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Issue 02
2007
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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
Solutions with
Added Value
Turck customers benefit from a broad product portfolio,
application know-how and individual consultation
Integration
Expanded I/O system BL20
optimizes factory and process automation
Page 32
Identification
RFID system BL ident
ensures transparency and
traceability
Page 27
Combination
BL67 routes I/O and HF
signals in ultrasound welding
systems
Page 18
02
EDITORIAL_CHRISTIAN WOLF
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Are you familiar with Turck?
Do you primarily view Turck as a sensor provider? I am
pleased that in this issue of our customer magazine
[email protected], we are able to more accurately present
the company and its positioning. In the cover story, we
will show you why Turck has long been much more than
a component supplier and how you as a customer benefit
from it.
When it comes to “me too” products with which suppliers are only distinguished from one another due to price,
neither manufacturer nor customer is happy. Continuously
driving the costs down, results in a loss of quality. You do
not want that, we do not want that. Turck therefore uses
its excellent location advantage and develops and produces
in Germany where the majority of our customers also develop
and produce. That is how – working in close collaboration with
you, our customer – solutions with added value are developed,
which originate from the impressive offerings of more than
13,000 products in the areas of sensor, fieldbus, interface and
connection technology for factory and process automation, as
well as from customized products designed specifically for your
application. The problem of understanding the customer means
transforming yourself from sales person to consultant and solving the entire application issue.
The fact that Turck is on the right path with its transformation
from component supplier to solution supplier is also evident in
our growth figures. For the sixth time in a row, the family-owned
and operated company recorded double-digit growth. We are
expecting a revenue of about 330 million euro at the end of this
year. Read more in the coming pages. You can look forward
to an interesting mix of current product presentations, exciting
trend and application reports and much more from Turck with
[email protected]
I hope you enjoy your reading and that the information provided
adds value to your daily work.
Warmest regards,
Christian Wolf, Vice President Marketing
CONTENT
CONTENT_2_2007
NEWS
Turck Expects Double-Digit Growth
Block I/Os for Profinet Realtime Communication
M12 Quick Plug-In
Factor 1 Sensor with Rotating Housing
New Interface Modules
uprox+-Sensor with Terminal Chamber Connection
First 2 Wire DC Sensors without Reduction Factor
New Magnetic Field Sensors for Pneumatic Cylinder
04
04
05
05
06
06
07
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FRIMO uses Turck’s I/O system BL67 also for transmitting high frequency signals
Page 18
COVER STORY
SOLUTION COMPETENCY: Solutions with Added Value
08
For the first time, the interplay between a broad product portfolio with practiceoriented application knowledge leads to customer solutions with added value
INSIDE
FOCUS ON PACKAGING: “Partnership with our customers” 12
IEE Editor-in-Chief Frank Nolte spoke with Dr. Bernhard Grimm about Turck's
commitment to the food and packaging industry
ESCHA: Loving Connectors
38
Whether a standard design or a special production – Escha supplies
more than just the Turck Group with innovative connectors and housings
TREND
FDT/DTM: Transparent Production
14
Standardized FDT/DTM technology guarantees simple integration – from
configuration through diagnosis to documentation
Our customer Basell places its trust in the all-around
galvanic separation of Turck multibarriers Page 24
APPLICATIONS
FIELDBUS / SENSOR TECHNOLOGY: Routing Station
18
The Turck I/O System BL67 processes signals on the FRIMO ultrasonic welding
systems – including high-frequency
FIELDBUS / SENSOR TECHNOLOGY: Targeted Packaging 22
Turck BL67 and Banner Pick-to-Light systems ensure error-free
boiler production at the Netherlands Bosch subsidiary Nefit
FIELDBUS TECHNOLOGY: Flexibility thanks to the Fieldbus 24
Turck power conditioners and multibarriers ensure plant operation at the
Frankfurt-Hoechst Basell plant
RFID: The Direct Perspective
27
RFID system ensure transparency and traceability in the manufacture of
consumable materials
CONNECTION TECHNOLOGY: Plug & Play Cabling
30
Within the Turck Group, Escha is a specialist for
innovative connection technology
Page 38
Turck I/O modules and quick disconnect cables support modular
machine concept from Automatic Feed
TECHNOLOGY
I/O SYSTEM BL20: The Integrator
32
Turck extends its IP20 I/O system BL20 with new modules for use in
factory and process automation
BASICS: Functional Principles of Flow Rate Sensors
36
Part 2 of our basic series: Design, functional principles and
mounting options of the most important sensor technologies
SERVICE
CONTACT: The Fast Lane to Turck
42
Whether on the Internet, at trade fairs or directly on site,
we will show you how, when and where Turck is there for you
CONTACT: Imprint
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03
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N E W S _ I N N O VAT I O N S
RFID System Enhanced
Double-Digit
Growth
 Once again Turck is forecasting double-digit sales growth for
the 2007 fiscal year. As Management Board member Christian Wolf
announced during a press conference in Düsseldorf, the company
is expecting a 12 percent increase
in Group revenue totaling 330 million euros by the end of the year.
The number of employees at all 25
Turck Group locations rose 5 percent in 2007 to 2,600 worldwide.
In Germany, the family-owned and
operated company with offices
in Mülheim, Halver, and Beierfeld
combined has 1,350 employees
– among them 65 trainees – almost
5 percent more trainees than last
year. According to Wolf, the reasons
for success include Germany as a
development and production location as well as Switzerland, having
numerous independent subsidiaries
in the world’s top-selling markets
and a product and solution portfolio
that is developed in close collaboration with customers and users.
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Info
You can find more information
on the reports or product presentations 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.
 Turck will introduce additional enhancements to its high temperature RFID system, BL ident. In addition to a new handheld reader,
similar to a PDA, the company is now offering a write-read head
which provides an enormous range of up to 500 mm for industrial
applications. The PDA Reader is an inexpensive solution and
suitable for use in maintenance and service applications.
As the only handheld device of its kind on the market,
the Turck Reader can process Philips-I-CodeSL2(SLI)- and RAM data carriers.
The new 500 mm write-read head combines an antenna and electronics into one
device which makes it particularly insensitive to electromagnetic interference.
The compact, flat design (350 x 350 x
25 mm) and IP67 degree of protection
allows it to be used in numerous industrial application fields. This means
that the write-read head is ideal for
any situation where large tolerances
emerge in the overrun position or
particularly high write-read distances are required.
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Block I/Os for Profinet
 With the FXEN, Turck has introduced Block I/Os for Profinet in
IP67 degree of protection. Thanks to the integrated Autocrossing Ethernet switches, the modules allow for the set up of a line
topology and thus offer greater flexibility with planning and installation.
The FXEN supports Profinet-Real-Time (RT)
communication for the cyclical exchange of
I/O data. The XSG16 version has 16 digital
channels that can be configured as an input,
output or inverted input, depending on the
application requirements. The new Block
I/Os support configuration and parameterizing with the help of the open FDT/DTM
standard. A 4-pin, D-coded M12 rounded
plug-in connector is used to connect the
vibration and shock-tested modules to the
Ethernet, eight 5-pin M12 connectors are
available for the I/Os. The modules function
in the temperature range of 0 to 55 °C.
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Director of
Fieldbus/System
Technology
M12 Quick Connection
 Turck will be showing a practical concept for M12 quick connection technology at the SPS/IPC/DRIVES trade show in Nuremberg. The M12 quick plug-in
connector is compatible with all M12 threads, even badly diecast threads are not a
problem. The connector is assembled 85 percent faster than a comparable M12x1
plug-in connector and is the fastest connection coupling on the market. The quick
plug-in connector developed by Escha Anschlusstechnik – a Turck Group company – meets IP67 degree of protection. The “Key Way Display” gives the user clear
acknowledgement concerning interlocking. Together with the high holding forces
of the plug-in connector and integrated overmolding, high plug-in reliability for the
connection is guaranteed. While the coupling is already available as a 4 or 5-pin
model or in a straight or angled type, the plug-in connector versions will follow at
the beginning of 2008.
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 Norbert Gemmeke has been
appointed Director of the Fieldbus/
System Technology and Factory
Automation Business Division at
Turck. In his new position, the 45-year
old is responsible for all development
and product management activities
in his division. Gemmeke will continue his previous
duties as President
of MT ElectroniX
GmbH, a joint venture between Turck
and Micro Innovation.
“For Turck, the Fieldbus/System Technology Business Division ensures the con- Norbert Gemmeke
nection between the
components and the control level,”
explains Gemmeke in describing his
new area of responsibility. “With the
new structure, we are perfectly set up
to be able to offer our customers
optimal solutions for their applications.”
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Factor 1 Sensor
for “Turning”
UK
OD
R
0-P
P1
T
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Awarded for
Excellence
TO
 Turck is expanding its factor 1 sensor family, uprox+, by
adding the new QV40 model. The 40 mm cube inductive sensor that provides IP 68 degree of protection was developed for
rapid, toolless assembly. With a simple “click”, the QV40 can be
manually locked into its mounting or removed. The innovative
housing design also permits a toolless turning of the active surface so that the sensor can be aligned in five directions. Despite
this flexibility, the robust QV40 remains firm in its adjusted
inserted position. The new magnetic field resistant uprox+ QV40
guarantees major time
and cost savings when
it comes to assembly
and service, above all in
areas with high sensor
usage, for example in
conveyor technology.
 For the second time in a row,
Turck was nominated for the Automation Award from the trade publication
elektro Automation. Following the success of the RFID-System BL ident last
year, Turck’s metal sensor impressed
the jury of experts in 2007. As the
first sensor of this type worldwide,
this Turck innovation is not only able
to identify the presence of a metal,
but also its composition – regardless
of the object size and the distance
between the sensor and the object.
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N E W S _ I N N O VAT I O N S
Global Player
 With the three new subsidiaries that Turck founded in 2007, the
German family-owned and operated company decisively highlighted
its claim that it is represented by its
own teams in the most important
markets of the world. In the last two
years, the sensor, fieldbus, connection technology, and
interface specialist
has founded a total
of seven new subsidiaries. Besides Turck
Sweden and Turck
Middle East – both
founded in summer
2007 – Turck AusCameron Dwyer
tralia Pty. Ltd., founded in September
2007, is now the newest addition
to the global Turck family. Cameron
Dwyer is the head of the new Australian subsidiary. The new managing director brings with him a broad
range of industry
experience. Prior
to coming to Turck,
Dwyer was most
recently the sales
and marketing
director of the Australian Turck distributor Micromax.
Thomas Winemar Thomas Winemar
heads up the new
Turck office in Sweden, which was
founded in summer 2007. He is a
mechanical engineer and enjoys
support from Ulf Löfqvist, who
graduated from the technical university in Linköping, Sweden, with
a degree in control
and feedback control systems. Nabil
Nader is the head of
the new Turck subsidiary Turck Middle
East SBC with headquarters in Bahrain.
Nader will focus on
Nabil Nader
the area of process
automation in the
Middle East. The office in Manama
currently has two employees.
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Terminal Chamber
Connection
 The new uprox+ sensors
with an integrated terminal
chamber promise great flexibility with regard to assembly. Because this assembly
type will be mainly used in
the food industry, the first
thing Turck did was to equip
its uprox+ wash-down series
with a terminal chamber. Just
like the sensors that are available in the M12, M18, and M30
(all flush and non-flush) designs, the terminal chamber also
meets the requirements for food-safe materials that are resistant to cleansing agents and high-pressure cleaning. The FDAconforming terminal chamber sensors allow for a straight cable
output or also a 90° angular one. The cable is inserted into the
terminal chamber cover using a standard M16 screw.
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New Interface Modules
 FDT/DTM-based interface modules with display and the Interface Module Small IMS 6.2 mm in width are new members of Turck’s interface portfolio.
The IMS is suitable for galvanic isolation, signal conditioning, and temperature
detection in numerous application areas in process and factory automation. The
IMS program consists of one and two-channel devices for galvanic isolation
without signal conditioning and various models for signal conditioning. After the
IM34 temperature measuring transducer was introduced last year, the following models, IM21 and IM21Ex (speed sensing switch), IM33Ex (measuring transducer – feeding isolator) and IM43 (limit value control
gauge), have now completed the display series. In
addition to a double-spaced transflective
LC display, all modules are equipped
with a circular buffer for comfortable
process diagnosis. A broad voltage range power supply and the
option for HART communication
round off the feature profile.
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2-Wire Sensors
Photo Competition
 As the first supplier of this type of product, Turck
has introduced the 2-conductor DC sensors without
reduction factor. The inductive uprox+ 2-wire sensors are primarily of interest to machine manufacturers that supply to Japan, France, and
the USA because 2-wire sensors are frequently
used in these countries. Furthermore, the new
sensors are ideal for the quick replacement of
mechanical switches on existing machines or
systems because the existing wiring – 2-wire as a
rule – can continue to be used. The first series of Turck
2-wire DC sensors is available in the M12, M18, M30,
and CK40 connector types.
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“Convenient” Solutions
for Pneumatic Cylinders
 Turck is expanding its BIM-UNT
family for the position monitoring of
pneumatic cylinders. BIM-UNT sensors
can detect all magnets in commercially
available pneumatic cylinders without
multiple switching points. With the new
models, Turck customers can meet
their individual target requirements.
Besides the standard model with cable
output, a Namur version is available
for use in the explosion-risk area as
well as models with direct M8/M12
plug-in connection on the housing. A
dual-solution with two sensors on an
M12 plug-in connection considerably
reduces the time and cost expenditure
for cabling. As an inexpensive alternative to magnetic field sensors with reed
contact, Turck is now offering the BIMUNT-AP7X, which may be primarily of
interest to machine manufacturers and
OEMs. At a price level comparable to
the reed contact, the BIM-UNT is wearand bounce-free. The maximum operating current of 50 mA is sufficient for most applications.
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 -The winning photo of the photo competition from [email protected]
1_07 was taken by Benedikt Knüttel
from Elfershausen, Germany. The
ambitious photographer was able to
impress the jury with his photo impression of a paint line.
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Global Director
Oil & Gas
 Ragnar Sach
is the first Global
Director for Oil &
Gas at Turck. In
this newly created
position, Sach,
from the Norwegian
town of Stavanger,
is responsible for
Ragnar Sach
Turck’s involvement
in the petro-chemical industry. Sach has excellent industry knowledge and numerous contacts
in international project business.
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08 C O V E R S T O R Y _ S O L U T I O N - O R I E N T E D
COMPETENCE
Sense it –
Connect it –
Bus it – Solve it:
Turck specialists
find the right solution
for the most
varying customer
requirements
Solutions with Added Value
Turck customers benefit from a broad product portfolio, application know-how and
individual consultation
09
For the Ford plant in Belgium,
Turck developed RFID high-temperature data carriers for reliable
identification up to 210 °C – even
in the furnace
I
Thousands and thousands of
inductive proximity switches from
Turck are ensuring order in the
reverse vending systems manufactured by Wincor Nixdorf
n the increasingly complex world of automation,
optimal solutions have to be increasingly customized to meet the specific application of the
customer. This applies to entire systems as well as
for individual components. Those who do not want
to disappoint their customers will do well to look at
their products and solutions in the context of the
customer’s application.
Whether products with added value such as
uprox+, uniform standards such as FDT/DTM and
IO-Link or complete solution packages like RFID or
Pick-to-Light applications, Turck does not just focus
on individual components, but rather on the optimal
solution to meet customer requirements. This begins
in the company’s original product field – sensor technology. Not until we know what kind of task and in
which environment a sensor is meant to function can
we offer the appropriate solution for the respective
customer. Components from the existing package
are used as are completely new products that were
specially developed for the respective purpose.
For example, a customized sensor solution from
Turck is being used in the cold pilger rolling mills from
In the cold pilger rolling mills
from SMS Meer, the special Turck
eddy current sensor identifies the
material and the diameter of a
tube or pipe
SMS Meer. Jan Asbeck, project engineer in charge
at SMS Meer, is absolutely satisfied with the result
of the close collaboration: “At the beginning, the
sensor did not offer everything we needed, but then
we were able to change that by working together
with the Turck developers. Now we have a solution
whose flexibility is unbeaten and that gives us clear
plus points on the market,” confirms Asbeck.
Knowing the environment
It does not always have to be a customized solution,
even with “catalog products”, process and application know-how is helpful. A good example is temperature sensors: In order to select the right sensor, you
have to know in which environment it will be working,
which temperatures are prevalent, what medium is
supposed to be measured and what kind of features
it has. That is why Turck consults its customers in
selecting the right sensors. Because even with temperature measurement, involvement in the process is
the critical factor. Only in seldom cases is a standard
sensor enough.

 Quick read
Efficient factory and process automation demands solutions that best meet the respective individual
requirements. Turck is therefore offering not only a comprehensive range of automation components,
but also application-specific know-how and the corresponding solution-oriented competence.
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10 C O V E R S T O R Y _ S O L U T I O N - O R I E N T E D
COMPETENCE
Whether system solution or individual product – Turck offers innovations for factory…
“
At the beginning,
the sensor did not
offer everything we
needed, but then
we were able to
change that by working together with the
Turck developers.
Now we have a
solution whose
flexibility is unbeaten
and that gives us
clear plus points on
the market.
”
Jan Asbeck,
SMS Meer
In order to reduce the multitude of variants for
the customer and to simplify operation and maintenance, Turck developed a product that separates
the sensor and the electronics. The result is the
TS400/TS500 family in which the electronics are
housed in a separate casing and varying sensors
can be mounted. This means a standard sensor can
be directly mounted on the M12 interface or via a
standard cable, but an entire range of special cable
or sensor solutions is also possible. Even solutions
with protective tubing into which the measuring element is simply inserted are part of our product palette. This makes it easy to remove the sensor for
replacement or calibration without having to interrupt
the process. And especially because with temperature measurement, many errors are made during
assembly and installation, Turck offers special training sessions which demonstrate how to correctly
...and process automation
install temperature sensors. This, too, is a part of the
complete solution.
New knowledge from system sales
This competence in the field of components is an
important aspect for creating customer benefits.
By adding interface and fieldbus technology to the
product palette, this know-how was almost inescapably expanded due to system competence because
now it means integrating the right sensors into a
company’s world of automation using the right systems.
To this end, Turck has intensified system sales
and further expanded divisions such as pre-sales,
application consulting and support. By doing so,
Turck also benefited from its long-term activity in the
so-called “Emerging Markets” such as in China. Turck
Collaboration with the customer
Compared to other suppliers, Turck understands its task as a
solution supplier is not just selling Turck products and systems,
but finding the optimal solution for the customer, if necessary, even with customer-specific developments or
modifications. In order to highlight this approach,
a separate field service team was assembled
in Germany especially for “customer-specific solution sales”. Holger Spies (l.) and Udo
Branigk (r.) are the first key account managers for OEM sales at Turck. “Our customers
now expect more than the product,” says Udo
Branigk, who has been with Turck for over 30
years. “Frequently, integration into existing
customer applications plays a major role.”
11
With innovative
extrusion coating technology
and customized
cable and plug-in
connector solutions, Turck is the
undisputed market
leader in the USA
has been doing business there since 1994. Because
almost no automation know-how existed there,
Turck emerged as a system integrator in China right
from the start. A great deal of experience was gained
from these activities and it flowed directly into our
product developments and solutions. An example
of this is the programmable Gateway, or a compact
SPS: The development of this fieldbus gateway,
which is available in the IP20 and IP67 degrees of
protection, was originally initiated in China because
that is where a correct control solution had to be
developed. Even now users in countries in which
a mature automation landscape already exists are
benefiting from it. Because when it comes to decentralized automation, Gateway has advantages.
Gateway is programmable in accordance to
IEC 61131-3 with CoDeSys and relieves the higherlevel control system in RFID applications. The functional component necessary for SPS (Proxy Ident
Block) is listed on site in the programmable Gateway.
With the higher-level control system, only the user
data have to be replaced. The overall RFID communication can now be handled decentrally in Gateway.
This gives the customer a simple solution for rapidly
and reliably expanding an RFID system.
Tailored to real-life
The RFID system BL ident is a perfect example of
how the combination of existing know-how and experience gained from working in applications results in
new solutions. During its development, Turck was
able to rely on its experience with the contact-free
detection of objects from the field of inductive sensors. These sensors work with high-frequency fields
just like those in RFID systems. The electronics in
the write-read heads were integrated into the sensor’s existing housing type. Because no new tools
had to be developed to manufacture the housing,
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Turck was able to launch the RFID system on the
market in record time. The customer benefits from
this approach because he can install its RFID heads
with identical accessories and assembly tools also
used for the sensors.
The fact that the application was always the
focus during the development of the RFID system is
also evident in other details. For example, an essential requirement from the automobile industry was
resistance to high temperatures in order to enable
reliable identification even in the furnace. Turck
therefore came up with a solution in which data carriers – or tags – are equipped with a special covering.
It enables them to resist temperatures of up to 210
°C and to be operated in furnaces without any problems. The tag can be reliably described and read out
directly after coming out of the furnace, a cooling
down period is not necessary.
Knowing your target industries
Turck’s success in the automobile industry shows
how important it is to know the requirements and
challenges of its target industries and to meet them
with the suitable solutions. Turck is currently involved
in a new target industry: the food and packaging
industry. To be able to provide this new industry with
the solution-oriented competence, the company
hired a separate industry manager for this market.
His task is to analyze and expand our existing product offerings for the new target industry (read more
about this in the interview on the next page). Here,
too, Turck will rely on existing components and
applied applications in order to enhance them and
continually create new innovations that will give the
customer added value.
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Author
Christian Wolf is
Vice President
Marketing of Hans
Turck GmbH & Co.
KG
12
I N S I D E _ F O C U S PA C K A G I N G
Dr. Bernhard Grimm
intends to establish
for Turck just as
strong a foothold
in the food and
packaging industry as it has in the
automobile industry,
manufacturing and
process automation
“
Technology partnership
with our customers
”
IEE Editor-in-Chief Frank Nolte spoke with industry manager Dr. Bernhard Grimm
about Turck’s commitment to the food and packaging market
Why does a sensor and fieldbus
specialist such as Turck have an
industry manager for the food and
packaging industry?
Because this industry uses field components on a large scale. To be able to offer
customers the ideal solution, we have to
offer the right process know-how. Because
the food and packaging industry is a new
target industry for Turck, my job is to incorporate, together with product management, the technological requirements and
the specific demands of the users into
innovative products and solutions, and in
a way that is product comprehensive.
What products do you intend to
conquer the packaging machine
market with?
Turck has numerous components in its
product portfolio that are ideal for bottling
and packaging machines. A few years
ago, we even began to develop products
made up of FDA-conforming materials
that are hygienic, chemically resistant
and that meet the IP69K degree of protection. These include, among others,
the uprox+ WD (wash-down) inductive
sensors, the F&Bplus plug-in connector as well as the wash-down read-write
heads and data carriers for our RFID high
temperature solution BL ident. All these
products are especially suited for bottling and packaging machines for beverages and liquid foods because popular
cleansing and disinfectant products do
not interfere with their operation. This has
also been verified for us by Ecolab, one
of the leading manufacturers of cleansing
agents.
How do you achieve this high
resistance?
The active area of the uprox+ washdown version and the BL ident read-write
heads is made from a highly resistant
13
plastic called Vectra. Vectra is one of the
best materials for the food and packaging industry, and it does not have to
conceal itself behind stainless steel.At
the same time, these sensors have all
the advantages of uprox+ technology,
such as the very high and, above all, the
same switching distance on all metals
and flexibility during assembly. With the
FBplus (Food and Beverage) plug-in connectors, the sheath and the handle are
made of resistant polypropylene and not
PUR or PVC as is the case with standard
plug-in connectors.
And what about other types of
sensors?
Turck has a great deal to offer here too.
Our partner Banner, which is already very
successful in the packaging industry in
the United States, offers a particularly
water-resistant series of opto-electrical
sensors called EZ Beam as part of its
product portfolio. I should also mention
our comprehensive line of light guides.
Another example is our compact current
sensor – the FCI compact – which is used
to reliably record small currents. We have
adapted it for one customer such that it
perfectly matches its bottling machine
and is unbeatable in terms of cost for this
task.
Are such customized designs the
order of the day in the packaging
market?
No, the majority of our products for the
food and packaging industry is available
ex works as is the standard. This example
illustrates our ability to attract customers
with our solution-oriented competence.
We often sit with our customers and intensively discuss how a certain task can be
optimally achieved. A classic win-win situation: Turck always knows what the market demands, and Turck customers can
depend on getting what is currently feasible – from the catalog or as a customized
application – in the areas of sensor, fieldbus, interface and connection technology.
In addition to sensor technology,
fieldbus technology is an important
inherent part of the Turck portfolio.
Do you also have appropriate solutions for the packaging industry in
this field?
Naturally, in addition to its sensors, Turck
also offers solutions for new target markets in the area of fieldbus technology.
With piconet, we have a modular and a
fully encapsulated IP67 I/O system which
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is ideal for packaging machines thanks to
its very small housing dimensions. And
more recently we made enhancements
to our IP20 fieldbus line BL20: From programmable gateway to economy disks,
plant and machine builders find the right
module for their applications.
Which sensor trends, in your opinion, will become important in the
packaging market?
That is difficult to say. In addition to innovative technologies, such as RFID, that are
quickly spreading into this market, established sensor models also have development potential. An example of this is the
topic of “ultrasound”. These sensors are
becoming faster, better and, above all, less
expensive. They will soon be suitable for
tasks that so far have only been able to be
implemented using optos. For example, an
ultrasonic sensor can be used as a reflex
barrier in clear object recording.
Is IO-Link a possibility for the
­packaging industry?
Naturally. Through an increasingly large
diversity of packaging systems and associated product changes, the machine must
be as flexible as possible. If used smartly,
the I/O-Link can be a huge aid in retrofitting. For example, with batch changes, the
controller could write the new parameters
into the sensors and therefore easily adapt
to the new packaging. As one of the few
suppliers, Turck is able to operate both the
sensor side as well as the fieldbus side of
the IO-Link using the corresponding products.
What are your next goals?
As in our traditional industries, we also
intend to establish ourselves as a field specialist with solution-oriented competencies
in the packaging machine industry. One
advantage for customers, for example, is
that we are a one-stop shop for sensors,
plug-in connectors and fieldbus technology. This is extremely significant in the food
industry because of the importance of
compactness. We want to enter into technological partnerships with our customers
by asking the following questions: “What
should the machine look like? What are
your problems? How can we solve them?”
We can answer the above questions with
our existing product portfolio, by modifying
existing products or developing customized solutions.
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“
Turck has numerous components in its product portfolio that
are ideal for bottling and packaging machines. We intend to further
expand this program.
„
Dr. Bernhard Grimm
“
We want to impress our customers with our competence
and solutions in the sensor, fieldbus and connection technology
fields.
„
Dr. Bernhard Grimm
Author
Frank Nolte is
Editor-in-Chief
of the trade
­publication IEE
www.iee-online.de
14 T R E N D _ F D T / D T M
I
The benefits
of FDT/DTM
are not only
used in
process automation, but
increasingly
also in factory
automation
n process technology systems, a large number
of sensors and actuators which can be parameterized are traditionally used. The same
is increasingly also true of factory automation.
Manufacturers often supply their own proprietary
software for parameterization and diagnosis of
each of these field devices. This is a considerable
obstacle if the system is to be controlled in an SPC
environment or managed in an asset management
system. This is because central management, diagnosis and parameterization is possible only if the
system has access to the full functional scope of
each individual device program. This colorful world
of proprietary device programs is also a problem
when servicing is due: a service engineer would
have to be familiar with a variety of different parameterization tools and use the right software from
each device manufacturer.
Manufacturer independence
FDT/DTM (Field Device Tool/Device Type Manager)
technology provides a solution here by standardizing the communications interface between field
devices and control systems while operating independently of the communications protocol used
and of the higher-level SPC environment or management/asset management system. FDT technology thus makes it possible to address any devices
with a DTM via any systems using any protocols.
For this purpose, each device manufacturer
develops a DTM for each of its devices or groups of
devices. In principle, this is a driver, like that required
for connecting a printer to a PC. The DTM contains
all the device-specific data, functions and operating
rules like device structure, existing communication
facilities, parameters, internal dependencies and
graphical user interfaces. A DTM accordingly provides functions for calling up device parameters, for
configuration, for diagnosis and for documentation
of the device.
While DTMs are used for configuring field devices
like valves, position controllers or motors, communication DTMs are required for communicating with
a field device over a point-to-point link or a network
structure. Communication DTMs are obtainable for
various systems like Ethernet, Profibus and RS232
and are also available for communications components like fieldbus I/O systems, gateways, interface
components or remote I/Os. If DTMs are available
for the gateways between different bus protocols, a
field device can also be addressed and configured
Transparent Production
Standardized FDT/DTM technology guarantees simple, manufacturer-independent
device integration – from configuration through diagnosis to documentation
15

 Quick read
Modern systems, whether in the process or production industries, are more and more frequently being
equipped with complex, intelligent field devices and decentralized peripherals. In order to integrate
these devices perfectly in a system, it must be possible to operate and use them centrally. FDT/DTM
technology does just this, especially for complex components. Although it originated in the process
industry, it is increasingly also found in factory automation.
beyond the confines of a network. This makes FDT
technology simultaneously an open and fieldbusindependent configuration tool.
A DTM is no more a piece of executable software than is a driver. Access to the DTM can be
obtained only via an FDT container, a framework
application such as project management device or
system management tools, for example. The FDT
container ensures general connection of the device
to the engineering and operating environment of
the system. For the different DTMs from the various
manufacturers to function correctly in every framework, the interfaces with the surrounding system
and with other DTMs need to be clearly defined.
This interface definition is called FDT.
Systems in competition
In 2003, various manufacturers got together in the
FDT Joint Interest Group to establish an international standard based on FDT technology with broad
support from within the industry. The FDT Group
now comprises 59 members including Turck. The
definition of binding standards means that FDT
makes it possible to integrate field devices from different manufacturers, such as fieldbus I/O systems,
process measuring devices, remote I/Os or motor
controls to any kind of engineering and SPC environments and any kind of management systems.
This allows configuration, parameterization and
diagnosis of field devices to be improved significantly. System operators no longer have to worry
about the compatibility of field devices and can
concentrate on selecting the devices best suited to
the task in question.
The EDDL system which now exists in parallel
to FDT technology was developed as long ago as
the early 1990’s. In contrast to FDT, EDDL has its
own language defined for device manufacturers to
create text-based descriptions of their devices. This
“electronic device description” (EDD) is then processed by an interpreter, allowing an individual software tool to operate and parameterize a wide variety of device types through interpreting the device
description.
Both systems have benefits and drawbacks:
EDDL has the advantage that it is not dependent
on any particular operating system. The specified
extent of the language allows a simple application, but restricts the scope of potential function.
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This makes EDDL more suitable for straightforward
parameterization tasks and for transmitting simple
device functions to control programs. With FDT
technology, device manufacturers have every freedom with regard to the functional scope of operating programs/DTMs, therefore FDT provides a high
degree of flexibility and is particularly suitable for
complex devices like fieldbus I/O systems. Another
important argument in favor of FDT is its independence from certain bus systems.
FDT growing in factory automation
Turck always supports the technology the user
requires, but there is one overriding argument in
favor of using FDT technology: it is already known in
factory automation. EDDL, on the other hand, has
only been used in process automation. Production
automation will be an interesting area of use for FDT
in the future, as the sensors and actuators used
here are becoming more and more intelligent. A
great many components like fieldbus I/O systems,
drive controllers and intelligent sensors, for example, now have the option of processing programs
decentrally like classic SPC and the industry PC.
The decentralized peripherals, in particular, now
more and more frequently cover computing functions in addition to their actual tasks.
Relocating software components to programmable gateways of decentral fieldbus I/O systems
reduces bus load, for example, and increases
SPC performance – benefiting the entire system.
FDT/DTM: In a
framework application like PACTware, for example,
the device-specific DTM allows
access to the
device, in this
case Turck’s
I/O system BL67
16
TREND_F D T / D T M
Turck supplies
DTMs to allow
FDT technology to be
used for numerous
products, for example
the fieldbus
I/O systems BL67
(photo) and BL20
The consequence is that not only are the devices
becoming more and more complex, the number of
different parameters is also continuously increasing
and the number of software tools for the automation devices from different manufacturers is rising in
tandem. Every manufacturer pursues its own operating philosophy with data retention specific to each
device, and data is usually deployed only locally on
the device itself and not beyond the confines of the
fieldbus. This is making the engineering more and
more time and labor-intensive.
frames, for example those with which the user is
already involved and familiar.
Turck continues to meet the requirements of
factory automation with DTMs for its fieldbus I/O
systems BL20 and BL67, though now on the basis
of the open FDT standard. The software concept
reduces system complexity and makes the overall solutions lean and manageable. All the relevant
device properties are represented transparently and
visualized with a user-friendly, uniform look and feel.
Existing data can thus be used efficiently in the ideal, specific way as the system operator would like.
Simple system engineering
Author
Raphael Scholzen
is a product
specialist in fieldbus
technology at
Hans Turck GmbH
& Co. KG
FDT/DTM technology provides a solution here too.
The fact that the DTM is supplying the field device
with all its information, such as parameters, dialogs
and communication drivers for subsidiary fieldbuses, simplifies the entire procedure. Devices can be
exchanged effortlessly as the parameters are filed
centrally in the FDT framework application. Parameterization and consequently the whole of system
engineering can be realized from within a single
tool. Furthermore, central filing of device data provides the opportunity of assigning user rights selectively through the framework application.
Turck used the recently-introduced I/O-ASSISTANT 3.0 to make its project management, commissioning and servicing tool for fieldbus I/O systems fit
with FDT technology. In contrast to its predecessor,
Version 3.0 uses all the benefits of the open standard. It is made of DTM software components for the
fieldbus I/O systems BL20 and BL67, as well as the
framework application (frame – preferably PACTware). The modular software concept also provides
the option of using the DTMs in other FDT-based
Two worlds – one solution?
Based on the new OPC “unified architecture” (UA)
which achieves independence from software platforms by using standardized web technologies, the
Lehrstuhl für Informationstechnik im Maschinenwesen [Chair of Machine Information Technology]
at the Technical University in Munich supervised
by Prof. Dr.-Ing. Klaus Bender developed a client/
server architecture that merges FDT and EDDL so
that the benefits of the respective technologies are
retained, but the drawbacks should be avoided.
A prototype demonstrating the feasibility of this
“Future Device Integration” (FDI) has already been
shown at the Hannover Messe in 2007. The EDDL
Cooperation Team (ECT) and the FDT Group
have now launched a joint project to work out a
standardized solution to future device integration,
though it will probably be some time until a concrete solution for the customer is found.
17
“
I don’t see a
competition
”
With 17 years experience in automation, Meinrad Happacher
is something of a founding father in the relevant trade journal
sector. We asked him for his view of EDDL versus FDT/DTM.
Mr Happacher, a dispute broke out
in mid-2004 about which technology would be best suited to incorporating field devices into engineering and management systems
– EDDL or FDT/DTM. Is this dispute
justified?
Yes and no. Yes, in the sense that neither of the two technologies is perfect:
EDDL has its advantages when simple
field devices need to be linked, but it has
severe restrictions to its functional scope.
FDT/DTM wins when complex devices
need linking, but has the drawback that
it is closely linked to Windows as its
operating system. Nevertheless, I do not
really view this situation as a competition
between these two solutions, as neither
EDDL nor FDT/DTM perfectly covers the
broad range of applications from simple to
highly complex field devices. The solutions
complement one another, really.
At the Hannover Messe in 2007, the
EDDL Cooperation Team and the
FDT Group announced that they
were going to specify a joint solution for device integration. Does
this mean an end to the wrangling
is in sight?
The two parties are moving closer. A significant contribution towards this rapprochement was made by Prof. Dr. Klaus Bender
from the Institut für Informationstechnologien im Maschinenbau [Institute for Information Technologies in Engineering] from the
Technical University in Munich. The concept he proposed envisages using OPC
UA to merge the two technologies, EDDL
and FDT, and to eliminate their drawbacks
– high complexity in the case of FDT and
limited functionality in the case of EDDL.
A proposal which met with
approval?
After a certain amount of consideration,
yes. At the Hannover Messe in April the
EDDL team and the FDT Group agreed to
start work on a joint solution based on this
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concept and called Future Device Integration or FDI for short.
How do you assess the likelihood
of this concept being realized?
Initial approaches are very promising; the
extent to which the plans can be realized
in a workable solution is yet to be seen. At
the moment, activities are still at the concept stage, so people should not expect
results especially quickly. The plan is for
the specification and initial prototypes to
be in existence by the end of 2008, but it
is bound to be another four or five years
at least before the first management systems with implemented FDI are actually
available on the market. Of course, we
can’t rule out FDI failing, either!
Should a user put off investing in
EDDL or FDT and wait for an FDI
solution?
To look at this question we can take the
parallel of the history of the fieldbus: fieldbuses had scarcely begun to become
established and yet by 2000, we were talking about them being displaced by industrial Ethernet. But automation technology
is not as fast-moving as the consumer
world. Fieldbus technology is still experiencing incredible growth rates today. But
to return to the subject: FDT in particular
is only just becoming established in the
market. The FDI solution we were discussing, on the other hand, is still a pure
scenario for the future. So if a company
is about to start on modern asset management, it would be inept to make the
decision on investment dependent on the
potential development of FDI, especially
as investment made now should not represent a poor investment even if there is a
subsequent switch to FDI. Those involved
have made it very clear that they will be
incorporating in the FDI solution a clear
migratory path to existing EDDL and FDT
solutions.
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Meinrad Happacher has been
active as a trade press journalist
since 1990. From 1993, he was
responsible for the Automation
Technology section of the trade
journal Elektronik. Five years later,
Meinrad Happacher became
Editor-in-Chief when Weka
Fachmedien set up “Computer &
AUTOMATION”, now considered
one of the leading trade journals
for automation in Germany.
www.elektroniknet.de
18 A P P L I C AT I O n s _ F i e l d b u s / s e n s o r
technology
The modular
BL67 I/O
fieldbus
system can
optimally
process
numerous
signals in
the welding
systems
Routing Station
The Turck I/O System BL67 processes signals on the FRIMO
ultrasonic welding systems – including high-frequency
W
hether gluing, riveting, screwing or
welding – when it comes to joining materials together, the right joining technique is playing an increasingly important
role – for the design of a product as well as its
efficient manufacture. Even if it involves “just” joining two plastic parts, the user is spoiled for choice
between numerous technologies, including heatedtool welding, hot-air riveting, heat contact riveting,
infrared welding, laser welding or ultrasonic weld-
ing/riveting. The latter is primarily used for interiors
in the automobile industry because it is particularly
well suited for surface welding and riveting with
cold tools.
Ultrasonic welding
Ultrasonic welding involves using high-frequency
oscillations (ultrasound between 20 and 40 kHz)
beyond the human hearing range to join plastics
19
together. Ultrasound is produced using a generator that converts the low-frequency energy in the
AC power supply into higher-frequency ultrasonic
oscillations. The mechanical resonance unit combined with the generator (consisting of a converter,
amplitude transformation unit and sonotrode)
is mounted on a pneumatic cylinder. Using the
sonotrode, the mechanical oscillations generated in
the converter under pressure are forwarded to the
thermoplastic adherends. In the joining areas, the
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
 Quick read
Typical of ultrasonic welding systems is the multitude of signals that have
to be processed in these plants. In addition to the information on position
and penetration depth of the sonotrodes, it is primarily the high-frequency
signals that stimulate the numerous weld heads to oscillate. In the new
ultrasonic welding systems from FRIMO, Turck’s IP67 I/O system BL67
ensures that all signals are processed, including the welding process.
20 A pp L icatio n s _ F i e l d b u s / s e n s o r
technology
“All inclusive”:
Even the high
frequency signals
for actuating the
sonotrodes
(orange cables) are
routed via the Turck
I/O system BL67
“
With his
competence in the
area of fieldbusoriented signal
processing and the
sensor technology,
Turck was able to
offer us a solution
that met our high
requirements for this
project
„
Detlev Böl,
FRIMO Technology
ultrasonic energy produces molecular and boundary friction, which heats up and softens the plastic
parts. The sonotrode’s penetration depth into the
plastic is a yardstick for the quality of the joined
area in which case each material has its specific
optimal value.
Demand for strong I/O system
The enormous number of input and output signals to be processed in an ultrasonic welding system makes a powerful I/O fieldbus system essential. After an intensive market analysis, FRIMO,
one of the leading suppliers of ultrasonic welding
systems, decided to place its trust in the Turck
BL67 solution. “After comparing traditional market
I/O fieldbus systems, we came to the conclusion
that the Turck system was the best suited due to
its high transmission speed that met our requirements,” is how Thorsten Geldmacher, technical
project manager responsible for introducing the
I/O systems, explains FRIMO’s decision in favor of
the BL67. This system combines all the benefits of
modern IP20 bus terminal systems for the switchgear cabinet and consequently transfers them into
the raw IP67 world.
The benefits of such a solution are obvious. The
BL67 system can be brought directly to the sensor without a switchgear cabinet. This saves on
materials and assembly time and with a multitude
of signals contributes to cost reduction. Furthermore, the BL67 system is enormously flexible and
can thus be adapted to meet future needs. If further I/O channels should be required in the future,
the additional modules can be simply added to
the existing installation without further expense. The
BL67 system is connected to the FRIMO system
via a profibus, but it is also available for other fieldbus systems. Besides the high speed, the FRIMO
decision-makers were impressed by the complete
separation of electronics and connection level in the
BL67. In case of a service call, the “hot swap” functionality developed ensures smooth plant operation
while the defective module is replaced by the new
one in the blink of an eye.
High frequency through the
I/O system
Anyone who takes a quick glance at such a system
will immediately appreciate the value of each cubic
centimeter of space saved by an ultrasonic welding system. For FRIMO, a decisive factor was being
Turck produces analog magnet field sensors
“FRIMO by Turck” especially for this application
able to do without an additional switchgear cabinet
by routing the high frequency signals necessary for
welding via the I/O system. In close cooperation
with Turck, this concept could finally be implemented.
While 19” racks with relay printed circuit boards
21
The user
With around 1,200 employees at 17 locations worldwide, the FRIMO Group is a leading specialist for turnkey machine tool and
plant technology for the manufacture of high quality plastic components in the automobile industry and other plastic processing
industries. These include, for example,
manufacturing facilities for laminating, backfoaming or thermoforming
instrument panels or door paneling.
At ­ FRIMO ­ Technology GmbH PlasticJoining in Hamburg, the company
focuses its competence in the area of
plastic joining technologies. FRIMO
gives customers process-neutral
advice when selecting the appropriate technology and supplies the corresponding systems. Its product lines
range from heated-tool welding, to
hot-air riveting, thermal contact riveting, infrared welding, laser welding to
ultrasonic welding/riveting.
were used to distribute the high-frequency signals,
FRIMO now uses the I/O system BL67 for high-frequency transmission in its current serial systems.
The sonotrodes can therefore be comfortably controlled by software. With its competence in the area
of fieldbus-oriented signal processing and sensor
technology, Turck was able to offer us a solution
that met our high requirements for this project,”
explained Detlev Böl, technical director of FRIMO
Technology GmbH PlasticJoining in Hamburg.
The BL67 has meanwhile proven itself ­during
comprehensive field tests in FRIMO ultrasonic
welding systems. One of the many companies to
purchase FRIMO welding systems with the Turck
I/O system is automobile supplier Johnson Controls Interiors in Lüneburg, Germany. At its Lüneburg plant, Johnson Controls produces door panels for the new Volkswagen Tiguan which was
launched in September at the International Motor
Show.
Sensors and connection technology
As a specialist for sensor, fieldbus, interface and
connection technology, Turck has not only equipped
the FRIMO ultrasonic welding systems with fieldbus
technology, but has also supplied special sensors
for detecting the pneumatic cylinder, as well as
the associated connection technology. In order to
make a material change possible – from art leather
to plastic – without manual intervention – a sensor
was required that can detect contact-free the penetration depth of the sonotrodes during the welding process regardless of the materials used. “Turck
was even able to deliver a solution for this task that
not only met the technical specifications, but also
the high FRIMO quality standards,” says Böl.
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The analog FRIMO magnet field sensor that was
a result of this cooperation now makes it possible
to change over to new materials during ongoing
operation without retrofitting the system. Thanks to
its compact design, the sensor can be mounted
directly on the T or dovetail joint pneumatic cylinders; a standard plug-in connector is used for connection.
The sensors from the FRIMO series have a
current or a voltage output. The measured length
of the analog path sensor is about 40 mm, with
an average accuracy of 0.1 mm, in which case
the repeating accuracy comes to 0.3%. Due to
the analog measuring process, the actual reproduceability is even better with brief movements.
The very brief blind zones (only 8 mm on both
sides) further ensure an exact recording of the
end positions of the pneumatic cylinder. Additionally, the sensor has a measurement range display, called the “in-range” function with LED display. Thanks to this functionality, it is immediately
obvious whether the actuation magnet on the
pneumatic cylinder is in the measurement range or
not.
Author
Successful together
Using the example of ultrasonic welding systems, it
becomes clear how the close cooperation between
manufacturer and supplier is mutually beneficial.
With competency and innovative solutions, Turck
supports the distinctive know-how of its clients
and thereby does its part to allow FRIMO customers to manufacture goods faster, more safely and
at lower cost using the company's systems.
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Jörn Stoevesandt
is team manager
of the North sales
region at Hans Turck
GmbH & Co. KG
22 A P P L I C AT I O N S _ F I E L D B U S / S E N S O R
TECHNOLOGY
The green
light shows
the operator
exactly which
bin he has to
remove the
appropriate
part from
Targeted Packaging
Turck BL67 and Banner Pick-to-Light systems ensure error-free
boiler production in the Netherlands
W
ith more than 1.5 million high performance boilers sold in the past
25 years, the Bosch subsidiary Nefit
is the market leader in the Netherlands. “We are
currently producing about 400 boilers per day,”
says Jos Plasschaert, technical manager at Nevit in
Deventer. “The center of a high performance boiler
has about 30 components from which the majority
are available in various dimensions and capacities.
Theoretically, we are able to offer about 250 different
boiler models.” Just like in automobile production,
each boiler is individually produced. The boilers are
moved along the assembly line in groups of four. A
central SPS and a pick-to-light application signalize
which components should be integrated into the
boiler at what time.
“With the previous pick-to-light system, the
engineers had to turn off the light themselves after
removing a component from the container. This
creates errors, such as the removal of an incorrect component or incorrectly turning off the
light,” says Plasschaert. There was an incident in
23
Fundamental changes
The Pick-to-Light modules from each picking station
are controlled by a separate SPS – the Turck I/O
System BL67 ensures reliable signal transmission
“This project means more than just setting up extra
shelves with new pick-to-light modules,” explains
André Simonse, project manager at Hollander
Techniek. “The infrastructure had to be adapted and
expanded. The innovative aspect of the new system
lies in the fact that the pick-to-light modules are controlled by several SPS (stored program controllers)
and no longer from one PC. We decided in favor of
the Turck BL67-I/O fieldbus modules that are connected to one another via Profinet, because both the
input signal as well as the output signal can be coupled via an M12 plug-in connector.” Using the modular remote I/O system BL67, Nefit is currently able to
change the allocation of the picking stations retroactively as well. The system can be mounted quickly,
takes up little space, is maintenance free and can be
quickly reconfigured.
The pick-to-light system itself is also supplied by
Turck. For integrated upgrading, a sensor cable ranges from the picking station to the Profinet I/O, which
heavily reduces the installation time. This is a considerable benefit compared to the previous system
which still worked with individual sensors and picking
LEDs. Manually turning off the lights is no longer an
issue, because an infrared beam records the hand
of the operator automatically so that the green LED
turns off and signalizes that the right part was removed. If the operator removes the wrong part from a
different container, then the light turns red immediately. This is how the pick-to-light system developed
“
We work with
several suppliers, but
Turck has set itself
apart. The customeroriented attitude of
Turck employees contributes heavily to the
success of a project
such as the one with
Nefit.
„
André Simonse,
Hollander Techniek

 Quick read
In order to implement a “zero error philosophy” the Dutch Bosch subsidiary Nefit has redesigned and rebuilt its existing assembly line. System
integrator Hollander Techniek was commissioned for this project and relied
on components from Turck and Banner to complete it.
which an incorrect switching operation caused the
outage of the entire production line. On top of that,
the engineers were using only one central picking
station. The entire process had to become efficient
and trouble-free.
“In the Bosch Group, a zero-error philosophy
applies to manufacturing and assembly processes
which we intend to follow to achieve the required
quality of the end product as early as possible,”
says Plasschaert. During numerous workshops, we
determined how this philosophy could be implemented at the Deventer plant as well. Instead of
one central picking location, there are now six
picking stations and each one is optimized for a certain assembly phase. Because this meant a drastic
redesign and construction of the existing production
line, Nefit brought the system integrator Hollander
Techniek into the project.
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by Banner saves not only time, but it also drastically
reduces the error possibilities.
Author
Eliminating error sources
“We started reconstruction in December 2006,”
explains Plasschaert. “On a hardware level, everything functioned immediately, on the software level,
we were able to quickly eliminate a few small bugs.
Once all the new picking stations are in operation, this
will further improve our efficiency.” Hollander-Techniek project manager André Simonse emphasizes
Turck’s support: “We work with several suppliers, but
Turck has set itself apart. The customer-oriented attitude of Turck employees contributes heavily to the
success of a project such as the one with Nefit.”
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Marcel Vennemann
is the director
of field sales at
Turck BV in the
Netherlands
24 A P P L I C AT I O n S _ F I E L D B U S
TECHNOLOGY
In the
Frankfurt
plant, Basell
was able to
install the first
Foundation
fieldbus lines
with Turck
multibarriers
in record time
Flexibility Thanks to
the Fieldbus
Turck power conditioners and multibarriers ensure plant operation at the
Frankfurt­Hoechst Basell plant
T
he polyethylene production plants at the
Hoechst Industrial Park in Frankfurt have
been in operation for more than 50 years.
What started under the management of Hoechst AG
is now operated by Basell Polyolefine GmbH. The
Basell Group was founded six years ago by a joint
venture between BASF and Shell, and is one of the
leading suppliers of polyethylene, polypropylene,
high-performance polyolefins and polyolefin catalysts. Basell supplies customers in over 120 countries
and has production facilities in 21 countries on five
continents. Its headquarters are based in Hoofddorp,
near Amsterdam, in Holland. The company employs
more than 6,500 employees from 35 countries.
Basell has three production facilities in Germany:
one in Wesseling near Cologne, Münchsmünster
near Ingolstadt and in Frankfurt. At the Frankfurt
facility, about 160 employees produce raw materials
for plastic film, small and large containers such as
tablet packaging or drums, special pipes or netting.
Basell has also concentrated its research activities in
Frankfurt where just 300 employees work to ensure
the company’s future.
Plant rebuilt in record time
Production at the Frankfurt plant was actually meant
to be ramped down at the beginning 2006 by
moving sections of the plant to Poland. However, an
explosion at the Münchsmünster plant in December
2005 put an end to this plan. The plant was completely destroyed, so instead of dismantling line 2 at
the Frankfurt plant as originally planned, the line was
modernized and operations from Münchsmünster
were transferred there. The highly flexible production
facility in Frankfurt is now in operation, producing
more than 30 different products, including all the
products from Münchsmünster.
25
The full galvanic isolation of the Turck multibarriers impressed the Basell
decision makers immediately
Because the integrated power conditioners of the Rosemount interfaces
(top left) were not
powerful enough,
external Turck power
conditioners now
feed the FF lines
For Harald Liebisch, team leader for automation
at Basell in Frankfurt, an exciting phase started in
December 2005 when the polymerization plant had
to be rebuilt in record time: “Once the initial decisions
regarding the new plant had been made at the end of
the year, things moved very quickly”, Liebisch summarizes. “We were able to update the plant within
three months and equip it with Foundation fieldbus
lines.”
Liebisch had already had some initial experience with multibarriers, though he was not entirely
satisfied with the results. When the Turck solution
was presented, the decision was made very quickly:
“We were immediately impressed by the full galvanic
isolation of the Turck multibarriers,” the automation
manager explained, “it was exactly this feature that
was missing before.”
Multibarriers with full
galvanic isolation
The Turck MBD-49-T415/Ex multibarrier allows
for the installation of Ex-i drop lines up to 120 m
in length. The full galvanic isolation is provided
both between the trunk line and the output circuits as well as between the four output circuits.
This prevents compensation currents from developing due to potential differences. The integrated
short-circuit protection is activated if a short-circuit
occurs at a fieldbus node. Only the output affected
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is disconnected – the trunk line and the other outputs of the affected fieldbus segment remain in
operation.
Actual planning was able to be completed just as
quickly as the decision process, thanks to the configuration tool from Turck. “We used the tool to make
a preliminary plan of the segments. The length of the
fieldbus lines, the division of the fieldbus barriers, the
assignment of inputs to multibarriers – the configuration tool allowed us to define all these points very
quickly,” ­Liebisch explained.
Broad base
A total of nine fieldbus lines are currently in operation
at the Basell polymerization plant. Power conditioners
connected upstream from each one are ­provided for
supplying the fieldbus segments. The scope of this
project also includes plans for expanding the Foun-

 Quick read
In order to take over the production of another site at short notice, Basell
Polyolefine GmbH was able to upgrade its Frankfurt-Hoechst plant within
three months by installing the Foundation fieldbus system. Central elements
of the new installation are the Turck power conditioners and multibarriers
which offered more impressive features than just their channel-specific
galvanic isolation.
26 A pp L icatio n s _ F I E L D B U S
TECHNOLOGY
New Power Conditioner with FF Diagnostics Tool
“
We are very
happy with the
Turck products.
In addition to the
galvanic isolation,
their reliability and
simple operation
are outstanding.
”
Harald Liebisch,
The Foundation Fieldbus
Diagnostic Power Con­
ditioner system (DPC) is
a brand new item in the
Turck product portfolio. The
power conditioner features
an integrated diagnostics
unit that supports the user
in commissioning a fieldbus
installation, and also detects
faults and even inconspi­
cuous changes within indi­
vidual fieldbus segments. A
suitable alarm function ena­
bles fieldbus-related instal­
lation faults to be prevented
completely. The DPC system
primarily provides a redun­
dant supply of up to 16 seg­
ments with a max. 800mA
output current and max. 30 The new diagnostic power conditioner system with integrated diagnosis
VDC output voltage for each tool immediately detects even subtle changes in FF segments
segment. In practical appli­
cations, this also enables the installation of long-distance segments up to 1900 m in length, along with the
connection of stations with a high power consumption. Turck has also implemented full galvanic isolation
on the new DPC system. In order to make complex fieldbus diagnostics transparent for the operator, the
individual values and parameters are displayed graphically via a DTM (Device Type Manager) in the asset
management system, which can be integrated in any FDT frame application as required.
Basell
Author
Markus Haller is key
account manager
for process automation at Hans Turck
GmbH & Co KG
dation Fieldbus network to 15 segments. “We are
very happy with the Turck products,” Harald Liebisch
says. “In addition to the galvanic isolation, their reliability and simple operation are outstanding. Since
we have completely migrated to Turck, we have not
had any more difficulties. We therefore also intend
to implement the next expansion stage using Turck
products.”
Despite the time pressure under which the project was completed and the absence of a test phase,
installation of the new technology was largely trouble-free. Rapid support was only required once in the
initial phase when the first line could not be put into
operation. This problem was caused by an insufficient power supply for the three multibarriers due to
the internal power conditioners of the Rosemount
interfaces used in Frankfurt. These interfaces connect the FF segments to the ABB Symphony control
system.
We were able to rectify the problem within a few
days. “Turck was a big help in solving it. The short
communication routes within the company were very
helpful,” reflects Liebisch on his experience. “Our
problem was taken seriously and dealt with immediately. With the short implementation time available
for the project, it was very important that we found a
solution quickly.”
The multibarriers are now supplied with external Turck power conditioners that not only provide
enough power, but also allow a clean separation between the interface converter and the fieldbus.
Conclusion
The changeover to fieldbus technology has enabled
the installation planners at Basell in Frankfurt to
create the basis for a flexible response to market
requirements. The speed at which the installations
can be adapted has already been put to the test with
the first FF project. The installation in the polymerization plant had to be made operational as quickly as
possible without a test phase.
With its high-performance power conditioners
and multibarriers with channel-specific galvanic isolation, Turck has provided the most suitable technology for the demanding Basell application. However,
it was also the “soft facts” – from the configuration
tool to easy handling to prompt availability – which
enabled the Mülheim fieldbus, sensor and interface
specialists to make such an impression that Turck
has also remained supplier of choice for the planned
expansions.
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A p p L i c At i o n s _ R F I D
27
In total, 250
read-write
heads in the
BL ident system detect the
workpiece carriers during the
entire manufacturing process
The Direct Perspective
RFID systems ensure transparency and traceability in
the manufacture of consumable materials
A
renowned manufacturer of consumable
materials manufactures about 20 million
units for process engineering every year at
its German plant. A large portion of the goods produced there are currently exported to the UsA. By building its own plant in the UsA, the manufacturer intends
to reduce the capacity problems at its German manufacturing facility and, in the future, manufacture on
location for one of its largest markets. the U.s. facility
is being planned by the company’s own plant con-
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
 Quick read
A renowned manufacturer of consumable materials for process engineering is
currently building a new factory in the UsA in order to relieve its German production facility. it will begin production in just a few months and is scheduled
to manufacture about ten million products on its production lines each year.
the RFiD system BL ident from turck will provide transparency on these new
production lines and ensure FDA-compliant traceability of each product.
28 A p p L i c at i o n s _ R F I D
Same high
­switching
­distances to all
metals: even
the inductive
Factor 1 sensor
uprox+ is used
in the system
struction department in Germany. Around 40 employees are involved in mechanical construction, process
engineering, special tasks and automation. The team
was able to gain experience in RFID technology with
the last production line. Using radio-based identification technology, the high traceability requirements will
be fulfilled and the production flows optimized.
Cost-effective alternative
However, the company was not happy with the RFID
system being used that was supplied by a large automation manufacturer. “We were forced to look for an
alternative because of the high data carrier costs,”
commented the construction engineer who selected
the RFID supplier for the U.S. plant. “We quickly turned
to Turck which had previously supplied us with data
carriers when the original manufacturer was unable to
supply them.”
The attractive data carrier cost was only one of the
reasons why the final decision was made in favor of
Turck. “The BL ident system by itself was also a very
convincing factor. Another important one was that all
the read-write heads were available as standardized
sensor housings. This significantly simplifies installation
and eliminates the need for inconvenient mounting
The RFID data carriers are mounted on the lower
end of the workpiece carriers
brackets.” What also clinched it for Turck's BL ident
system was the ability to mount the read-write heads
at very small distances from each other. There are
areas in the system where several read-write heads are
installed in confined spaces. The minimum clearances
required by the Turck heads are ideal here.
Intelligent workpiece carriers
The RFID system consists of about 70 gateways,
250 read-write heads and around 1,000 data carriers.
29
The RFID package BL ident
With its high-temperature RFID solution BL
ident, Turck, the sensor, fieldbus, interface and
connection technology specialist, offers a complete package for non-contact identification in
an industrial environment. The BL ident product
line is based on the modular BL67 I/O system
(on-site assembly) and BL20 (switchgear cabinet
mounting), and consists of data carriers, readwrite heads, connection technology and gateways. The RFID system can be easily integrated
into existing BL67 and BL20 I/O systems.
Gateways are programmable with CoDeSys
and comply with IEC 61131. They communicate with the read-write heads and are available for simple installation and for reducing the
burden on higher-level controls. In addition to
the standard data carriers, which are rated for
temperatures up to 120 °C, BL ident also operates with high temperature tags up to 210 °C.
For example, when burning in paint layers in car
manufacturing, this means that the data carriers can pass through the oven on the vehicle
skids.
The tags are available with EEPROM and
FRAM memory where the latter allows almost
an unlimited number of read and write operations. BL ident can be modularly adapted to the
respective application with two, four, six or eight
channels. Fieldbus interfaces are available for
Profibus DP, DeviceNet, Ethernet/IP, Profinet IO
and Modbus-TCP.
It is used for monitoring the workpiece carriers. For
this purpose, each workpiece carrier is provided with
an RFID data carrier on its base, the so-called tag.
Information on the workpieces is stored on these data
carriers which are incorporated into the workpiece
carriers. This means it is possible to trace the production line that the workpiece came from at any time,
the injection molding machine and cutting machines it
used, the shift during which it was manufactured and
many other details. All this information is stored on the
data carrier until it is exported to a transfer point and
then transferred to the databases. Some stored data
even move along the entire production line – from start
to finish because it is needed by certain processing
centers. If a line is changed or the workpiece carrier
is replaced, this data can be reimported onto the
data carrier.
An important criteria for the Turck solution according to the customer was the high read-write speed:
“We performed precise speed comparisons with the
competitor’s device. With the RFID system previously
used, we sometimes had problems with data transfer
to another workpiece carrier. Sometimes it appeared
that only half the information had been written to the
tag even though the write process had been indicated as complete and the workpiece carrier had already
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Simple mounting: All read-write heads in the Turck RFID system BL ident
are fitted to standard sensor housings
Up to four I/O
­modules can be
connected to the
BL ident gateway
(left) for up to a
maximum of eight
read-write heads
moved on. We no longer have these problems with the
speed offered by BL ident.”
“Very good support”
When an important project such as the installation of
an RFID system is completed without any major problems, it should not go without praise. The Turck concept of user-friendly technology combined with equally user-friendly support was a complete success as
confirmed by the customer: “The system was easy to
install in our system, previous projects required more
time and expense. Close contact to the manufacturer
is helpful, particularly in the test and training phase. We
were always able to rely on the excellent support provided by Turck product managers.”
In contrast to other manufacturers, Turck puts a
lot of effort into documenting its solutions. The results
speak for themselves said the design engineer: “We
quickly found all the information in the documentation.
This may sound very mundane, but this is not standard
when it comes to documentation. In my opinion, Turck’s
documentation was comprehensive and of high quality,
just like the cooperation and support we received.”
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Author
Walter Hein is
the RFID product
manager at Hans
Turck GmbH &
Co. KG
30 A P P L I C AT I O N S _ F I E L D B U S / C O N N E C T I O N
TECHNOLOGY
Decentralized machine
concept
instead of the
switchgear
cabinet: All
components
are in individual modules
and mounted
directly onto
the machine
Plug & Play Cabling
Turck I/O modules and quick disconnect cables support modular machine
concept from Automatic Feed
A
utomatic Feed Co. located in Napoleon,
Ohio is a premier designer and manufacturer of coil handling and press feeding
automation systems. Its management has long recognized the importance of streamlining processes by
simplifying design and embracing lean manufacturing.
The company has been actively developing programs
to accomplish this since the 1980’s.
One of its more recent initiatives is to convert
operations to a “one-day build cycle” that targets one
person and one process in one day. By standardizing
equipment and distributing control devices through-

 Quick read
With a modular machine concept, the American Automatic Feed Co. was
able to increase its efficiency and reliability and reduce its assembly time
and costs at the same time. The I/O modules and cables come exclusively
from Turck.
out the machine, Automatic Feed has moved point
of control to the physical application reducing setup
time and decreasing the entire production cycle. This
process, coined Distributed Device Architecture or
DDA, has allowed the company to drastically improve
its productivity, reliability and quality.
DDA’s basic approach is modularity. This is
accomplished by incorporating control devices onto
a sub-system, each with self-contained, modular
mechanics, control devices and logic. Control devices
are removed from traditional enclosures and built to
a standard on the sub-system. Adhering to standard
control devices allows Automatic Feed’s customers to
specify components at a lower cost and dramatically
improved the company’s reliability and efficiency. The
coiling and press feeding machines are now designed to fit virtually any OEM requirement, as machine
components, like motors, cylinders or valves, are
interchangeable commodities on the sub-system.
This design ensures applications are specified to
customer’s particular standards and allows them to
31
be implemented more efficiently. This often results in a
cost savings to the customer.
Schematics, measurement, testing and wiring
are all part of the modular solution provided by the
DDA, and industrial controls and hardware devices
are located next to the machine. Prior to the DDA
program, a device had eight connection points before
reaching the PLC. Devices now have only two connection points before reaching the PLC. According to
Mike Wolfrum with Automatic Feed, “we saved 25%
on the cost of electrical components by using the AIM
blocks (junction boxes) and Turck plug-ins (quick disconnects).”
By using Turck devices for part of the DDA program, Automatic Feed was able to reduce the number
of junction boxes required on the press feed line by 97
percent and on the coil line by 90 percent. The DDA
program also reduced enclosures, connection points
and potential failure points. Before the implementation
of the DDA program, a device had eight connections
with nineteen potential failure points. Now the same
device has only two connections with six points. This
reduction was achieved with the implementation of
the stand-alone sub-systems, and by using Turck
DeviceNet AIM stations and cordsets.
Wolfrum notes that “we used plug and play technology to eliminate almost all wire reconnections requiring a screwdriver except the 480 Volt. The E-connect
plug and play on all safety circuits has eliminated
wiring errors reconnecting the safety circuits. Even the
cables to each gate are molded from the factory to
the correct length to reduce wiring errors. The connections to the panels are also plug-ins, except the
480 Volt, to speed installation time and reduce wiring
errors,” adds Wolfrum.
Author
Dramatic savings
Automatic Feed reduced communication and power
cable by 70 percent, with a 50 percent reduction in
wiring man-hours. This is a direct result of implementing quick-disconnect cordsets in place of hard wired
terminations. Hard-wired machine terminal points were
reduced by 87 percent, and hard-wired panel termination points were reduced by 38 percent. Implementing the DDA program has helped ensure Automatic
Feed can provide their customers with efficient, timely and high quality service. The company constantly
seeks ways to improve their operations to continue
providing their superior products and services.
Only easily installable quick disconnect cables from
Turck are in use on the machines
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With the DDA
package,
Automatic Feed
can now offer
its customers
efficient and high
quality solutions
that are fast and
easy to install
more20754e
Bob Gardner is
senior product
manager for I/O
systems at Turck
Inc. in Minneapolis,
USA
32 T E C H N O L O G Y _ I / O - S Y S T E M
BL20
Free choice:
Turck supplies
numerous
modules for
BL20, from
RFID to motor
starter to
Economy or
classic I/O
modules
The Integrator
Turck extends its IP20 I/O system BL20 with new modules for use in
factory and process automation
33
W
ith the numerous extensions Turck
has now introduced for its I/O system BL20, the sensor, fieldbus, connection and interface specialist has brought a
fresh approach to the fieldbus market. Whether we
consider compact control systems, RFID integration,
motor starters or Economy modules, the new product portfolio means the system more than justifies its
title of “Integrator”.
The core of the BL20 system is the gateway
for communication with the fieldbus. The Standard
gateway is available in different versions, for Profibus
DP, DeviceNet, CANopen, Ethernet/IP and Modbus
TCP. If up to 16 modules need to
be connected and the system
has to be integrated in a Profibus or CANopen network,
the Economy gateway can
be used as an alternative.
Programmable
gateway
The programmable gateway is
especially suitable for the RFID
system, BL ident, but also for
other small control tasks. This
compact PCS can be programmed
with CoDeSys to IEC 61131-3 and
supports the growing demand for
decentralized automation technology.
The user can choose between the standard programming languages LD (Ladder Diagram),
CFC (Continuous Function Chart), STL (Statement
List), ST (Structured Text) and SFC (Sequential Function Chart).
The core of the new gateway is a 32-bit RISC
processor with a 512 kB program memory which is
able to process 1000 STL commands in less than a
millisecond. Two programmable interfaces are available, 10/100-Mbit Ethernet and RS232.

 Quick read
Fieldbus systems are already a well-established technology in production automation. Whether the remote I/Os are used in a control cabinet
with IP20 degree of protection, or directly in the field, i. e. on machines
with IP67 degree of protection, the decision in favor of one or the other
solution is often a question of personal taste or the application in question. Turck customers always get the right product family for any situation
and application, from the intrinsically-safe remote I/O excom developed
specifically for the process industry, to the BL67 system with IP67 degree
of protection, to control cabinet solution BL20 with its numerous extension
modules.
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34
TECHNOLOGY_I/O-SYSTEM BL20
Alternative: Economy gateways
for Profibus DP or CANopen
supplement the BL20 portfolio
I/O-ASSISTANT
3.0 supports the
planning, commissioning, testing
and operation of
the I/O system
linked to any control system, no matter which manufacturer, without complicated alignment and programming effort, even if no function block is available
for the control system.
Separation of connection level and
electronics
Up to 72 expansion modules can be aligned on the
right-hand side of the gateway. The base/connection
modules are passive components which are simply
snapped into the system. This creates a compact
and mechanically stable unit that can be flexibly
extended at any time. The electronic modules are
slid into the base modules and then firmly engaged
in position. The compact design of the BL20 components means that the fieldbus node can be mounted
in the control cabinet to save space. Separation of
connection level and electronics means that up to
The FDT/DTM
standard makes
configuration and
parameterization
simple for the
user
The programmable gateway
perfectly rounds off Turck’s
RFID complete package, BL
ident, which can be integrated
in the BL20 I/O system with
the RFID modules now available. The “intelligence” gained
in this way allows the gateway
to relieve the higher-level control system, as the occasionally complex RFID communication is now handled entirely
by the gateway on a direct,
decentralized basis.
The function block (Proxy
Ident Block) required for the
PCS is locally run in the programmable gateway. This enables specifically only effective
data to be exchanged with the
higher-level control system.
The RFID system can now be
The BL20 DTM can be operated in any FDT frame – such as PACTware, the
free-of-charge industry standard
35
Maximum I/O
density: The new
BL20 Economy
modules have
up to 16 digital
inputs/outputs per
13 mm slice
two adjacent electronic modules can be replaced
during operation without provoking any malfunctions
or having to disconnect the wiring. Depending on
the individual application, the customer can choose
between single or block modules, each available with
screw or cage clamp terminals.
In its new Economy modules, Turck is providing
very compact and cost-saving I/O modules that can
host either 8 or 16 digital inputs/outputs in a width of
only 12.5 mm. The Economy slices can, of course,
be combined with the standard modules. The integrated connection level allows the Economy modules
to be fitted without tools thanks to ‘push-in’ cage
clamp technology. The “Integrator” highlights its flexible application options with its new motor starter
modules, available as direct or reversing starters to
switch up to 15 kW. Each gateway can take up to
three modules, and up to 16 motor starters can be
connected to each module.
Comprehensive software support
Turck provides support for BL20 users with regard
to configuration, commissioning and maintenance in
the form of its I/O-Assistant 3.0 software which is
free of charge. In contrast to the previous versions, I/
O-Assistant 3.0 is based on standardized FDT/DTM
technology which also supports all other Turck products. The modular software concept allows the DTM
(Device Type Manager) of I/O-Assistant 3.0 to be
used for various frames, reducing the complexity of
many systems and making the overall solution manageable. All the relevant device functions become
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transparent and are visualized in a user-friendly manner. This provides optimum, efficient and selective
use of data together with a pleasant look and feel.
I/O-Assistant 3.0 supports the user through all
the phases of a system. Starting with configuration
of a modular fieldbus node, it provides useful information such as the type, type designation and part
number of the components required. The user can
save an enormous amount of money, time and effort
by assembling a node graphically, as the related
documentation (order and parameter lists, technical and dimensional drawings) is generated automatically. At the same time, incorrect configuration
is prevented because the software only displays
logically meaningful base modules for the electronic
module in question and calculates the maximum
total currents of the digital inputs and outputs for
this. What is more, the quantity of data permitted
for the fieldbus in question is checked and errors are
displayed.
During commissioning, the user can read in,
set or assign values to all digital and analog outputs
using the I/O-Assistant, allowing all the wiring and all
sensors and actuators to be checked at the click of a
mouse. The BL20 gateway is connected to the service PC via the RS232 serial interface, while Ethernetbased gateways can also be actuated via Ethernet.
Each fieldbus node can be tested as a local unit using
the I/O-Assistant beforehand, reducing commissioning time considerably. If problems do occur, the
software also provides valuable diagnostics support.
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Author
Phil Whorton is
Product Manager
for fieldbus
technology at
Hans Turck GmbH &
Co. KG
36 T E C H N O L O G Y _ B A S I C S
Flow rate
sensors from
Turck are
mainly used in
manufacturing
Functional Principles of…
…Flow Rate Sensors
Part 2 of our basic series: Design, functional principles and mounting options of
the most important sensor technologies
I
n order to ensure trouble-free operation and
identical results in manufacturing, a uniform
inflow and outflow of liquid or gas-formed media
is required for numerous processes. In addition to
pressure and temperature, current plays a vital role
in automated production processes. Depending on
whether a continual measurement or the monitoring
of a limit value is desired, the output signal from
the current or flow rate sensors can be an analog
or binary value according to the current velocities.
Every application has its specific requirements for
flow sensors.
Various principles
For electronic current or flow-through monitoring,
various measurement methods exist according to
numerous physical principles that have specific
advantages and disadvantages. Using the Thermodynamic Principle, the sensor is heated to a certain temperature. Depending on the medium’s flow
rate, the heat energy is diverted, allowing the flow
rate to be measured.
Inline sensors are used to determine the flow
rate based on the known pipe cross section. The
37
Heated measuring resistance
Magnet spools
Measuring pipe
Measuring
­electrodes
Measuring resistance
sensors first detect the current velocity and from it
are able to calculate the flow rate. The FTCI sensors
from Turck show the flow rate in the display. Such
sensors are reasonable and reliable, but due to the
different heat conductive features of the respective
media, they are usually only suitable for water and
water/glycol blends.
Considerably more expensive is a mass flow
meter that functions according to the Coriolis
Principle, which measures liquids and gas flow
rates. A medium flowing through a pipe elbow causes it to oscillate and the resulting Coriolis force is
measured. The advantages of the mass flow meter
are a very high measurement accuracy and measurement range dynamics, as well as the low pressure
loss. Furthermore, it is also suitable for both gases
and liquids.
For ultrasonic flow measurements, there are
two reliable processes. The Doppler Process uses
an ultrasonic wave's change in frequency reflected
from the medium and occurs when the sender and
recipient move relative to one another. With the
Run-Time Process the sound speed superimposes the current velocity of the medium. If the ultrasonic impulse runs with the current, this lowers the
run-time while the run-time in the opposite running
direction increases it. The current velocity can be
calculated from the measurement of the run-time
difference.
An additional important principle is the vortex
frequency process, also called the Vortex Principle.
Behind an obstruction that is integrated in the cur-

 Quick read
Flow rate sensors are often used in manufacturing automation for monitoring in order to detect
critical deviations from the flow velocity or the flow
rate. While the current sensors detect the velocity of a medium, the flow rate sensors measure
the flow-through volumes per time unit for a defined
pipe cross section.
Measuring principles of the
Turck flow rate sensors:
Thermodynamic, FTCI
(above left); magnetic
inductive, FCMI (above);
Vortex, FCVI (left)
Readings recorder
Obstructions
rent, the so-called Karmann Vortex Street is formed. Starting as of a certain flow rate, vortexes are
released periodically on both sides of the obstruction. The flow rate results from the frequency of the
vortexes that occur. Vortex flow rate meters, such
as the FCVI from Turck, are insensitive to pressure
and temperature changes of the medium. They are
therefore perfect for controlling process and cooling
water circuits, especially as the FCVI is exclusively
suitable for water.
The Differential Pressure Process is based
exclusively on the Bernoulli Principle. The pipe
cross-section is narrowed into the form of an orifice plate or nozzle. Because the volume and flow
current is the same in all areas of the piping system,
there results a pressure drop from which the flow
rate can be calculated according to the Bernoulli’s
Principle.
Flow rate meters that measure according to
the Magnetic Inductive Principle are suitable
for all conductive media that indicate a minimum
conductive capacity of 15 µS/cm. When creating a
magnetic field, the moved charge carriers induce
an electrical voltage in the current whose size is
proportional to the average flow rate of the medium. The FCMI magnetic inductive flow rate meter
from Turck has a high measurement accuracy of
two percent of the measured value and requires
no mechanically moved parts in the volume flow.
In addition, a reduction in the pipe cross-section is
not necessary so that in this process practically no
pressure loss occurs.
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Author
André Overländer is
product specialist
for process sensors at Hans Turck
GmbH & Co. KG
38 I N S I D E _ E S C H A
Escha is now
considered
one of the
leading manufacturers in
connection
technology
for automation
components
Loving Connectors
Whether a standard design or a special production – Escha supplies
more than just the Turck Group with innovative connectors and housings
39
Hand-made in
Germany: Escha
makes customerspecific cable
and connector
solutions – in small
batch sizes, too –
at its Halver site in
Sauerland, Germany
W
hether requiring M12x1 round connectors, 7/8” valve connectors, actuator/
sensor boxes or connectors which can
be assembled freely – anyone needing to connect
devices in automation technology will find the right
solution at Escha, a Turck Group company. What is
more, that solution can not only be picked from the
extensive catalog of standard products, as Dietrich
Turck, Managing Director of Escha Bauelemente
GmbH, emphasizes: “We stand out from the competition by some margin because we supply not only
classic standard connectors from the catalog, but
also any number of variants of these standard products – manufactured entirely to suit individual customer requirements.”
Beginnings in toolmaking
The origins and name of the company go back to
Halver toolmakers Eugen Schmidt. Escha was
founded from this company with the idea of being
able to develop and manufacture plastic parts and
connectors within the Turck Group. Escha’s toolmaking expertise was to effect an entry into injection
molding technology. With success – in no time, the
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2/2007
Halver site was being used to produce the first plastic housings for Turck.
Toolmaking also created a bridge to connectors, as
Escha built the tools Turck initially used to make its
first connectors in the USA. Later, Escha started producing the connectors itself – now the focus of the
company’s activities. For many years, Escha manufactured essentially for just one customer: Turck.
When Dietrich Turck, son of one of the founders
of Turck, assumed directorship of the company seven years ago, one of his primary objectives was to
make the company more independent and to develop its own product strategy and sales & marketing.
Escha is now one of the leading manufacturers in

 Quick read
Modern automation technology would not work without connectors.
Although standard catalog products are often sufficient, it is becoming
more and more common to need specific solutions tailored to suit the
customer’s requirements. Escha in Halver supplies both kinds of product
and has consequently developed into a successful company within the
Turck Group.
40 I N S I D E _ E S C H A
Escha customers benefit from the company’s high-performance toolmaking
connection technology for automation components.
Its broad range of standard products includes readyassembled, molded-on round connectors, valve
connectors, 2-way distribution systems, actuator/
sensor boxes with up to eight connection locations
for decentralized wiring at field level and connectors
for free assembly.
“
In an ideal
situation, Escha
can realize a new
customer-specific
product within one
to two weeks.
„
Marco Heck, Escha
Tailoring the standard to suit the
individual
The ability to adapt standard connectors to suit the
individual customer application is a special feature
of Escha. “We have a separate department for this
– and by the way, it’s our most successful”, says
Dietrich Turck. So if a customer needs standard
connector X, but with crossed wires, he can get it
from Escha. Variants in color, with individual cable
lengths or extra connectors fitted are also possible.
One reason for Escha’s success is the fact that these
variants can even be made in small batches. “Escha
entered the market for industrial automation technology connectors pretty late”, explains Turck. “In order
to distinguish ourselves from the established competition, we simply concentrated on the things that
no-one else wanted to make, including the manufacture of individual products in small batches.” A
frequent batch size for connectors without too much
variance is 20. Possible changes to standard connectors can be equipment with different connectors
on the ends; individual flange connectors assembled
to form chains of flanges are also possible, as are
cables printed specifically for customers or customer
logos embossed on the connector.
Successful subsidiary Escha TSL
Escha TSL GmbH is a former division of Escha
Bauelemente GmbH. It started life as Escha
Schalttechnik in 1986, making and selling dooropening buttons for road and rail vehicles. Patented buttons for inside and outside, reliable switching under harsh conditions of use and – typically Escha – rapid implementation of customer
requirements made the division the leading manufacturer in the sector. In developing the buttons,
particular attention is paid to the needs of people
with restricted mobility. The business was so successful that in 2006, the decision was made to
take the division out of Escha GmbH and set it up on its own as an independent company. For more
information, go to: www.escha-tsl.de
41
Highly flexible production
This is made possible by a highly flexible production
process in which a great deal is still done by hand
– all at the Halver site in Germany. This is a perfectly
conscious decision, as Dietrich Turck underlines: “If
numbers are small and constantly changing, you not
only need competent staff and the right technical
equipment; it also has to be possible for engineers
from Development to work closely with staff in Production. This would be very hard using staff in China
or Hungary.”
A product or project manager at Escha now has
direct access to Production. “This means that on a
Monday he can approve a drawing amendment for
a new variant and by Friday be accompanying the
pilot run to approve the component”, says Marco
Heck, Marketing Manager/Product Management. “In
the ideal situation - in other words if the customer is
well prepared and has a design specification for the
new product, Escha really can realize a new product
within one or two weeks.”
Escha likes to satisfy special
requirements
“Of course that only works with an outstandingly well-equipped toolmaking department which
builds all our tools itself”, says Turck. “Toolmaking
was the company’s core business before my father
took over. Now this expertise is the prerequisite
for rapidly adapting tools to suit the customer’s
requirements.” Only high-performance toolmaking
enables special products to be developed, the kind
you can’t just find in the market. “We combine our
expertise in toolmaking with experience in plastic
forming and connection technology”, is Heck’s comment on their recipe for success. “For us, inquiries
of this kind are not a nuisance as can be the case
for some of our competitors, frequently resulting
in “brush-off” quotations with high prices and long
delivery times. These are precisely the inquiries we
want.”
This is why the experts at Escha work in close
collaboration with their customers, often on board
at the project management stage. This then results
in in-house developments – like distribution components into which electronics will subsequently
be fitted for their customer Turck, for example. Or a
connecting block for light curtains for another wellknown customer from the automation sector, for
example, equipped with all the necessary contacts
and which simply has to be inserted in the appropriate diecast housing. “The customer initially wanted to
use a closed box, drill holes in it and then fit flanges
from behind. We developed a solution for them that
resulted in considerably less handling and assembly
effort”, explains Turck.
“We now deal with some 600 project inquiries of
this nature every year”, adds Heck. “Of course they
aren’t always as extensive as that, but in our business, two worlds very often collide. For example, the
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2_2007
industrial environment has to be linked to the office
world. Connector suppliers usually come from either
one sector or the other, but if the customers want
a finished product, a cable to connect those two
worlds, they need a supplier who deals with unfamiliar subjects and technologies. We are that kind of
supplier.”
Flexibility as a
factor for success:
Dietrich Turck
loves the orders
which leave the
competition cold,
“especially the production of individual
products, even in
small batches”
Innovative approach to standard
products, too
Its high degree of problem-solving competence
in special products does not mean that Escha is
neglecting standard products. The company provides innovative solutions here, too. “Some eight
percent of our staff are involved in developing new
products,” emphasizes Turck. “We want to be leading-edge suppliers in standard products – and we’re
very successful at that, too.”
As a result, Escha has often succeeded in
launching completely new product families with
properties previously non-existent in the market. An
example is the complete family of connectors for high
temperatures. New materials mean that they can still
operate with absolute reliability at temperatures up
to 150° Celsius. Escha also supplies a completely
newly-developed product portfolio to suit the food
industry – one of the highlights of SPS/IPC/DRIVES
2007 (see Page 4) – the innovative connector-maker
in Halver is once again making sure it causes a stir
in the market.

 Webcode
more20731e
Author
Olaf Meier is a freelance journalist in
Mönchengladbach
42
S E R V I C E _ C O N TA C T
Turck at trade fairs
Turck presents current product innovations and tried and tested solutions for
factory and process automation at numerous national and international trade fairs.
Be our guest – come and be convinced!
Trade fairs in Germany
Date
Name of fair
Location
21.04. - 25.04.2008
24.04. - 30.04.2008
22.09. - 25.09.2008
25.11. - 27.11.2008
Hannover Messe
Interpack
MOTEK
SPS/IPC/DRIVES
Hanover
Düsseldorf
Stuttgart
Nuremberg
International trade fairs
Date
Name of fair
Location, country
04.12. - 06.12.2007
04.12. - 07.12.2007
11.12. - 13.12.2007
19.02. - 22.02.2008
11.03. - 14.03.2008
12.03. - 14.03.2008
01.04. - 04.04.2008
01.04. - 04.04.2008
01.04. - 04.04.2008
21.04. - 24.04.2008
15.04. - 18.04.2008
14.05. - 16.05.2008
20.05. - 23.05.2008
20.05. - 23.05.2008
26.05. - 29.05.2008
04.06. - 06.06.2008
17.06. - 19.06.2008
23.06. - 27.06.2008
24.07. - 27.07.2008
15.09. - 19.09.2008
25.09. - 28.09.2008
30.09. - 03.10.2008
01.10. - 03.10.2008
07.10. - 10.10.2008
07.10. - 11.10.2008
20.10. - 24.10.2008
28.10. - 01.11.2008
30.10. - 31.10.2008
09.12. - 12.12.2008
PTA Ural
Industrial Automation India
Elektro Vakbeurs
Magyarregula
Smagua
Automaatika
Amper
Automaticon
Minskexpo Automation
Romcontrola
Elcom
PTA
Het Instrument
Agrokomplex
Eliaden
ISA Expo Control
RAX
Oil & Gas Show
Expo Pack
MSV
Automation
Aandrijftechniek
PTA Ural
Vienna-Tec
TIB
Expoquimia
Matelec
Sibpolitech
Automatisation
Ekaterinburg, Russia
Bangalore, India
Hardenberg, Netherlands
Budapest, Hungary
Saragossa, Spain
Tallinn, Estonia
Prague, Czech Republic
Warsaw, Poland
Minsk, White Russia
Bucharest, Romania
Kiev, Ukraine
St. Petersburg, Russia
Utrecht, Netherlands
Nitra, Slovakia
Lillestrøm, Norway
Mexico City, Mexico
Tel Aviv, Israel
Moscow, Russia
Mexico City, Mexico
Brno, Czech Republic
Mumbai, India
Utrecht, Netherlands
Moscow, Russia
Vienna, Austria
Bucharest, Romania
Barcelona, Spain
Madrid, Spain
Novosibirsk, Russia
St. Petersburg, Russia
Imprint
Publisher
Hans Turck GmbH & Co. KG
Witzlebenstraße 7
45472 Mülheim an der Ruhr
Tel. +49 (0)208 4952-0
[email protected]
www.turck.com
Responsible
Klaus Albers, -149,
[email protected]
Editors
Klaus Albers, Karen Keller
Collaborators on this issue
Bob Gardner, Markus Haller,
Walter Hein, Olaf Meier, Frank
Nolte, André Overländer, Raphael
Scholzen, Jörn Stövesandt, Christian Wolf, Marcel Vennemann
Art Direction/Graphics
Arno Krämer, Britta Fehr (images)
Realization
PICS publish-industry Corporate
Services GmbH
Nymphenburger Straße 86
80636 Munich
Project Management PICS
Jens Otte
Printing
Laupenmühlen Druck, Bochum
All rights reserved. The right to errors and technical amendments is reserved. Permission willingly given
for copying and electronic processing with the written consent of the publisher.

 Webcode more20780e
Turck on the In
Whether you are looking for sensor, fieldbus,
find the right solution for your application at the
search functions will help you in the process.
Visit Turck at several
trade fairs all around
the world. Experience
the “Full Range” for
factory and process
automation in a unique
environment. Under the
motto “Living Yellow”,
we offer you a perfect
view into the Turck
topics “Sense it! Connect it! Bus it! Solve it!”
3D visualizations on
touch panels open new
paths into interactive
communication
 Full text search Are you looking for a
product name, a known ID number or a particular feature? Just enter it in the search field
top left.
 Tree structure Are you looking for products
in a particular group, like cylindrical inductive
sensors, for example? Then click through the
menu structure on the left.
 Power Search Are you looking for a product to meet quite specific technical parameters? Then use the feature search to take you
to your specific solution.
www.turck.com
nternet
interface or connection technology – you can
touch of a button on www.turck.com. Three
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2_2007
43
Turck on site
With 25 subsidiaries and numerous branch offices, Turck is always close
by, wherever you are in the world, guaranteeing that you can get hold of
your Turck contacts quickly and obtain direct local support.
GERMANY
Headquarters HANS TURCK GmbH & Co. KG
Witzlebenstraße 7 ı Mülheim an der Ruhr ı (+ 49) (0) 208 49 52-0 ı e-mail [email protected]
 ARGENTINA ı Aumeco S.R.L.
(+ 54) (11) 47 56 12 51 ı [email protected]
AUSTRALIA ı TURCK Australia Pty. Ltd.
(+ 61) (3) 95609066 ı [email protected]
AUSTRIA ı Intermadox GmbH
(+ 43) (1) 4 86 15 87-0 ı [email protected]
 BAHRAIN ı TURCK Middle East SPC
(+ 9 73) 17 814 920 ı [email protected]
BELGIUM ı Multiprox N. V.
(+ 32) (53) 76 65 66 ı [email protected]
BRAZIL ı Sensor do Brasil
(+19) 3897 9412 ı [email protected]
BULGARIA ı Sensomat Ltd.
(+ 359) (58) 60 30 23 / 43 ı [email protected]
 CANADA ı Chartwell Electronics Inc.
(+ 1) (9 05) 5 13 71 00 ı [email protected]
CHILE ı Seiman S.A. ı (+ 56) 32 2 69 93 10 ı [email protected]
CHINA ı TURCK Tianjin Sensor Co. Ltd.
(+ 86) (22) 83988188 ı [email protected]
COLUMBIA ı Colsein Ltda.
(+ 57) (1) 2 36 76 59 ı [email protected]
COSTA RICA ı Tecnologia Interactiva C&L SA ı Cartago
CROATIA ı Tipteh Zagreb d.o.o.
(+385) 1 381 65 74 ı [email protected]
CYPRUS ı AGF Trading & Engineering Ltd.
(+ 357) (22) 31 39 00 ı [email protected]
CZECH REPUBLIC ı TURCK s.r.o.
(+ 420) (49) 5 51 87 66 ı [email protected]
 DENMARK ı Hans Folsgaard A/S
(+ 45) (43) 20 86 00 ı [email protected]
DOMINICAN REPUBLIC ı VZ Controles Industriales, CXA
(+ 809) 5 30 56 35 ı [email protected]
 EGYPT ı Egyptian Trading and Engineering Co. (E.T.E.)
(+ 20) (2) 2 90 83 80 ı [email protected]
EL SALVADOR ı J.R. Controles industriales SA. De C.V
(+ 503) 260 0172 ı [email protected]
 FINLAND ı Oy E. Sarlin AB
(+ 358) (9) 50 44 41 ı [email protected]
FRANCE ı TURCK BANNER S.A.S.
(+ 33) (1) 60 43 60 70 ı [email protected]
 GREAT BRITAIN ı TURCK BANNER LIMITED
(+ 44) (1268) 57 88 88 ı [email protected]
GREECE ı Athanassios Greg. Manias
(+ 30) (210) 9 34 99 03 ı [email protected]
GUATEMALA ı Prysa Productos y Servicios Integrales, S.A.
[email protected]
 HONDURAS ı Partes Industriales, S. DE R.L. DE C. V
(+ 504) 2 37 72 30 ı [email protected]
HONG KONG ı Hilford Trading Ltd.
(+ 852) 26 24 59 56 ı [email protected]
HUNGARY ı TURCK Hungary Kft.
(+ 36) (1) 477 07 40 ı [email protected]
 ICELAND ı Km Stal HF
(+352) 567 89-39 ı [email protected]
INDIA ı TURCK India Automation Pvt Ltd.
(+ 91) 20 25 63 00 39 ı [email protected]
INDONESIA ı PT. Yabestindo Mitra Utama
(+ 62) (21) 9 24 48 26 ı [email protected]
IRAN ı Partow Ideh Pars Company (PIP Co.)
(+ 98) (21) 88 75 17 71 ı [email protected]
IRELAND ı Tektron Electrical
(+ 353) (21) 4 31 33 31 ı [email protected]
ISRAEL ı Nisko Electrical Engineering & System Ltd.
(+972) (8) 9 25 73 55 ı [email protected]
ISRAEL ı Robkon Industrial Control & Automation Ltd.
(+ 972) (3) 6 73 28 21 ı [email protected]
ITALY ı Mazzeri S.R.L.
(+ 39) (02) 2871161 ı [email protected]
ITALY ı TURCK BANNER S.R.L.
(+ 39) (02) 90 36 42 91 ı [email protected]
 JAPAN ı TURCK Japan Office
(+ 81) (3) 33 77 56 10 ı [email protected]
 KOREA ı TURCK Korea Branch Office
(+82) (31) 500 45 55 ı [email protected]
KUWAIT ı Kana Controls Company
(+ 965) 4 74 13 73 ı [email protected]
 LATVIA ı Lasma Ltd.
(+ 37) (1) 7 54 52 17 ı [email protected]
„
LATVIA ı Osauhing “System Test
(+ 37) (2) 6 40 54 23 ı [email protected]
LEBANON ı Key Electronics
(+ 961) 471 52 90/1 ı [email protected]
 LITHUANIA ı Hidroteka
(+ 370) (7) 35 21 95 ı [email protected]
LUXEMBOURG ı Sogel S.A.
(+ 352) 4 00 50 51 ı [email protected]
 MACEDONIA ı Tipteh d.o.o. Skopje
(+ 389) 70 399 474 ı [email protected]
MALAYSIA ı Electrical Marketing SDN BHD
(+ 60) (3) 21 42 14 44 ı [email protected]
MEXICO ı TURCK Mexico S. DE R.L. DE C.V.
(+ 52) 844 482 6924 ı [email protected]
 NETHERLANDS ı TURCK B. V.
(+ 31) (38) 4 22 77 50 ı [email protected]
NEW ZEALAND ı W. Arthur Fisher Ltd.
(+ 64) (9) 2 70 01 00 ı [email protected]
NORWAY ı HF Danyko A/S
(+ 47) 37 04 02 88 ı [email protected]
 OMAN ı Advance Oilfields & Industrial Supplies LLC
(+ 968) 7 71 47 86 ı [email protected]
 PANAMA ı Accesorios Industrial S.A.
Panama City
PERU ı NPI Peru S.A.C.
(+ 51) (1) 2 37-11 66 ı [email protected]
PHILIPPINES ı Rantrade Industrial Sales
(+ 63) (88) 8 56 85 65 ı [email protected]
POLAND ı TURCK Sp.z.o.o.
(+ 48) (77) 443 48 00/19 ı [email protected]
PORTUGAL ı Salmon & Cia. Lda.
(+ 351) (21) 3 92 01 30 ı [email protected]
PUERTO RICO ı J.R. Electronics & Pneumatics corp.
(+ 1) (787) 292 7020 ı [email protected]
PUERTO RICO ı Premsco
(+ 1) (787) 268 40 40 ı [email protected]
 QATAR ı A.A. Engineering Services
(+ 9 74) 4 60 02 35 ı [email protected]
 ROMANIA ı TURCK Automation Romania SRL
(+ 40) (21) 2 30 02 79 ı [email protected]
RUSSIA ı TURCK Rus O.O.O.
(+ 7) ( 495) 2342661 ı [email protected]
 SAUDI ARABIA ı M.H. Sherbiny for Commerce
(+ 966) (3) 8 94 42 98 ı [email protected]
SERBIA AND MONTENEGRO ı Tipteh d.o.o. Beograd
(+ 381) (11) 3 13 10 57 ı [email protected]
SINGAPORE ı Jaytron & Systems Pte. Ltd.
(+ 65) (6) 7 43 60 84 ı [email protected]
SINGAPORE ı TURCK Singapore Office
(+ 65) 6562 8716 ı [email protected]
SINGAPORE ı World Best Components Pte. Ltd.
(+ 65) 6844 3680 ı [email protected]
SLOVAKIA ı Marpex s.r.o.
(+ 421) (42) 4 42 69 86 ı [email protected]
SLOVENIA ı Tipteh d.o.o.
(+ 386) (1) 2 00 51 50 ı [email protected]
SOUTH AFRICA ı R.E.T. Automation Controls (Pty.) Ltd.
(+ 27) (11) 4 53 24 68 ı [email protected]
SPAIN ı Elion S.A.
(+ 34) (932) 982 000 ı [email protected]
SWEDEN ı TURCK
(+ 46) (31) 471605 ı [email protected]
SWITZERLAND ı Bachofen AG
(+ 41) (1) 944 11 11 ı [email protected]
SWITZERLAND ı Econotec AG
(+ 41) (1) 8 38 48 11 ı [email protected]
 TAIWAN ı Taiwan R.O.C. E-Sensors & Automation Int‘l Corp.
(+ 886) (7) 7 22 03 71 ı [email protected]
THAILAND ı Technology Instruments Co., Ltd.
(+ 66) (2) 7 22 22 36 ı [email protected]
TRINIDAD ı Control Technologies Ltd.
Marabella
TURKEY ı DacelACEL Mühendislik Ltd. Sti.
(+ 90) (2 12) 210 7646 ı [email protected]
TURKEY ı Gokhan Elektrik
(+ 90) (2 12) 2 21 32 36 ı [email protected]
 UKRAINE ı SKIF Control Ltd.
(+ 7) (44) 2382037
UNITED ARAB EMIRATES ı Dynamic Electro Mech. Eng.
(+ 971) (4) 336 99 55 ı [email protected]
URUGUAY ı Dreghal S.A.Importaciones-Representaciones
(+ 598) (2) 903 16 16
USA ı TURCK Inc.
(+ 1) (7 63) 5 53 92 24 ı [email protected]
 VENEZUELA ı CADECI C.A.
[email protected]
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Witzlebenstraße 7
45472 Mülheim an der Ruhr
Germany
[email protected]
www.turck.com
D900383 1107
Page 38
Hans Turck GmbH & Co. KG
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