Ultrasonic Sensor Technology for Safety in All Areas with the Pepperl + Fuchs USi- safety

The USi-safety ultrasonic sensor system from Pepperl + Fuchs is breaking down the barriers imposed by other sensing solutions. Whether operating in challenging, dusty conditions or outdoor  – industrial machines, vehicles, processes  and the people using them can be protected using the advanced ultrasonic technology utilised in these sensors.

Intelligent Design for Every Situation

When a miniature sensor unit is detached from the control interface it means the sensor system can be used in confined spaces, and the unique design allows the sensor to cover an elliptical 3-D sound field with opening angles of ± 17° and ± 5°, providing improved safety.

Manipulation protection and Parameterisation

Preventing safety functions from being overridden is challenging, the USi-safety system features a teach-in process when a machine part is used as a reference target, the sensor can register deviations immediately. Comprehensive parameterisation software and automatic documentation make commissioning the ultrasonic sensor system quick and simple.

Elliptical Sound Field for a Wide Sensing Range

The USi-safety features a strongly elliptical sound field, creating a wide sensing range in one plane and a narrow sensing range in the other. The system can be used just above ground level or close to a wall, allowing the sensor to detect targets or obstacles that are overhanging or near to the ground.

Two Category 3 PL d Safe Systems in a Single Evaluation Unit

A maximum of 2 ultrasonic sensor units can be connected to the evaluation unit. These ultrasonic sensor units have a single-fault tolerance, 2-channel structure. A safe sensor system is achieved even when only one sensor unit is connected. One signal output and safe OSSD outputs in accordance with category 3 PL d are available.

This capable ultrasonic safety sensor system can be used in applications where left/right or forward/reverse movements need to be safeguarded, such as on Auto-Guided Transport (AGT) Systems. Applications can be implemented in which both sound fields are focused directly adjacent to each other or overlapping, securing the widest possible collective sensing range.

ultrasonic sensor USi-Safety

A Complete System

The USi-safety ultrasonic sensor system consists of an evaluation unit, a sensor unit, a temperature sensor, and the software.

The evaluation unit contains two microcontrollers that monitor the connected sensors, their own hardware, and each other to ensure that the components are functioning correctly. In addition, there is an input for a temperature sensor and a USB interface for parameterisation via a PC.

IP69K protection makes the system’s 2 ultrasonic sensor units suitable for even the most demanding conditions. With their miniature design, they can be flexibly integrated into numerous applications. The system reliably detects even the smallest objects within their wide 3-D sensing range.

The parameterisation software allows a wide range of settings such as switch points, output logic, safety parameters, and ultrasound-specific parameters to be customised. The interface can be used to initialise periodic tests and automatically generate safety protocols.

USi-safety Ultrasonic Sensor Application Examples

ultrasonic sensor USi-Safety

Collision Avoidance in the Fork Tip

Reliably preventing collisions involving driverless forklifts is ideal for the USi-safety ultrasonic sensor system. As the technology is resistant to dirt, temperature, air currents, and humidity, it significantly expands the area of use for these automated guided transport systems.

Machine Safeguarding in the Wood Industry

Usually, machines are safeguarded by photoelectronic light curtains. The USi-safety, used as a sound curtain, is insensitive to wood dust and other particles and can withstand demanding environments.

Personal Safety in Lane-Guided AGVs

Lane-guided AGVs follow a lane on the ground and transport goods from one station to the other. In this process, the detection range of the sensors can be quickly and easily adapted via the parameterisation software to help prevent collisions.

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RFID UHF Reading and Writing

ST-G RFID Sensors with Multi-tag Ability for Industrial Process Control and Safety Applications

RFID or Radio Frequency Identification uses a digitally encoded tag with information that can be read and captured by a reader using radio waves. A basic RFID system consists of the tag, and an RFID reader. Typically, an RFID tag transmits digital information to an RFID reader within close proximity, which then converts that information into usable data for interpretation and a system response from another piece of equipment. RFID has found multiple uses within industry, including process control and the increasing the safety of machine guarding.

Pizzato are a well-known manufacturer of process control equipment including a broad range of machine access and safety control devices including Safety Hinges, Safety Modules and Limit Switches.

RFID Sensors – Positional Accuracy

The Pizzato’s ST-G RFID sensors extend all the technology used in their traditional ST-D series sensors, and do that in an even more compact housing.  The RFID technology within provides each actuator with different coding, making it impossible to tamper with a device by using another actuator of the same series. Ultimately, this means millions of different coding options are possible for the actuators, classifying them as high-level coded actuators according to EN ISO 14119.

Versatile, these RFID sensors are suitable for a host of process control applications and the clever housing design allows the same sensor to be used on both left and right-hand safety doors by simply rotating the sensor onto itself. The industry standard 22 mm fixing pattern and compact external dimensions means traditional magnetic sensors can be easily replaced with these more sophisticated RFID Sensors, providing maximum reliability and safety. The robust monolithic housing allows the ST-G RFID Sensors to be used in even the most aggressive industrial environments and the signalling LEDs providing immediate diagnostics of the input and output operating states.

ST-G RFID Sensors and Actuators

Within this range of industrial sensors is an extended temperature version that is certified by ECOLAB, this ensures that these sensors are ideal for machines used in the food and pharmaceutical industry. Constructed with redundant electronics means that the maximum PL e and SIL 3 safety levels can be obtained via the use of a single device on a guard, avoiding expensive wiring and speeding up installation.

ST-G RFID Sensors and Actuators

Multitag Programming

What sets the ST-G series of RFID sensors apart from the competition is an exceptional feature which Pizzato has called Multitag. Multitag is the ability of the sensor to recognise 2 or more actuators in a processing environment. The internal firmware can be factory programmed, memorising up to 16 actuators and associating a different device behaviour to each once the actuator has acknowledged the sensor. This ability allows the user to activate or deactivate the sensor outputs and send information regarding which actuator is in front of the sensor via an O3 signalling output. This signal can be sent to a PLC and processed.

ST-G RFID Sensors and Actuators

This Multitag function is ideal for machines and industrial processes with several workstations that require various operating modes based upon the recognition between different actuators and the sensor – such as during the change-over of machine parts, robot positioning during manufacturing, industrial process rotary tables control and so on.

For safety gate applications the combination of a sensor and 2 actuators can fully monitor safety guard opening and closing by acknowledging when the guard is fully open and again, fully closed, eliminating the uncertainties caused by incomplete guard positioning and ultimately increasing intrinsic safety.

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ST-G RFID Sensor Features

  • Pizzato Multitag programming system, up to 16 actuators
  • Symmetrical easy-to-mount housing
  • 22 mm standard mount hole spacing
  • M12 fixed connector and prewired M12 cable options
  • Compatible with all ST series actuators
  • Process Control and Safety Gate applications
  • Digitally coded actuators
  • Connect as many as 32 sensors in series
  • Actuated from multiple directions
  • IP67 and IP69K protection versions
  • M12 plastic or stainless-steel connector versions
  • Multicolour signalling LED, visible from both sides
  • Approvals CE, cULus, TUV, EAC

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Sirius Act ID Key-Operated Switch Starter Kits!

Utilised in applications the world over, the electronic ID key-operated switches from the Siemens SIRIUS ACT family of commanding and signalling devices has proven its durability and flexibility compared to conventional solutions over-and-over again.

Customisation Abilities

These high-spec switches feature customisation abilities that allow the user to set authorisation for machine access, represented by 4 separate and individually coloured keys. A built-in RFID chip makes the keys uniquely identifiable ensuring they are used correctly and there is also an optional white key that can be configured to the customers specifications.

If the SIRIUS ACT ID Key is lost the systems remain secure as the key can be blocked and replaced. Individual access levels act as a time stamp to see who has used the HMI, and when a key has been inserted on the PLC side via a monitored output. With two different Starter Kit versions available this allows customers to choose the option that best suits their individual needs.

SIRIUS ACT ID Operated Key Features

  • Individual authorisation management for groups and individuals
  • Unambiguous identification of users
  • Increase plant safety
  • Highly flexible authorisation assignment

Take a look at the variety of ID key-operated switches available and see for yourself how the Starter Kits work.

Siemens SIRIUS ACT ID Key-Operated switch kit

Choice of pre-programmed and freely programmable options for the perfect application solution.

The two Starter Kits contain everything you need to get started:

  • SIRIUS ACT components, ID key operated switch including ID key
  • Label holder with 4 labels
  • Partially insulated screwdriver
  • IO-Link electronic module (pre-programmed or freely programmable)

 

SIRIUS ACT Starter Kit Advantages:

  • Individual authorisation management for groups or individuals
  • Unambiguous identification of users
  • Increased plant safety
  • IP65 protection rating
  • Different coloured RFID keys for each authorisation level
  • Unrestricted selection and combination of authorisation levels, freely programmable for individual special locks via IO-Link
  • Easy integration into plant via TIA Portal (Port Configuration Tool)
  • Highly flexible authorisation assignment

Siemens SIRIUS ACT ID Key-Operated switches

SIRIUS ACT ID Key-operated Switch Starter Kit 1 – 3SU1900-0XD10-0AA0

  • ID Key-operated switch with pre-programmed IO-Link Electronic Module
  • IO-Link module with four pre-programmed authorisation levels
  • Coloured keys: Authorisation levels encoded at the factory
  • White key: Authorisation levels 1–4 freely programmable via IO-Link (individual special lock)
  • Simple disabling if keys for special locks are lost
  • Easy plant integration via TIA Portal (Port Configuration Tool)

 

SIRIUS ACT ID Key-operated Switch Starter Kit 2 – 3SU1900-0XE10-0AA0

  • ID Key-operated switch with freely programmed IO-Link Electronic Module
  • Fulfilment of customer-specific application requirements, the four LEDs on the actuating element can be encoded as required

IO-Link is used to transmit the following signals:

  • Impulse rotate left
  • Impulse rotate right
  • ID key inserted
  • ID number

 

With the ability to reduce the use of personalised passwords and the issues caused by their loss and maintenance and to improve device control and security it is easy to see how the SIRUIS ACT ID Key products are the ideal solution.

Kempston Controls, as a Siemens supplier partner, has access to the entire SIRIUS ACT ID Key range, call us on +44 (0) 1933 411411 or email sales on sales@kempstoncontrols.co.uk or use the enquiry from below to discuss your requirements today.

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STC5 – the Next Level in Intrinsically Safe Transmitter Power Supplies

The Pepperl + Fuchs STC4 range of transmitter power supplies will no longer be available from the end of December 2021, it’s time you considered switching to the more advanced and far more capable STC5 Models.

STC5 – The Next Level in Transmitter Power Supplies

The innovative STC5 transmitter power supply isolation barriers and signal conditioners have been designed for the protection of intrinsically safe circuits in hazardous areas providing galvanic isolation between field circuits and control circuits. Feature-packed, the STC5 provides current and voltage limitations and electrical isolation (in a diminutive 20 mm housing) between a field circuit and control mechanism in an intrinsically safe installation.

Flexible, Dependable, Reliable

Designed to last, the STC5 range of transmitter power supply isolation barriers and signal conditioners offers more flexibility than their predecessors, using a double output function to the control side. Advanced circuitry with reduced power dissipation in the device when in sink output mode lowers cabinet temperatures, leading to an increased lifetime of the installed modules.

STC5– Ideal for high-channel density installations

  • Highest packing density on the market
  • High power dissipation capability
  • Connectivity for 3-wire transmitters
  • Supplies 2-wire and 3-wire SMART transmitters
  • Can be used with 2-wire SMART current sources
  • Digital signals may be superimposed on the input signal and transferred bidirectionally
  • Sink mode or a source mode output on the safe area terminals
  • Internal resistor if the HART communication resistance in the control circuit is too low
  • Test sockets for the connection of HART communicators integrated into the device terminals
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Make the Change

Kempston Controls, a supplier partner for Pepperl + Fuchs, is here to help you. Whether you are retrofitting or building an entirely new intrinsically safe installation, the STC5 is the perfect solution. Give Kempston Controls a call today on +44 (0) 1933 411411 or email us at sales@kempstoncontrols.co.uk, or use the enquiry form below.

View the STC5 Range

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Safety Light Curtains with Advanced Bluetooth Interface

Safety light curtains, or as they are often known as – light barriers, light grids and light guards to mention just a few alternatives are classed as Electro-sensitive Protective Equipment. Consisting of a transmitter and a receiver head, light curtains generate a field of infrared light between these heads which is classed as the detection zone.

Invisible Light Protection

Typically, these diligent devices are situated around access points to a piece of processing machinery, shutting down the device should a person, or a part of a person, cross the beams of the safety grid.  Advantages of a light curtain include reduced operator fatigue, when compared to mechanical options such as gates and barriers, and the subsequent upkeep of these mechanisms and simplifying maintenance and set-up times.

safety light curtain installation

Utilised across numerous industry sectors for many years, light curtains come in many shapes and sizes. Schmersal, renowned for their impressive range of Safety Light Curtains decided to add yet more functionality to these popular process safety devices by adding a built-in high specification Blue Tooth interface.

The Schmersal SLC440/COM Safety Light Curtain range with built-in Bluetooth BLE (BLE stands for Bluetooth Low Energy) is an active optoelectronic protective device that can provide real-time status and diagnostic data of the light grid on a smartphone or a tablet via a Bluetooth interface.

Ideal for Predictive Maintenance

The Bluetooth interface allows easy start-up using a smartphone or tablet with the integrated set-up aid. There is also the useful option of saving the data, which can then be used to document a repeat test or for predictive maintenance purposes. The transmission of data to smartphones / tablets (Android, IOS) is facilitated by an app developed by Schmersal.

NFC technology has been used successfully in the past when it came to recording and monitoring device diagnostic data, however it is limited to only a few centimetres. The Bluetooth BLE interface contained within the SLC440/COM Light Curtains can achieve a range of up to 100 times more, around 5 metres in total.

This means the BLE interface is perfect when the safety light curtain installation is in a relatively inaccessible position. Bluetooth BLE also offers a greater range of applications because not all smartphones or tablets are equipped with NFC. As Bluetooth is an international industrial standard, the SLC440/COM range can be used all over the world.

safety light curtain installation

Safety and Efficiency

The SLC440/COM Safety Light Grid with BLE are ideal for improving efficiency and availability in manufacturing processes as their status can be accessed easily and in real-time, meaning issues can be captured early. Status information and diagnostic data enables processes to be reactivated quicker, particularly in the event of a system shutdown if a hazard is detected.

It also represents an economical innovation as, compared to classic Bluetooth, BLE is characterised by considerably lower energy consumption and reduced costs at a similarly high communication range.

All of the SLC440/COM range of light curtains are available from Kempston Controls, give our sales team a call on +44 (0) 1933 411 411 or email them at sales@kempstoncontrols.com, or use the enquiry form below and let us help you select your ideal light curtain solution.

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Gas Valve Shut off Safety with the Emerson ASCO Series 158 Gas Valve & Series 159 Motorised Actuator

Designed specifically for burner-boiler applications, the Emerson ASCO Series 158 Gas Valve and 159 Motorised Actuator helps provide OEMs, distributors, contractors and end-users with a robust, reliable and dependable combustion safety shut off valve option that enhances safety and reliability and increases both flow and control.

Double the flow rate

The 158 Gas Valve which features a flow rate double that of competing valves, offers a higher close-off pressure of 75 psi (5.2 Bar) ensuring a safe shutoff in the event of a fuel train system failure and eliminating the need for additional safety components. This Gas Valve provides the highest BTU rating in the industry and will not suffer any reduction in performance and operation should the gas inlet pressures vary.

gas valves are used to control burners

Erik VanLaningham, vice president of marketing for industrial automation at Emerson stated – ‘We’re offering our customers a highly adaptable safety shutoff valve that offers the same high levels of safety and reliability they have come to associate with the ASCO combustion valve products. We are dedicated to providing easy-to-use, globally applicable combustion control solutions with the flexibility to address a full range of commercial and industrial applications.’

Takes up less space, easy to install

Simple to install, and with a small physical footprint, piping union free end connectors and with a ventless monoblock construction that eliminates the need for additional vent piping and helps limit greenhouse gas and vented emissions. The ASCO Series 158 Gas Valve is available in sizes from ¾” NPT to 3” NPT (DN 10 to DN 80) in both single and monoblock construction.

The rugged ASCO Series 159 Motorised Actuator can be mounted in any orientation and provides a visual indication when open. Rated for an ambient temperature range of -40°C to 66°C (-40°F to 150°F).

gas valves, typical industrial backdrop

The Series 158 and Series 159 meet up-to-date National Fire Protection Association (NFPA), UL, Canadian Standards Association (CSA) and FM Global standards and have earned Restriction of Hazardous Substances (RoHs) and European Standards (EN) approvals.

Perhaps you are installing a new burner/boiler combination in your processing plant or retrofitting an existing set-up? You need to speak to the friendly people at Kempston Controls! Call us today on +44 (0) 1933 411 411 or email sales@kempstoncontrols.co.uk or use the enquiry form below and let us help you find the perfect product solutions.

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