SicWave – 80 GHz Free-space Radar Level Detection for all Liquids and Solids

The storage of products such as grains, sugar, ore and liquids can take up a lot of space, typically utilising silo systems which can reach considerable heights. Measuring the level of product within these storage facilities can be difficult at the best of times where both the height and the media within can cause various issues with accurate level sensing. Similarly, production processes that involve stirrers and preparation tanks can create internal environments where accurately measuring the level of the contents within is challenging.

Dust and Foam Frustrations

Dust, moisture, foams, the build-up of residues and other obstructions within a storage or processing vessel can frustrate your average sensor, leading to down time, additional costs and frustration. What you need is a sensing solution that can deliver reliable level sensing results no matter how tall the silo or how demanding the process and the media involved prove to be.

To address these challenges and more, SICK, world renowned for their sensor solutions, have created the high-specification SicWave LFR and LBR ranges of level sensors, these sensors utilise an 80 GHz free-space radar technology delivered via a highly-precise narrow beam that is a thousand times more sensitive than previous generations 26 GHz radar technology.

SicWave LBR – For Solid Media Level Detection

SicWave LBR sensors

Demanding situations require dedicated solutions, the SicWave LBR free-space radar provides continuous non-contact level measurements, is highly resistant to external interference, dust and deposits and works with all solids. A high-contrast built-in LCD display option is available, aiding set-up and installation and providing the user with essential sensor feedback data. Utilising a unique non-contact 80 GHz radar technology and a highly-focused narrow beam, the LBR range is simple to install and is maintenance-free. With a wide range of options such as antenna design, process connectivity and housing material types ensures these sensors are ready for any application.

Avoiding Those False Signals

The narrow field of view also avoids the potential for false signals caused by dusts and deposits on walls or by other obstructions inside the storage vessel the LBR Level Sensor helps prevent unexpected downtime.

SicWave is accessible using bluetooth

 

Remote set-up and interrogation of the sensors is straightforward, either using the on-board WPAN interface to a smartphone or tablet via Bluetooth or through standard HART communication which also enables easy integration with control and diagnostic systems. These sensors feature a 4 – 20 mA output, allowing signals to be monitored and displayed on a cloud-based dashboard environment using IIoT gateways such as SICK’s Telematic Data Collector.

 

 

 

SicWave LBR Solid Media Level Sensor Range Features

  • Non-contact detection principle, continuous measurement
  • 80 GHz free-space radar with various antennas
  • Highly-focused narrow beam microwave radar pulse
  • Built-in high-contrast display option
  • Measuring range: up to 120 m
  • WPAN, HART and Bluetooth communication
  • 4-20 mA output
  • Process temperature: −40 °C to +200 °C
  • Process pressure: −1 bar to 20 bar
  • Sensor element accuracy ≤ 5 mm
  • Process connection options: thread, flange, special brackets
  • Housing: plastic (IP66 / IP67) or aluminium (IP66 / IP68)
  • Certificates: Ex d, Ex ia, Ex ta

View the Range

 

Typical SicWave LBR Sensor Applications

  • Crushers, belt transfer, raw meal, clinker and cement silos as well as silos for solid fuels
  • Breakers, storage silos for ore, silos in the metal and steel industry
  • Bulk material stockpiles, belt transfer, buffer and production silos in the mining industry
  • Storage and small silos in the food and beverage industry
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SicWave LFR for Liquid Level Detection

SicWave LFR Sensors

The 80 GHz SicWave LFR non-contact free-space radar sensor, with its highly-focused narrow beam, provides continuous level measurements, works with all liquids and is highly resistant to external interference, false signals, foam and deposits. Insensitive to material build-up, the LFR range of level sensors helps prevent unexpected downtime.

Up and Running in No Time!

Easy to commission, the LFR range can be put into operation quickly and easily and is maintenance-free. A wide range of options for antenna design, housing materials and a range of process connections ensure these sensors are ready for any application. A durable stainless-steel housing option is available for use in hygienic environments such as those required in the food, beverage and drug industries. A high-contrast built-in LCD display option is available, aiding set-up and installation and providing the user with essential sensor feedback data. Remote set-up and interrogation is carried out in the exactly the same way as the LBR range.

SicWave LFR Liquid Media Level Sensor Range Features

  • Non-contact detection principle, continuous measurement
  • 80 GHz free-space radar with various antennas
  • Highly-focused narrow beam microwave radar pulse
  • Built-in high-contrast display option
  • WPAN, HART and Bluetooth communication
  • 4-20 mA output
  • Measuring range: up to 30 m
  • Process temperature: −196 °C to +200 °C
  • Process pressure: −1 bar t0 25 bar
  • Accuracy of sensor element ≤ 1 mm
  • Process connection options: thread, flange, clamp
  • Housing: plastic (IP66 / IP67), aluminium (IP66 / IP68) or stainless steel (IP69)
  • Certificates: Ex d and Ex ia, WHG, shipbuilding

View the Range

SicWave LFR sensor in action

Typical SicWave LFR Sensor Applications

  • Chemical industry: large tank storage, storage and buffer tanks, reaction and transport containers
  • Oil and gas industry: mud pits, trip tanks, shakers and wastewater containers
  • Food and beverage industry: large, stirring and preparation tanks, thickener and filling tanks
  • Water industry: storage tanks for flocculants, coarse and fine screens
Enquire Now

 

Kempston Controls is the place to come to find the perfect SicWave Level Sensor for your next retrofit or installation project. Call us today on +44 (0) 1933 411 441, use the enquiry form below, or contact us via email at – sales@kempstoncontrols.co.uk.

 

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Motion Capture

deTec Safety Light Curtains
Kempston Controls

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.

Enquire Now

 

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POG 83 rotary encoder

Baumer’s POG 83 Series Rotary Encoders, Built for a life at Sea

Rotary encoders, or shaft encoders as they are often referred to as, are a popular engineering choice when it comes to location, speed and distance monitoring of an axle or a shaft that is located within a mechanical system. Typical encoder applications include industrial control systems, robotic production lines and conveyors, cranes, radar systems and more. Typically, Rotary Encoders come in two particular variants, these being absolute and incremental, absolute encoders provide details of a shaft’s current location, incremental encoders monitor the angular motion or the position of a shaft.

Electro-mechanical in nature, angular position and motion data from the monitored shaft is detected and converted into an analogue or digital signal for interpretation by other aspects of the installations control system to gauge speed, location, distance and act upon that information.

When it comes to motion, speed and distance monitoring in demanding conditions such as those found at sea, you will need a Rotary Encoder that has been specifically designed to resist and ignore the harsh and demanding environmental it is destined to function in.

POG 83 rotary encoder Offshore

Survival at Sea

Baumer are world renowned for their technically advanced Rotary Encoders and their POG 83 range is no exception having been designed specifically for harsh marine and offshore environments. These hardwearing Incremental Rotary Encoders are the go-to device for navigating your way around the extremely harsh perils of a working life at sea.

The POG 83 variants shown below are Incremental Rotary Encoders, with optical sensing and have been specifically designed to resist the adverse conditions found on deck all thanks the materials used and the impressively robust construction which ensures they remains environmentally sealed throughout their entire lifetime. Capable and durable, these rotary encoders pass IP tests not only when new or following DNV-GL tests, but even after via additional stress tests that simulate the aging effects of the sea.

Whatever you can throw at them these Incremental Rotary Encoders are suitable for a wide range of applications including – on-board cranes, floating cranes, on-deck motors, winches and many more.

POG 83 rotary encoder offshore installations

POG 83 Series of Offshore and Marine Incremental Rotary Encoder Benefits

  • High resistance to demanding sea conditions
  • High corrosion resistance to adverse deck conditions
  • No corrosion with salt spray or salt surface drying due to the high-quality stainless-steel housing
  • Liquid tight during temporary water overflow or high-pressure cleaning
  • Resistant to shocks and vibrations caused by waves or docking manoeuvres
  • Robust housing and high-quality ball bearings
  • Maximum machine availability
  • Long-term sealed design prevents the entry of water and vapour
  • Longer service life proven by upstream stress tests and IP tests
  • Minimised service costs, less frequent servicing
  • Variations with DNV-GL approval for simplified ship approval
  • Ready for the roughest conditions on deck
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POG 83 and POG 83 DNV-GL Incremental Rotary Encoders

POG 83 Rotary encoder

POG 83, POG 83 DNV-GL Shaft Encoder Common Features

  • Specially designed for deck machinery and cranes in offshore and marine environments
  • Stainless steel construction with optical sensing
  • Solid shaft ø11 mm with EURO flange B10 (ø115mm)
  • Robust bearings for extended service life
  • M23 flange box and circular plug-in connector in stainless steel
  • Protection class IP 66, IP 67, and IP 69K, offshore and saltwater firm
  • Pulse per revolution 512 – 4096
  • Phase shift 90 ° ±10°

 

POG 83 Additional Features

  • Tested long-term sealing with an expanded test series beyond DNV-GL
  • Voltage supply 4.75 – 30 Vdc
  • Approvals CE, UL/E217823

 

POG 83 DNV-GL Additional Features

  • Tested long-term sealing with stress tests
  • DNV-GL tested for quick ship approval
  • Voltage supply 7 – 24 Vdc
  • Approvals CE, UL/E217823, DNV GL

 

Enquire now

You can rely on Kempston Controls to help you find the perfect Marine and Offshore Rotary Shaft Encoders specific to your application. With access to the entire Baumer catalogue of products you need not go anywhere else. Call us today on (0) 1933 411 411 or email us at sales@kempstoncontrols.co.uk, or contact us using this form to discuss your requirements.

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PowerProx Sensors – Powerful Photoelectric Sensing in Miniature

Photoelectric Sensors are utilised in a vast array of industrial applications, from monitoring products on a production line in a food and beverage processing plant to controlling automatic doors for safety and security. Whatever the installation, there is a photoelectric sensor out there to suit your particular application, but when the installation is limited in space, you need a quality photoelectric sensor from one of the worlds renowned leaders in the design and manufacture of dependable sensor technology, SICK.

Powerprox Sensor in situ

SICK has taken its ultra-reliable, high-performance, PowerProx sensor and shrank all that technology into a space-saving miniature housing that is capable of some of the longest detection range distances ever achieved for a sensor of this scale.

Size Does Matter

The diminutive SICK WTT4SL PowerProx Mini photoelectric sensor measures in at just 12.2 x 41.8 x 17.3 mm but packs a big punch, delivering outstanding performance that you would expect from a sensor 4 times its size. Capable of detecting objects up to 1300 mm away. The knock out performance of the WTT4SL makes it ideal for high-speed production and logistics applications.

This capable photoelectric sensor can be integrated into tight machine spaces such as the grippers of picking robots or for material handling duties in AGVs, as well as for empty bay and clearance detection in high-bay warehouses.

Packed with innovation, SICK has crammed its renowned autocollimation time-of-flight sensing technology into the tiny housing. Autocollimation ensures reliable high-speed detection and outstanding repeatability even in challenging ambient conditions, without cross-talk interference from other sensors.

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Finding the Edge

Even at high process line speeds the ultra responsive PowerProx Mini will register the leading edges of products with precision, even through small holes, such as those found during the quality control inspection of automotive parts and assemblies. Its red-light Class 1 laser, small-light spot size and wide angle of incidence with switching frequencies up to 1 kHz ensure highly-competitive performance across a broad range of applications.

David Hannaby, SICK’s UK Product Manager for Presence Detection stated :
“The SICK PowerProx Mini can replace through beam, background suppression or reflex sensors, so machine builders and production teams can streamline their inventories while still guaranteeing high-performance sensing. The PowerProx Minis can be set up in an instant using the on-board teach-in function, or via IO-Link. It’s all the reliability, repeatability and versatility you expect from SICK, packed into a sensor no larger than a packet of sugar cubes.”

Powerprox Sensor in situ

Easy to Configure

The PowerProx Miniature Photoelectric Sensor can easily be configured for multi-task applications, packed with features including the option of IO Link communication and up to 8 variable switching outputs. Detection is guaranteed with 100% background suppression ensuring that only the desired target is detected, ignoring any interference from shiny objects and materials behind the detected subject. Available in speed or distance variants for optimum performance and with superb repeatability ensuring reliable component counting, sorting and quality control applications in high-speed fast moving consumer good processes, even with products that feature varying surfaces.

Enquire Now

If you are looking for a reliable Miniature Photoelectric Sensor solution then look no further than Kempston Controls to help you decide upon the best product solution for your particular installation. With access to the entire SICK product range we have all of your bases covered, give us a call on (+44) 1944 411 411 or email us at sales@kempstoncontrols.co.uk, or use this contact form today to discuss how the PowerProx Miniature Sensor can help you.

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SICK W4 Inox

Curtains of Light

Kempston Controls

Magnetic Rotary Encoders from Pepperl + Fuchs Designed for Demanding Conditions

Absolute Magnetic Rotary Shaft Encoders can be found in masses of industrial and commercial machinery applications that depend on the precise position monitoring of their moving elements. These Encoders record the current angular position of an axle or a shaft and convert that into a digital output. This valuable data is maintained when power is removed and made available immediately when power is reapplied, unchanged. Dependable, these encoders provide a feedback mechanism for the exact position, angle and speed, for the correct operation of expensive machinery, such as robotic systems, process packing machinery, CNC machines, bottling plant lines and much more.

Magnetic Rotary Encoders utilise a series of magnetic poles to monitor the position of the encoder shaft in unison with magnetic sensors, with the sensor reading the position of the magnetic poles. Due to the efficiency and dependability of recording magnetic effects, a Magnetic Rotary Encoder is ideal for use in harsh environmental conditions where other encoders may fail due to dust or debris accumulation. Magnetic Encoders are also capable of resisting vibration and shocks and are not affected by minor misalignment during their operation.

Designed to Last

The IO-Link enabled Absolute Magnetic Rotary Shaft Encoders from Pepperl + Fuchs offer a wide range of mechanical interfaces and settings. Designed to last, these encoders have multiple software configuration options readily available, meaning a single device can be used in a wide variety of applications, maximising flexibility and warehouse efficiency and ultimately saving money.

The Pepperl + Fuchs Single and Multi-turn Rotary Encoders with IO Link are high-precision encoders with ultra-reliable internal magnetic sampling for precise position monitoring results every time. Robustly designed they have been created to thrive in demanding industrial environments where other encoders fail to cope. The integrated IO Link interface makes it easy to adapt to different applications through parameterisation as well as providing process data transfer and condition monitoring, keeping you ahead of the game when it comes to ensuring production process downtime is reduced.

Snapshot view of some of the Range

 

ENA58TL-S*** -IO-Link, Solid Shaft Rotary Encoders

• Absolute Magnetic Rotary Encoders with solid shaft
• Linearity error ≤ ± 0.1 degrees
• Operating voltage 18-30 Vdc, No-load supply current max. 50 mA
• Power consumption 1.5W
• Time delay before availability <1 second, Minimum cycle time 1.5 ms
• Relative humidity 98% no moisture condensation
• Starting torque < 3 Ncm, Shaft load Axial 40N, Radial load 110N

 

 

 

ENA58TL-R***-IO-Link, Recessed Hollow Shaft Rotary Encoders

• Absolute Magnetic Rotary Encoders with recessed hollow shaft
• Linearity error ≤ ± 0.1 degrees
• Operating voltage 18-30 Vdc, No-load supply current max. 50 mA
• Power consumption 1.5W
• Time delay before availability <1 second, Minimum cycle time 1.5 ms
• Relative humidity 98% no moisture condensation
• Starting torque < 3 Ncm, Shaft load Axial 24N, Radial load 198N

 

 

 

Absolute Magnetic Rotary Shaft Encoder Features

• Solid shaft and recessed hollow shaft versions
• Simplified condition monitoring via critical detection warnings
• IO-Link Interface for process data, parameterisation and diagnosis
• Measuring range, direction of rotation and switching signals, programmable
• Flexible software configuration helps reduce costs and warehouse space
• Wear-free magnetic sampling
• High resolution and accuracy
• M12 connector, 5 pin, A coded
• Intelligent diagnostic functions increase system reliability
• Wide range of mechanical interfaces for easy integration
• Suitable for use in harsh industrial conditions due to IP65/67 rating
• Status LEDs
• Shock resistance to DIN EN 60068-2-27
• Vibration resistance to DIN EN 60068-2-6

Contact us to learn more

A range of comprehensive, downloadable software tools to facilitate easy installation and set-up of the Pepperl + Fuchs range of Absolute Magnetic Rotary Shaft Encoders are available here.

Pepperl + Fuchs are a globally renowned manufacturer of state-of-the-art production automation and control products and at Kempston Controls we have access to their entire product portfolio. Whatever your encoder needs, give us a call on +44 (0) 1933 411411 or email us at sale@kempstoncontrols.co.uk to discuss your requirements. Alternatively you can contact us here.

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SICK W4 Inox Miniature Photoelectric Sensors, Small, Tough & Powerful

Size does not guarantee strength or ability and this is certainly the case with the SICK W4 Inox range, SICK’s first miniature stainless steel photoelectric Inox sensor that has been designed for use in the most demanding hygienic installations, such as Sterilise-in-Place (SIP) & Clean-in-Place (CIP). Capable and dependable, this miniature photoelectric sensor combines stainless steel-shielded durability with in-built remote sensor intelligence, ideal for use in processing plant wet areas and packaging machines such as those found in the Pharmaceutical and Food & Beverage industries.

With an impressive IP69K rating, the W4 Inox Sensor range brings the latest advances in on-board sensor processing power called ‘Smart Tasks’ to fully-hygienic production processing environments. Smart Tasks are intelligent logic functions which the sensors uses to autonomously control process tasks such as counting products, checking sealing caps and pack sizes, and switching actuators.

SICK’s UK Product Manager for Presence Detection, David Hannaby, had this to say about the W4 Inox range.

“The SICK W4 Inox offers all the long-life durability you would expect from a high-class SICK Inox sensor. With a housing made from extremely resistant stainless steel, the SICK W4 Inox is designed to be completely impervious to water ingress or aggressive cleaning media, even in the most challenging conditions.

Regardless of whether you are dealing with a CIP or SIP processes, manual exterior cleaning such as in a filling line, or sterilizing pharmaceutical sterile boxes with hydrogen peroxide, the W4 can be relied on to keep on performing during a long life, as can the all-important connectors and accessories.
Part of the trend towards ‘edge computing’ capability, Smart Tasks remove processing time and load from PLCs or other higher-level controls.

The W4 Inox’s ability to operate defined tasks autonomously and remotely will therefore be particularly attractive in high-speed food processing plants, filling and packaging lines. It offers a chance to improve production efficiency and enable greater process responsiveness including more frequent product changeovers.”

 

 

Smarter Than Your Average Sensor

SICK W4 Inox sensor in sit

The W4 Inox’s built-in Smart Tasks initiates logic functions that process the sensors signals, linking them with additional binary switching signals from an external sensor if necessary. The Smart Task utilises this processing data to generate output process signals from the sensor.
For example, the SICK W4 Inox Smart Sensor can detect and measure objects and gaps between bottles on a filling line using the ‘object and gap monitor’ ability. As opposed to the PLC interpreting data, the W4 Inox alerts the control system only if there are deviations from predetermined values while controlling the process at hand.

The W4 Inox’s “counting and debouncing” Smart Task feature enables a quick completeness check, offering extra protection against errors caused by PLC cycling time. Immune to ambient light and with excellent background suppression the W4 can detect reflective, transparent, and jet-black objects with ease.

SICK W4 Inox sensor in situ

SICK W4 Inox Miniature Photoelectric Sensor Range Features

• Built-in ‘Smart-task’ internal signal process control
• Resistant to a large variety of disinfectants and cleaning agents
• Ideal for extreme washdown applications, CIP, SIP
• Highly visible laser-like light pinpoint LED
• Background suppression
• Teach-in button and cable adjustment options
• PNP, NPN switching output versions
• Flexible sensing settings, monitoring, diagnostics
• IO-link provides easy data access via PLC, easy to set up
• Available in a range of sensing distances up to 5 metres
• Detects reflective, transparent and black objects
• 316 L Stainless steel body
• Injection moulded unibody housing
• IP69K rated, water tight construction
• Range of connectivity options

View some of the range on offer