The King of Level Sensors – The KingCrown CleverLevel PL20 Series from Baumer

Down with Vibrating Fork Sensors, long live the King! The KingCrown CleverLevel PL20 Series Level Sensors are setting the stage as the most dependable and versatile level detection solution for a wide variety of troublesome media and processes.

With an adaptive-trigger function, these capable level sensors are a step ahead of vibrating fork sensors, automatically adjusting to all media without parameterisation. Applications vary from dry running protection for pumps through reliable overfill protection or leak detection to the selective detection and masking of foam or separating layers.

360 Degree Process Visualisation, Even in Daylight!

Robust process visualisation is built-in using 360° LEDs which provide real-time information on the process status, with 5 defined colours which can indicate whether the process is working as intended, the sensor is switching, or if there is an issue. Additionally, the colours can be used to indicate which medium is being measured and analogue values ranging from 4…20mA can be read out.

It doesn’t matter whether it’s bulk goods, powders, liquids or foam, or if the medium is sticky or has high or low viscosity, the KingCrown Level Sensor is the new King in town!

During industrial cleaning processes, such as CIP cleaning, sensors can switch incorrectly as they cannot differentiate between the process and cleaning media. The PL20 Level Sensors master this challenge by ignoring cleaning media. Also, media adherence, which can be caused by pasty materials, doesn’t affect these sensors, which adjust their switching level without the need for parameterisation.


Hot, Humid, No Problem!

In very humid areas, or those with temperature changes or water spray, a rugged impermeable design is needed to prevent sensor malfunctions. With exceptional resistance to impacts and fracturing during installation and production the KingCrown PL20 Series is perfect for demanding working conditions. Designed according to Baumers proTect+ Impermeability Concept, the PL20 Level Sensors are ideal for these challenging conditions. (Learn more about the Baumer proTect+ here).

Beverage and Rugged Industrial Application Versions

A built-in IO-Link interface provides easy access to valuable data, additionally it allows easy, location-independent parameterisation of the level sensor.

Available in two versions, with multiple mounting options, the PL20H for Food and Beverage process use and the PL20S variants for demanding high-pressure industrial applications.

PL20 Series Level Sensor Features and Benefits

  • 5 Multicolour LEDS, 360° real time status display even in daylight
  • Versions for Hygienic and Industrial applications, can be used in open tanks
  • Long term impermeability over entire service life according to Baumer proTect+
  • Measuring principle – Frequency sweep
  • IO Link interface
  • IP68 and IP69K protection rating
  • Impact and fracture resistant
  • PNP, NPN Output types, NO, NC, short circuit protected
  • Unaffected by temperature changes
  • Electrical connection made of stainless steel
  • Suitable for use in outdoor, hygiene and washdown applications
  • Point level sensor with automatic parameterisation with changing media and adherence
  • Universal for liquids and bulk materials (DK >1.5)
  • Separately adjustable switching outputs with IO-Link, optional 4 – 20 mA analogue output

With a reduction in the wide variety of components needed by using the same sensor type has many advantages including procurement, spares and maintenance costs. The development of new plant and machinery is also more efficient and the large number of available process connections and adapters available for the PL20S and the PL20H Level Sensors simplifies integration into existing systems.

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Kempston Controls and the SICK SPEETEC Sensor Help Solve a Real Steel Processing Problem

Recently, Kempston Controls eagerly answered the call when TATA Steel Tubes, who are based in Corby, Northants, called asking for a demonstration of the versatile non-contact SICK SPEETEC sensor to help them solve a processing issue.

TATA Steel Tubes manufactures a wide range of steel products and they were looking for a way of using the SPEETEC sensor system to monitor the speed of tubing travelling through a process, and another SPEETEC sensor to verify the length of the material being cut.

After an initial discussion with the engineering manager at TATA Steel a demonstration was arranged. A member of Kempston Controls technical sales team, along with a sensor specialist from SICK would be onsite. The production line would be stopped so they could set-up and test the advanced SICK SPEETEC sensor within the actual process itself.

The operating environment in a steel processing plant is, as you can imagine, very demanding, and during the demonstration the sensor was sprayed with industrial machine coolant and exposed to swarf from the cutting process which had no effect on the performance of the robust non-contact SPEETEC sensor.

During the Demonstration the Following Issues were Found:

  • The existing process demanded that an encoder be mechanically coupled to the tube, resulting in a potential for damage to valuable equipment and material
  • The speed reference provided to the flying saw was incorrect, resulting in angled cuts in the tubing with unwanted axial forces being placed on the cutting blade. Ultimately leading to damage to the processing equipment and unwanted down time
  • The typical speed of operation was 20m/min – 180m/min
  • For the second cut-to-length application the goal was to reduce material tolerances and waste

The Actual  SICK SPEETEC sensor within the Processing Machine

The Savings

The invoice cost of steel tube at the time of installation was approximately – £1000/ton. The Kempston Controls technical sales engineer based the calculation around using a typical mild steel tube of 50mm diameter and a 3mm wall thickness weighing 3.5 kilograms per metre. The steel processing line was running at approximately 90 metres per minute.

Assuming the tolerance could be reduced by 0.1% this would result in an additional invoice value of material of:

  • 90 x 3.5 x 0.1 / 100 = 0.315 Kg per minute
  • If the process was to be run continuously for 8 hours this would equate to 0.315 x 8 x 60 = 151.2 Kg
  • At £1000/ton that effectively means £151.20 per 8-hour shift

On this basis alone TATA Steel would see the return on investment of a SICK SPEETEC sensor system in only a matter of weeks!  Over a longer period-of-time the process savings will quickly add-up, not just by reducing the manufacturing cost of the product itself, but also by improving the reliability of the process, through-put, reducing wear on process machinery, and helping to keep downtimes to a minimum.

The SPEETEC Sensor

The rugged and maintenance-free non-contact SICK SPEETEC laser surface motion sensor has been designed to detect movement via the surface of a product. Measuring the speed, length, movement direction and the position of objects of almost any surface type. The ideal solution for use in encoder-based applications that feature fast and dynamic processes.

SPEETEC Sensor Features

  • Non-contact measurement speed, length, and position of objects
  • Compatible with multiple materials, colours, and surfaces
  • Very high measurement accuracy and repeatability, speeds up to 10 m/s
  • Laser class 1, rugged design, compact dimensions, low weight
  • Standardised communication interface
  • Maximum resolution 10 m/s
  • Wear free

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Read More about the SICK SPEETEC Sensor Here

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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SICK PBS plus Pressure Sensor – Added Versatility for Pressure Monitoring Installations

The PBS plus Pressure Sensors from SICK, expands upon their existing PBS Sensor range, they have been purposely designed for demanding industrial applications, providing an electronic pressure switch, pressure transmitter and display all-in-one, available with up to two switching outputs, analogue output and IO-Link communication.

PBS plus Pressure Sensor in actionSimple to set-up, the PBS plus features three large pushbuttons and an easy-to-read display and they can be set-up using IO-Link, which also provides diagnostic functions and simplifies predictive maintenance, external parameterisation also makes handling easier and ensures lower maintenance costs.

 

Easily adapted for countless installation possibilities

The PBS plus range of Pressure Sensors are easily adapted to suit numerous installations, for example, the housing can be rotated twice, once at the process connection and then at the display cap, meaning the electrical connection can be rotated in the desired direction at any time.

Versatile, thanks to the large number of available process connections, including a flush-mounted membrane for sticky, crystallising and viscous media, helps to widen the integration possibilities of the PBS plus Pressure Sensor series. With measuring ranges of 0.4 bar to 1,000 bar (gauge pressure), the PBS plus can be used in many different applications. It also has absolute pressure and vacuum measuring ranges.

PBS plus Pressure Sensor Applications

  • Measurement of system pressure in hydraulic systems
  • Control of the clamping pressure in CNC machines
  • Monitoring of the cylinder pressure in hydraulic presses
  • Control of the pressure in cooling and lubricant systems
  • Hydrostatic level measurement
  • Measurement of system pressure in PET bottle production

 

 

The best in challenging conditions

Whether in aggressive environments, with measuring ranges of 0.4 bar to 1,000 bar, or when used with viscous liquids, the PBS plus takes challenging environments in its stride. Due to the integrated electrochemical cell with fully welded stainless steel membrane, it can withstand even aggressive media, as no sealing medium is required between the electrochemical cell and the membrane. Temperatures between –20 °C and +85 °C are no problem for the PBS plus.

 

PBS plus Pressure Sensor in action

 

This series of robust pressure switches have been designed for optimum functionality and range of use, resulting in a wide range of setting options reducing the number of sensor variants required within a production process ultimately reducing costs for customers.

 

SICK PBS plus Sensor Benefits

  • Switchable switching outputs (PNP/NPN) and analogue output (current/voltage)
  • Scalable analogue output (5:1 turn down)
  • High measurement accuracy: ± 0.5%
  • IO-Link for transmitting process data to the control system, measured values in bar
  • Housing can be twisted in two places (process connection/display), display can be rotated 180°
  • Common process connections, also with flush-mounted membrane
  • Rugged design: stainless steel measuring cell
  • Extensive diagnosis options via IO-Link
  • Economic solution for hydrostatic level measurement
  • Reduced installation time

PBS plus Pressure Sensor Technical Features

  • Gauge pressure – 0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 1,000 bar (0 psi …14,504 psi)
  • Absolute pressure -0 bar … 0.4 bar (0 psi … 6 psi) to 0 bar … 25 bar (0 psi … 363 psi)
  • Compound pressure  -1 bar … 0 bar (-14.5 psi … 0 psi) to –1 bar … +24 bar (-14.5 psi … +348 psi)
  • Pressure unit – bar (can be switched to psi, MPa, kPa, kg/cm2)
  • Accuracy  ≤ ± 0.5 % of the span
  • Setting accuracy of switching outputs  ≤ ± 0.5 % of span
  • Output signal – Output 1: PNP/IO-Link, Output 2 (optional): PNP/NPN switchable, Analog output (optional): 4…20 mA / 0…10 V switchable
  • Electrical connection M12x1 round connector
  • Approvals CE, cULus
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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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Indoor Air Quality monitoring with the Lascar EL-WEM

For a considerable amount of our day just about everyone is spending a large amount of time indoors, either at home, shopping or working.  Without thinking about it we breath in the surrounding air for our bodies to extract the oxygen we need to survive and expel waste gases such as CO2, but do we give any consideration about the quality of the air we breathe whilst spending time indoors?

The Air Indoors

Air quality found in our homes or where we work can vary greatly depending on the materials used to construct, furnish, decorate, ventilate and clean these premises. Pollutants found within a typical indoor environment include radon, tobacco smoke, particulates and gases from burning candles, fuels, polishes and cleaning chemicals, seasonal allergens, Carbon Monoxide and Nitrogen Dioxide. Adding to that already extensive list are Volatile Organic Compounds (VOC) which can found in construction materials and furniture, such as formaldehyde and flame retardants in upholstery.

Asthma attacks, irritated eyes, nose and throat, coughing and other health issues can be caused by interior air that has a high particulate count. Particulates of 10 µm (PM10) in diameter include dust, pollen and mould spores. Smaller air particulates (less than 2.5 µm/PM2.5) include smoke, smog, bacteria, fine dust and liquid droplets which can lodge deep into the lungs causing long-term illness.

 

The Air Quality Solution

The need for particulate sensing and control is increasing around the world due to regulatory and government requirements and VOC sensors can play an essential role in managing interior air quality.

Lascar, who are renowned for the design and manufacture of environmental data loggers, panel meters and many other quality devices have created an easy to use solution for determining if the air you are breathing, whether at work or at home, is hiding potentially harmful particulates.

 

 The EL-WEW Range

The EL-WEM range has been designed to continually monitor the Interior Air Quality (IAQ) of a room, displaying the air quality status via a coloured status ring, a quick glance tells you all you need.

WiFi enabled, the EL-WEW Sensors will automatically upload data to the EasyLog Cloud (Lascars, single user, free cloud enabled sensor monitoring solution), allowing your data measurements to be viewed, analysed and downloaded from any internet-enabled device.

The EL-WEM measures particulate matter (PM2.5), temperature, humidity, VOC’s and pressure, rating the IAQ on five levels from Excellent to Inadequate and if the IAQ level is of a low quality a sounder will activate and an email and SMS notifications alert can be sent to a list of selected contacts, informing them of the air quality situation.

This clever Air Quality Monitoring Sensor also features a configurable night mode, which mutes the sounder and turns the lights off at certain times. The EL-WEM range is simple to set up, with a single button press and using the EasyLog Cloud App.

EL-WEM Air Quality Monitor Features

  • Monitors Indoor Air Quality (IAQ)
  • Automatically uploads data to the EasyLog Cloud
  • Coloured status ring show IAQ level
  • Sounder and instant SMS and email notifications when IAQ is poor
  • Detects VOCs from paints, lacquers, paint strippers, cleaning products, furnishings, glues, adhesives and alcohol
  • Power supply included
  • Internal back-up battery if power interrupted

Measures:

  • IAQ
  • Temperature
  • Humidity
  • VOC’s
  • Particulate Matter: PM1 (+ model only) PM2.5 and PM10
  • CO2 (+ model only)
  • Pressure

 

With the increasing need to monitor and control the quality of the air within a room, office or a specific enclosure you can depend on Kempston Controls to help you find the ideal product solution.

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