet.
„
Walter Steinmaurer,
Ness-Schneider
testing phase, Turcks modular RFID system BL ident
proved to be perfect and met all of the requested
requirements. The first project that was installed with
the Turck system was an important upgrade of the
functionality of the animal transporter washing stations
for slaughterhouses, developed by Ness-Schneider.
According to the EU hygiene directive the transport
vehicles have to be cleaned immediately after the discharge of the animals and the accruing wastewater has
to go into the wastewater treatment plant directly.
A cleaning facility has to be provided by the operators of the slaughterhouses, although they are not provided free of charge. To be able to operate the washing station onsite without staff, the engineers of NessSchneider developed an elaborate self-service concept
of their high pressure cleaning unit using RFID technology from Turck. The solution uses a RFID tag, which is
as small as a coin. Each driver loads a time credit onto
the data carrier. If the RFID tag is placed in front of the
combined read/write head of the control station, the
identification starts.
“All the data from the tag is read automatically,
for example the name of the driver and the transport
company, the number plate and any additional data.
The system software checks if the owner is authorized
to use the washing station and if there is still enough
credit available,” Steinmaurer describes. If everything
fits, the lock on the door of the hose box opens; the
driver can take the cleaning gun and start the cleaning
process. Water consumption, use of cleaning agents
and duration are registered. Afterwards, the hose has
to be rolled up again and the door needs to be locked.
Only then the driver can place the tag in front of the
read/write head again to end the process, reverse any
remaining credits and sign off.
Industry compatible outdoor solution
It was more than one benefit of the RFID system from
Turck that made the decision for Walter Steinmaurer.
The driver places
the RFID tag in
front of the read/
write head, which
reads all the relevant data and
forwards it to the
control systems
With its robust design, Turck’s BL ident system is
very suitable for outdoor use
The robust design of the components, the fact they are
available in IP20 and IP67, as well as the temperature
range of -25 to +85 °C, guarantee outdoor use and is
industry compatible. In addition, the diverse FRAM data
carriers (tags) are available in different sizes and designs,
the elaborate modular system offers fully encapsulated
heads, that are available in protection category IP69K,
RFID I/O modules and gateways as well as the fitting
connection technology.
“For us the openness with all kinds of controls was
especially important. We deliver our plants worldwide
and therefore have to be very flexible regarding the
control hardware. At the moment we are using four
different SPS systems,” Steinmaurer explains. “The Turck
system can be connected to all four controls without
problems, either over a standard fieldbus or via Ethernet. It can be upgraded anytime.” The gateways are programmable with CoDeSys and turn into decentralized
controls.
The software integration into the system of NessSchneider was no problem because of the open interfaces. “I am highly satisfied,” Steinmaurer praises. “The
solution from Turck works perfectly. We have also had
very good support from Alfred Fröstl, sales manager of
Turck in Upper Austria. We have found the reliable partner that we have been looking for. The implementation
into our system was done in only a few days and we
invested less than 100 working hours.”
Not only because of his positive experiences with
Turck, the company director is already thinking about
other applications for the Turck RFID system. “For example, the milk delivery to dairies, where documented and
traceable proof of the tank truck cleaning is needed,”
Walter Steinmaurer finally admits. N
40 A P P L I C AT I O N S _ R F I D
Transparency Enhancer
RFID system BL ident guarantees efficiency during the production of sodium glutamate
N
owadays RFID is widely applied in industrial
production as well as in logistics and warehouse management all over the world. Chinese companies are using this technology to create
more transparent and efficient processes. This was the
reason that a significant Chinese company in the food
industry applied RFID technology to the raw material
processing, production, storage and transportation to
trace materials and improve production efficiency.
Requirements of the customer
The company produces sodium glutamate with the
most advanced processes and technologies. The flavor enhancer is called “Gourmet Powder” in China. The
food producer emphasizes modern and reliable but
also cost-saving technology in their warehouse management. More precisely: they wanted to implement a
real-time material management system that allowed
the tracing and control of the raw material transfers via
RFID technology. The system has to evaluate the information from the warehouse data list and assign the
single pallets to material stocks. Then the data is written
by a combined read/write head via RFID onto the data
carrier that is attached to the pallet.
Next, the PLC automatically assigns warehouse
areas to the pallets and guides the forklift to store the
materials at the corresponding locations. The forklift,
which is also equipped with a combined read/write
head, saves the location and the product information
from the data carrier in the central system.
To guarantee a high availability, the system is
operated with redundancy built in for central and
decentralized data. For the outbounding process, the
First-In-First-Out (FIFO) principle applies. The system
automatically guides the forklift to carry the materials
to the corresponding production lines according to
the production tasks. During the transport, the read/
Author
Qiang Lin
operates the
market and
technology
department at
Turck in China
Webcode | more21151e
The Chinese food producer uses Turcks RFID
system for the control
and the tracing of the
whole material flow
Each pallet is equipped
with a resistant RFID
data carrier at the middle
bridge
41
write head at the forklift checks the data carrier on the
pallet to determine if the material is really required. If
there is an error during warehousing, outbounding
or carrying materials to the production line, the system gives an alarm and automatically indicates what
measures need to be taken to restore the system.
The pallets are recycled during the whole warehouse
management process.
Digitalized pallets
The RFID tags are already integrated into the pallets.
Compared to the traditional pallets with bar codes,
the digitized pallets make it easy to implement a precise digital management for large quantities of goods.
The workers do not need to print lots of bar codes in
advance, stick them onto the pallets and scan them
with a bar code gun. For the tagged pallets all this takes
place during one read/write procedure.
The RFID tags can also be applied in harsh environments. This is because scratches and stains on their surfaces don’t affect them as they affect a bar code. Tags
are recyclable and can be used during rain as well – contrary to common barcodes. Additionally the specific tag
UID improves the precision of the material tracing.
The production of sodium glutamate takes place
under humid production conditions. The powdery
raw materials are stored separately from the production because they need a dry environment. The system has to be able to work perfectly in dry and dusty
conditions as well as in a humid environment. That is
the reason the company uses Turcks BL67 fieldbus
gateways with the RFID module BL ident in IP67. It is
attached to the forklift and, due to its IP67 rating, it is
able to operate in both environmental conditions. As
tradition in the food industry, tags in IP68 are needed because raw materials come into direct contact
with the pallets. A BL ident read/write head that is
attached to the forklift allows reading and writing to
occur during transport.
Wireless forklift connection
The biggest challenge of this project was the connection of the gateways at the forklifts to the controls.
Since the forklifts move around it was impossible to
connect them with cables. After several discussions
and experiments, Turck suggested a wireless Ethernet
network that allowed the communication between
the programmable gateways and the control level. This
solution met the requirement of the customer to implement a real-time management for the whole logistics
of the production system and the life-cycle management of the products.
The technical department of Turck (Tianjin) Sensor
Co. Ltd was the system integrator of the project. Project leader Li Jiaxuan summarizes the advantages of BL
ident: “The shape of the read/write head from Turck is
identical to that of the proximity switch, which makes
them flexible to use and easy to install. In addition,
the tags can be read and written to a capacity of 200
bytes while driving by and the 0 to 200 mm read/write
more @
2_2011
The read/write head at the forklift collects the data of the pallet and
forwards it wireless over the BL67 I/O system to the PLC
distance absolutely meets our requirements. Together
with the prefabricated connection cables of 50 meter
length, Turck was able to provide a robust RFID package, which guarantees a reliable data transfer even
under harsh environmental conditions. Furthermore
the wireless network could be implemented with few
gateways and network nodes without any problems.” N

 Quick read
Storage and production environments of sodium glutamate have to meet different requirements. Turck’s RFID system BL ident can be used optimally in
both environments, the dry one at the warehouse and the humid one during the production process. This guarantees transparency during the whole
production and logistics chain, from storage and outsourcing of the raw
materials, over the production process up to the storage of the finalized
sodium glutamate powder.
42 S E R V I C E _ CO N TA C T
Turck at Trade Shows
At numerous national and international trade shows, Turck will introduce you
to current product innovations and reliable solutions for plant and process
automation. Be our guest and see for yourself.
Date
Trade Show
City, Country
25.01. – 27.01.2012
28.02. – 03.03.2012
13.03. – 15.03.2012
13.03. – 16.03.2012
20.03. – 23.03.2012
22.03. – 23.03.2012
29.03. – 01.04.2012
18.04. – 19.04.2012
23.04. – 27.04.2012
14.05. – 18.05.2012
22.05. – 24.05.2012
04.06. – 07.06.2012
18.06. – 22.06.2012
24.06. – 26.06.2012
26.06. – 29.06.2012
09.10. – 12.10.2012
09.10. – 12.10.2012
06.11. – 08.11.2012
27.11. – 29.11.2012
IFAM
Ipack IMA
Electron
Automation-Electronics
Amper
Automaticon
WIN 2
ISA
Hannover Messe
Technical Fair (UFI)
SPS/IPC/Drives Italia
Eliaden
Achema
DCS
Expo Pack
Vienna-Tec
EloSys
ISA
SPS/IPC/Drives
Celje, Slovenia
Milano, Italy
Prague, Czech Republic
Minsk, Belarus
Brno, Czech Republic
Warsaw, Poland
Istanbul, Turkey
Edmonton, Canada
Hanover, Germany
Belgrade, Serbia
Parma, Italy
Lillestrøm, Norway
Frankfurt, Germany
Miskolc-Lillafüred, Hungary
Mexico City, Mexico
Vienna, Austria
Trencin, Slovakia
São Paulo , Brazil
Nuremberg, Germany
 Full Text Search – Are you looking for a
product name, a known identification number
or a special feature? Then simply enter it in the
above left search field.
 Hierarchical Structure – Are you looking for
products from a certain group, such as inductive
sensors in cylindrical design? Then click through
the menu structure on the left.
 CAD Data – Simply generate the data
record that you need in our product data
database on the Internet – you can choose
from between 80 export formats in 2D
and 3D. This service is absolutely free, reg
registration is also not required.
 Power Search – Are you looking for a product that meets very specific technical parameters? Then use the feature search that specifically
leads to your solution.
Turck on the Internet
Whether sensor, fieldbus, interface or connection technology, HMI/PLC or RFID, in
the product database on www.turck.com you will find the right solution to your needs
at the touch of a button. Three search functions will help you.
43
Turck on Site
With 27 subsidiaries and numerous branch offices, Turck is always nearby,
anywhere in the world. This guarantees fast contact to your Turck partners and
direct support on site.
GERMANY
Headquarters HANS TURCK GmbH & Co. KG
Witzlebenstraße 7 ı Mülheim an der Ruhr ı (+ 49) (0) 208 4952-0 ı [email protected]
www.turck.com
Imprint
Publisher
Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
Tel. +49 (0)208 4952-0
[email protected]
www.turck.com
Editorial Staff
Klaus Albers (verantwortlich)
[email protected]
Simon Dames
[email protected]
Paul Gilbertson
[email protected]
Contributors to this issue
Markus Bregulla, Lars Franke, Andrea Gillhuber,
Stefan Kappel, Bert Kinzius, Qiang Lin, Evelyn Märtin,
Thomas Reznicek, Raphael Scholzen, Jay Silverberg
Art Direction / Graphic Design
Arno Kraemer, Britta Fehr (Art design)
Printing
Medienhaus Ortmeier, Saerbeck, Germany
All rights reserved. We reserve the right to make technical changes or correct errors. Reprint and electronic
processing permitted with written approval from the
publisher.

 Webcodemore21180e
more @
2_2011
LARGENTINA ı Aumecon S.A.
(+54) (11) 47561251 ı [email protected]
AUSTRALIA ı TURCK Australia Pty. Ltd.
(+61) (0) 395609066 ı [email protected]
AUSTRIA ı TURCK GmbH
(+43) (1) 4861587 ı [email protected]
LBAHRAIN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
BELARUS ı FEK Company
(+375) (17) 2102189 ı [email protected]
BELGIUM ı Multiprox N. V. (TURCK)
(+32) (53) 766566 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]
CHINA ı TURCK (Tianjin) Sensor Co. Ltd.
(+86) (22) 83988188 ı [email protected]
COLOMBIA ı Dakora S.A.S.
(+57) (1) 8611888 ı [email protected]
COSTA RICA ı TURCK USA
(+1) (763) 5539224 ı [email protected]
CROATIA ı Tipteh Zagreb d.o.o.
(+385) (1) 3816574 ı [email protected]
CYPRUS ı AGF Trading & Engineering Ltd.
(+357) (22) 313900 ı [email protected]
CZECH REPUBLIC ı TURCK s.r.o.
(+420) 495 518 766 ı [email protected]
LDENMARK ı Hans Folsgaard A/S
(+45) (43) 208600 ı [email protected]
LECUADOR ı Bracero & Bracero Ingenieros
(+593) (9) 7707610 ı [email protected]
EL SALVADOR ı Elektro S.A. de C.V.
(+502) 7952-5640 ı [email protected]
ESTONIA ı Osauhing “System Test”
(+37) (2) 6405423 ı [email protected]
EGYPT ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LFINLAND ı Oy E. Sarlin AB
(+358) (9) 504441 ı [email protected]
FRANCE ı TURCK BANNER S.A.S.
(+33) (1) 60436070 ı [email protected]
GREECE ı Athanassios Greg. Manias
(+30) (210) 9349903 ı [email protected]
LGREAT BRITAIN ı TURCK BANNER LIMITED
(+44) (1268) 578888 ı [email protected]
GUATEMALA ı Prysa
(+502) 2268-2800 ı [email protected]
HONDURAS ı TURCK USA
(+1) (763) 5539224 ı [email protected]
LHONG KONG ı Hilford Trading Ltd.
(+852) 26245956 ı [email protected]
HUNGARY ı TURCK Hungary Kft.
(+36) (1) 4770740 ı [email protected]
LICELAND ı Km Stal HF
(+352) 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]
ITALY ı TURCK BANNER S.R.L.
(+39) (02) 90364291 ı [email protected]
LJAPAN ı TURCK Japan Office
(+81) (3) 54722820 ı [email protected]
J ORDAN ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LKOREA (SOUTH) ı TURCK Korea Co. Ltd.
(+82) (31) 5004555 ı [email protected]
KUWAIT ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LLATVIA ı Will Sensors
(+37) (1) 7545217 ı [email protected]
LEBANON ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LIBYA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LITHUANIA ı Hidroteka
(+370) (37) 352195 ı [email protected]
LUXEMBOURG ı Sogel S.A.
(+352) 4005051 ı [email protected]
LMALAYSIA ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
MACEDONIA ı Tipteh d.o.o. Skopje
(+389) 70399474 ı [email protected]
MEXICO ı TURCK Mexico S. DE R.L. DE C.V.
(+52) 844 4116650 ı [email protected]
LNEW ZEALAND ı CSE-W Arthur Fisher Ltd.
(+64) (9) 2713810 ı [email protected]
NETHERLANDS ı TURCK B. V.
(+31) (38) 4227750 ı [email protected]
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]
LPANAMA ı TURCK USA
(+1) (763) 5539224 ı [email protected]
PERU ı NPI Peru S.A.C.
(+51) (1) 2731166 ı [email protected]
PHILIPPINES ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
POLAND ı TURCK sp.z o.o.
(+48) (77) 4434800 ı [email protected]
PORTUGAL ı Bresimar Automação S.A.
(+351) 234303320 ı [email protected]
PUERTO RICO ı TURCK USA
(+1) (763) 5539224 ı [email protected]
LQATAR ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LROMANIA ı TURCK Automation Romania SRL
(+40) (21) 2300279 ı [email protected]
RUSSIA ı O.O.O. TURCK Rus
(+7) ( 495) 2342661 ı [email protected]
LSAUDI-ARABIA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
SERBIA AND MONTENEGRO ı Tipteh d.o.o. Beograd
(+381) (11) 3131057 ı [email protected]
SINGAPORE ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
SLOVAKIA ı Marpex s.r.o.
(+421) (42) 4440010 ı [email protected]
SLOWENIA ı Tipteh d.o.o.
(+386) (1) 2005150 ı [email protected]
SPAIN ı Elion S.A.
(+34) 932982000 ı [email protected]
SOUTH AFRICA ı R.E.T. Automation Controls (Pty.) Ltd.
(+27) (11) 4532468 ı [email protected]
SWEDEN ı TURCK Office Sweden
(+46) (31) 471605 ı [email protected]
SWITZERLAND ı Bachofen AG
(+41) (44) 9441111 ı [email protected]
SYRIA ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
LTAIWAN ı Taiwan R.O.C. E-Sensors & Automation Int‘l Corp.
(+886) (7) 7220371 ı [email protected]
THAILAND ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
TURKEY ı TURCK Otomasyon Tic. Ltd. Ști.
(+90) (216) 5722177 ı [email protected]
Ukraine ı SKIF Control Ltd.
(+380) (44) 5685237 ı [email protected]
LUNITED ARAB EMIRATES ı TURCK Middle East S.P.C.
(+973) 13 638288 ı [email protected]
URUGUAY ı Dreghal S.A.
(+598) (2) 9031616 ı [email protected]
USA ı TURCK Inc.
(+1) (763) 553-7300 ı [email protected]
LVENEZUELA ı CADECI C.A.
(+58) (241) 8345667 ı [email protected]
VIETNAM ı TURCK Singapore Pte. Ltd.
(+65) 65628716 ı [email protected]
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48 F i d u c i a s o p
Witzlebenstraße 7
45472 Mülheim an der Ruhr, Germany
[email protected] | www.turck.com
*D900901 1111*
D900901 1111
Hans Turck GmbH & Co. KG
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