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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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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Temperature Control made easy with the K85 Controller from Ascon

The Ascon K85 Mini Programmable Temperature Controller has been cleverly designed to be installed inside an industrial control panel, mounted on a DIN rail and with or without the display showing through a cut-out in the control panel door. Mounting this unit inside a control panel helps remove the possibility of operators changing the controller’s settings and offers an increased degree of physical protection.

Versatile, this PID controller offers more flexibility than other panel mounted equivalents and can be used as an alarm module or PLC expansion module inside a control panel. Configurable and easy to install as either as a PID controller or in an ON/OFF thermostatic mode, programming is carried out using the 4 function keys, a programming device, or by use of a PC.

K85 HCRR Temperature Controller Features

  • Inputs – Thermocouples J, K, R, S, T, pt100, 0/12 – 60 mV
  • Number of Outputs – 2, Relay SPDT, 8 A
  • Single line  4 digit red display and 4 control buttons
  • Digital inputs – 2
  • Programs/Segments – 1 program, 8 segments (optional)
  • Power supply 100 – 240 VAC
  • Control – ON/OFF and PID
  • Communications – RS485 Modbus slave (optional), TTL Modbus
  • Certifications CE, UL
  • Front protection IP40, terminals IP20
  • Operating temperature range 0 to 50 °C
  • Dimensions 70 x 84 – Depth 60 mm

In addition, this temperature controller has a host of additional special functions, including – digital retransmission, hours/days worked, power on delay, soft start, transmitter power supply, user calibration and a Wattmeter.

K85 Mini Controller Applications

This Temperature Controller offers more flexibility than panel mounted equivalents and is often used as alarm modules or PLC expansion modules. In addition, the K85 has been designed to neatly interface with different kinds of HMIs from touch screens to bespoke PCB display boards.

Suitable for a wide range of industrial and commercial control uses including:

  • Laboratory equipment
  • Environmental chambers
  • Packaging machinery
  • Printing machines
  • Food processing machinery
  • Extruders
  • Industrial baking or large kitchens
  • Ultrasonic cleaning equipment
  • Alarm Trip amplifier
  • PLC expansion modules over RS485 comms (optional)

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O200 Miniature Photoelectric Sensors- Shiny, Transparent, Deep-Black Object Detection Made Easy

Photoelectric Sensors are found in many industrial installations in a wide variety of shapes and sizes, and they all basically perform the same function, the detection of objects passing through their beams.  The result of the sensors beam being broken could be an alarm if an item is missing or a signal triggering another function of an industrial automation process.

When the application concerns very transparent items or ones that are deep-black in colour and/or feature very irregular surfaces, then you will need to look beyond the average sensor offering.

The Baumer O200 Sensor range is one of the smallest available, but make no mistake, these are very capable sensors! This impressive range of miniature photoelectric sensors have been designed to detect awkward objects with a fast response time and with the highest of precision. Available to purchase from Kempston Controls, they come with a laser or LED output, V point or line beam shapes, thus providing the engineer with a versatile list of options for precise object detection. Whether components are transparent, small, passing by on a fast-moving conveyor, deep-black in colour or irregularly shaped and shiny this range of sensors will have a solution in its ranks.

Unaffected by LED Light & Reflections with Ambient Light Immunity & Reliability

With their innovative light algorithm, these photoelectric sensors ensure maximum detection reliability in any lighting situation, the interfering sources identified by the algorithm are suppressed so a high measurement speed can be maintained.

With 3 sensing solutions for long-term stable detection of transparent objects such as glass or PET bottles, ampoules, foils and trays:

V-optics – ideal for short distances and for the detection of shiny and transparent objects, with background suppression for distances up to 15 mm. Offering maximum luminous efficacy thanks to their V-shaped, extremely narrow LED light beams.

SmartReflect – transparent object detection without a reflector with a pinpoint LED or a laser light source with ranges up to 180 mm. Contamination or changes in the reference surface are not a problem with built-in compensation for a consistent stable application.

Retro-reflective photoelectric sensor with single lens optics – A pinpoint LED or laser light source and a range of up to 4 m. With a transmitting and receiving beam on the same axis providing reliable object detection, built-in compensation for the reflector and an additional mode for the detection of tears in transparent films.

Call us on 01933 411 411 to find out which Baumer O200 Sensor is right for you!

Photoelectric Sensors for any Application

  • Electronics – Extreme ambient light immunity with variants with a fine line beam provide a stable switching signal for irregular objects
  • Robotics – ideal for positioning tasks in grippers, laser beam variants allow for high-precision positioning tasks
  • Assembly & Handling – detection of small, transparent and shiny objects – V-optics provide dependable, reliable detection
  • Lab automation –  ideal for detecting transparent objects such as bottles, foils, ampoules or pipettes
  • Easy detection of glossy black objects – extremely dark and high-gloss objects without any loss of sensing range
  • Shuttle systems – ideal for the fine positioning of transport robots, providing stable detection of workpieces on transport robot systems

Transparent Object Sensors

  • Reliable detection of bottles, trays, ampoules, foils
  • Retro-reflective sensors with single-lens optics for ranges up to 1 m
  • V-optics for ranges up to 15 mm
  • SmartReflect the light barrier without reflector up to 180 mm
  • Short response times <0.25 ms
  • Fixed scanning ranges and adjustable variants

 

Fixed Focus Sensors

  • Diffuse sensors with calibrated sensing distance for simple commissioning
  • Sensing ranges 15, 30, 50 or 80 mm
  • Variants with V-optics for transparent objects

Shiny and Deep-black Object Sensors

  • Additional power reserves thanks to High-Power-Mode
  • Diffuse sensors with background suppression for distances up to 180 mm
  • Light barriers for extra range up to 6 m
  • Diffuse sensor with intensity differences up to 200 mm
  • IO-Link – Industry 4.0 and IIoT ready

 

Laser Sensors

  • Detection of smallest objects down to 0.05 mm thanks to focused laser spot
  • Very precise object positioning up to 0.05 mm accuracy
  • Highest reproducibility thanks to very low jitter < 30 µs
  • Detection through very narrow openings (keyholes) thanks to single-lens optics
  • Precise control of fast processes thanks to response times < 0.05 ms

Line Beam Type Sensors

  • Detection of irregular or perforated objects
  • Retro-reflective sensors with background suppression and ranges up to 120 mm
  • Up to 56 mm long line
  • Laser class 1 or Pinpoint LED
  • Short response times <0.25 ms

 

Light Barriers without Reflector – SmartReflect Sensors

  • Safe and easy referencing on machine parts
  • Sensing range up to 180 mm
  • Insensitive to dirt
  • IO-Link – Industry 4.0 and IIoT ready

Call us, use the Contact form above or email us today to discuss your Baumer O200 Photoelectric Sensor requirements.

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Distance Sensors when Precision Matters – the Panasonic HG-C

The Panasonic HG-C laser distance sensor has versatility built right in, with a repeatability of 10µm and a response time of 1.5ms and a small lightweight construction opening up a range of possibilities for industrial automation. Designed to be both robust and versatile, the Panasonic HG-C Distance Sensors are suitable a wide range of industrial applications including measuring the thickness of a panel, controlling the height of a dispenser head, measuring hoop slack in a process machine, checking for presence of O rings and controlling the height of a robot to name just a few.

Digital and Analogue Switching

This impressive range of distance sensors features both digital switching and analogue outputs, enabling their easy integration into existing installations. These sensors can be used in place of normal switching photoelectric sensors, or utilised as measuring devices in profiling and for measuring the contours of component parts.

Distance Sensor HG-C in action

Easy to set-up, you only need the function keys to configure the sensor and instantly the measured distance will be displayed in millimetres on the built-in four-digit LED display. A range of additional digital inputs are used to trigger the sensor, control the laser power, and to perform zero adjustment.  These sensors not only indicate measured values in millimetres, but they also output analogue voltage and current and this can be used for various calculations and logging when the output is sent to a PLC.

NPN and PNP Versions

This range of distance sensors, offered in 5 x NPN and 5 x PNP output versions, provides measuring ranges from a measurement centre distance of 30 ±5mm to 400 ±200mm.  All models are equipped with a red class 2 semiconductor laser encased in a robust aluminium die-cast housing with a temperature drift of 0.03%. Thanks to their diminutive size (22 x 44 x 25 mm) and light-weight body, the HG-C distance sensor range can be mounted on the moving parts of machines.

Distance Sensor HG-C in action

Distance Sensor Technical Features

  • Measuring ranges – 30 ±5 mm, 50 ±15 mm, 100 ±35 mm, 200±80 mm, 400 ±200 mm (model specific)
  • 5ms response time
  • Supply voltage 12 to 24 VDC
  • Red class 2 semiconductor laser
  • Aluminium die-cast housing (44 mm x 25 mm x 20 mm, 35g without cable)
  • IP67 degree of protection
  • Linearity ±0.1% F.S./C°
  • NPN and PNP control output versions
  • Output operation either Light-ON or Dark-ON
  • Beam diameter 50 to 500 μm (model specific)
  • Switchable response time – high speed, standard, high precision
  • Built-in short circuit protection
  • 5 core 2 metre cable

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