Tag: process improvement

Ethernet IO Modules with Integrated IO-Link Master – the best in Industrial Communication

Posted on by Rick Morgan

Pepperl+Fuchs’ Ethernet IO modules offer an array of innovative features. With a versatile multi-protocol capability, they provide optimum efficiency for standardizing manufacturing facilities. IO-Link and comprehensive diagnostics are important for maintaining and troubleshooting your machines. These innovative, high-performance ethernet communication modules can help optimise your installations.

Managing the Demands of Modern Industry and Beyond

If industrial process control sensors are to manage the demands of the future manufacturing processes, they need to do more than simply deliver process data to a PLC. An industrial process control sensor must be able to communicate with multiple receivers and send and receive data to and from higher-level information systems efficiently.

Ethernet IO modules

The Pepperl + Fuchs Ethernet IO modules with integrated IO-Link master deliver first-class communication between system management and process sensors and actuators as they assume a gateway function between Ethernet and IO‑Link. With these capable ethernet modules up to 8 IO‑Link devices may be directly connected, with 4 channels available for sensors and 4 channels for actuators.

The ICE1 series IO-Link master enables integrated diagnostics and parameterisation from the control level right down to the process sensor level, and commissioning times will be  reduced primarily in large production plants. Ultimately, this means that Ethernet IO modules with integrated IO-Link master can be incorporated into the requirements profile of innovative machine and plant manufacturers easily, forming a crucial component of Sensorik4.0.

Ethernet IO modules

Sensorik4.0 is the next generation of interconnected sensor solutions from Pepperl + Fuchs that helps bring Industry 4.0 to life. The integrated Ethernet IO-Link masters bring the concept of Sensorik4.0 to reality. IO-Link sensors and actuators can be easily connected across all technologies creating a whole range of possibilities for the user, ranging from parameterisation to diagnostics down to actuator/sensor level and simplifying maintenance, paving the way in the digitalisation of factories of the future.

IO-Link Masters with OPC UA Interface, Dependable Information Exchange from Field to Cloud

In addition to the ICE1 masters, designed for PLC-based applications, two other modules are available for use in cloud-based and hybrid systems: the ICE2 (EtherNet/IP) and ICE3 (PROFINET) IO-Link master series.

These 2 ethernet modules support industrial protocols such as EtherNet/IP, PROFINET, and MODBUS TCP, and provide an OPC UA (Open Platform Communication Unified Architecture) interface in addition to real-time fieldbus protocols.

Ethernet IO modules

The open architecture of OPC UA allows cross-vendor, platform-independent, and the interoperable collaboration of machines in processing environments and makes communication between machines and computer or cloud-based systems possible, both in closed networks and via the internet.

Both IO-Link masters come with web-based configuration for setting all module parameters and all connected IO-Link devices (web IODD operation).  When replacing or expanding modules, all the module settings can be saved as a separate file and transferred to a new device using the module cloning function. OPC UA ensures a constant exchange of information across all levels so that plant processes can be designed more efficiently.

IIoT Starter Kit—Connecting Factory Floor Sensors to the Cloud

With the IIoT starter kit and the user-friendly IO-Link masters from Pepperl+Fuchs simple visualisation and analysis of sensor data becomes a reality. Discover the advantages of IO-Link and experience the seamless integration of IO-Link sensor data into your Industry 4.0 application.

The kit includes among others:

  • An IO-Link master, (3) IO-Link sensors, an Ethernet switch, a power supply, RFID tags and all the necessary cabling to get started
  • A quick start guide for connecting the IO-Link master and IO-Link devices
  • Connections for various platforms such as AWS, PTC, AVEVA

Connect your software dashboard via OPC UA or MQTT for easy interpretation of real-time data and start the digital transformation of your installations now with the IIoT starter kit, available from Kempston Controls.

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FlexAlert from Trumeter, the Perfect Universal Small-form Countdown Timer

Posted on by Rick Morgan

The FlexAlert is a lightweight, small-form Countdown Timer range that can be used in a wide variety of applications where a countdown and reminder notification is required. This capable range of timers can be easily attached in the location required where they can be left to count down to the pre-set duration. When the allocated time-period has been reached the timer will produce an audible alert warning users that attention is required within a specific process or application, which will continue until it has been turned off. Typically, this alert will run for a minimum of 60 days until the timer has been reset so there can be no excuses!

Ideal for Service Intervals

The FlexAlert’s flexibility and versatility make it an ideal unit for domestic and industrial uses, suitable for a wide variety of applications that require interval notifications such as service intervals and equipment checks as well as reviews and component changes. Designed to be tamper resistant, the time interval is pre-set by design and requires the use of a screwdriver to access the battery reset function. Dependable, the FlexAlert range of small-form countdown timers ensures that those important activities are carried out on time, every time.

Compact and lightweight in design, only 40 mm in diameter and a tiny 60 grams in weight, this versatile range of countdown timers are small and discrete enough to be placed just about anywhere. Available with a wide range of standard options there is a countdown timing alert solution readily available straight out of the box.

FlexAlert Models Available:

View the Range at Kempston Controls

Easy to Install, Simple to use

Cable tie and hook and loop mounting fixtures help ease installation and the FlexAlert range is simple to use as well, just place one timer with a specified countdown interval in the location desired, pull the battery insulation tab free to start the timer and go. Suitable for use just about anywhere without making changes to an installation with their unobtrusive and sleek design

 

 

FlexAlert Countdown Timer Specifications

  • Timer Type – Alert Timer, audible beep, minimum 60 days until reset
  • Alert amplitude – >50 dB A
  • Manual Reset function
  • Unobtrusive design
  • Uses readily available CR2032 Battery (1000 days typical life)
  • Supplied with hook and loop adhesive pad and 200 mm cable tie
  • Protection rating – IP30
  • Dimensions 39.7 x 18.3 mm (16 mm deep without fixing pad)
  • Operating temperature -10 to + 60 ° C
  • Storage temperature -20 to + 70 ° C
  • Weight – 16 grams
  • White in colour
  • Design life – 10 years

Powered by the common CR2032 battery (with a typical life of 1000 days) that ensures you will never be searching for expensive hard-to-source batteries on a regular basis. Whatever you countdown timing application requirements the Trumeter FlexAlert range is here to help you achieve your goals. The FlexAlert can also be customised to meet your applications requirements with options including countdown timer duration and customer branding, speak to Kempston Controls for availability.

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PS1000 Power Supplies from Pepperl + Fuchs for ATEX Zones 2/Div. 2

Posted on by Rick Morgan

The Pepperl + Fuch PS1000 Power Supplies have been created for industrial applications where high system availability, redundancy and efficiency are demanded. In industrial and process systems, control cabinets and field boxes, the PS1000 range of power supplies ensures a reliable and efficient power supply from 5 to 40 Amps, for 12 VDC, 24 VDC or 48 VDC output.

Designed with versatility and for extended use, the PS1000 Power Supplies feature ATEX, IECEx, and EAC approvals and can be utilised in applications up to ATEX Zone 2/Div.2. The extensive range includes 1 and 3-phase power supplies, redundancy modules and PSUs with built-in redundancy. Suitable for universal use across all sectors, including applications with stringent requirements on reliability and quality and providing optimal immunity to interference.

Reducing Costs and Improving Efficiency

The PS1000 power supplies have reliability built-in and are up to 95% efficient. This efficiency reduces the need for additional hardware, due to minimal losses in terms of the power fed in, minimising cabinet cooling and reducing energy costs.

Compact, the PS1000 takes up very little space and is easily mounted on DIN rails and can be used in ambient temperatures of up to +70 °C, the cable length can be compensated in the application as the output voltage is adjustable.

Versatile Combinations

These versatile power supplies can be combined with other Pepperl+Fuchs DIN rail mounted devices in the control cabinet, including intrinsic safety barriers, signal conditioners and surge protection modules. When the input voltage is applied, the inrush current is actively limited, and networks and devices are protected. The ‘Peak Output Power function’ enables heavy loads such as motors and electronic devices to be switched on.

The Features at a Glance

  • Compact design saves space in cabinets
  • Suitable for a wide range of applications including Zone 2/Div. 2
  • Withstands temperatures up to +70 °C
  • N+1 and 1+1 redundant power supply configurations
  • Excellent energy efficiency – up to 95 %
  • Low inrush currents protect the network and components
  • Remote control for ON/OFF
  • I/O Link option
  • Relay contact for remote monitoring
  • Safe operation due to uninterrupted voltage supply of up to 40 A

Get a PS1000 Now!

Redundant Power Supplies

Power supply redundancy is important for increasing system reliability. Industrial facilities depend on bulk power supplies as they power the control system architecture and the process measurement instrumentation. Business critical applications can’t afford to be offline due to a power supply failure which could lead to a substantial amount of lost revenue for every minute the process is down.

This need for system integrity and dependable performance in demanding conditions necessitates power redundancy. N+1 and 1+1 are two reliable redundancy methods that ensure system functionality even during a power failure.

PS1000 Power Supplies

N+1 and 1+1 Topology?

The PS1000 Power Supplies can be used redundantly in both an N+1 and a 1+1 topology. With an N+1 redundant configuration, multiple components (N) have at least one independent backup component (+1) ensuring continued functionality during power loss. All the modules in a configuration share the load and if a system module fails, the functioning modules continue to share the load without compromising system integrity.

The 1+1 configuration provides redundancy with 2 power modules of the same power coupled by a MOSFET to supply the same load. Using MOSFETs instead of diodes in the redundancy function reduces heat generation and the voltage drop between input and output.

Utilising Redundancy with the PS1000 Power Supplies

These capable power supplies can be used in redundant topologies by using an external redundancy module (PS1000 XXX. RM) that has a decoupling MOSFET on the input, allowing for the connection of 2 power supplies for 1+1 redundancy, or by using a (PS1000 XXX. R) power supply with a decoupling MOSFET for limited space applications.

For power applications requiring less than 40 Amps, 1+1 redundancy is an economical solution when a redundant power system is required, N+1 is for critical applications. The versions featuring IO-Link offer a future-proof interface that allows comprehensive diagnostics and configuration processes to be carried out during operation.

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Bürkert Distributor

Kempston Controls becomes Midlands distributor for Bürkert valves

Posted on by Joe Shipton

Electrical component distributor, Kempston Controls, has become Bürkert’s official distributor for the Midlands region. Based in Northamptonshire, Kempston Controls now supplies end-users across the region with Bürkert’s range of process valves and flow control components. The main sectors of coverage include food & beverage as well as hygienic applications.

The new agreement means that Kempston Controls will supply a range of Bürkert products including process and control valves as well as solenoid valves. The distributor will also stock Bürkert’s range of WRAS-approved material valves to demonstrate UK regulations compliance of water fittings that transfer water to and from the public mains supply. Kempston Controls will stock Bürkert products on-site and also provide 24/7 cover to support customers out-of-hours.

As a distributor, Kempston Controls will receive expert project support from Bürkert to optimize the design, implementation and commissioning of customers’ process control projects. This includes technology such as Bürkert’s FLOWave volumetric flow meter for high accuracy measurement of pharmaceutical-grade water and ultra-pure media applications.

Kempston Controls will also have access to food & beverage solutions such as the tank blanketing system that enables the automated control of pressure and atmosphere inside a tank. The solution is deployed in applications such as brewery buffer tanks to maintain the desired conditions and prevent bacterial growth.

Having been a reseller of Bürkert products for several years, the formalised distribution agreement will enable Kempston Controls to expand its presence in the process sector. Thomas Steele, Midlands Area Sales Manager at Bürkert explains: “The agreement increases the support Bürkert can provide to customers in the Midlands with greater speed and availability of valves and associated process control components. It also enables our system design engineers to be more involved in projects, particularly within the food & beverage sector and hygienic applications.”

“Significant growth for Kempston Controls is taking place within the process sector and we’re serving an increasing amount of customer projects. For our customers, Bürkert’s support means very high-quality valves with rapid availability,” says Kempston Controls’ Sandeep Sarpal, Commercial Manager of the company’s Process Division.

“Bürkert’s backing also means support for process system design and Kempston Controls can directly integrate with the company’s flow control engineers. Our future growth plan is to offer a complete solution from design through to field support, and this agreement is the start of that,” Sandeep adds.

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

Posted on by Rick Morgan

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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R2000 2-D Lidar Sensors – Sensors with Depth Perception

Posted on by Rick Morgan

The R2000 range of LiDAR Sensors from Pepperl + Fuchs are equipped with innovative Pulse Ranging Technology (PRT). Built-to-last, these capable sensors have been created to provide industrial applications with reliable and extremely precise measuring and navigation abilities with gapless all-around 360° visibility even in the most demanding conditions.

Innovative Pulse Ranging Technology

Pulse Ranging Technology (PRT) provides extremely precise measurements and short response times in various ambient and object conditions, providing a highly accurate industrial-grade distance measuring system.

Detection of Small Objects

A sharp light spot in combination with a high angular resolution provides precise edge detection and detection of tiny objects from 1 mm in diameter and up, allowing you to monitor and detect with maximum precision.

All-Around 360 Degree Visibility

With a 360° measurement angle, the R2000 2-D LiDAR Sensor range offers an all-round visibility reducing the need to use multiple sensors.

Built-in Interactive Display

The interactive display provides text and graphical information, allows basic settings to be made directly on the device and diagnostic information to be displayed during operation.

A versatile LiDAR Sensor range with multiple capabilities for a wide range of industrial applications, here we take a quick look at their specifications and features.

R2000 LiDAR Sensor Range Common Specifications

  • Operating voltage 10 – 30 V
  • Scanning angle 360°
  • Diameter of light spot 25 x 105 mm at 10 M, (laser versions <20mm at 10 M), resolution 1 mm
  • Operational indicator LEDs for status updates
  • 2 Control buttons, Parameterisation indicator 24 x 252 pixels, red
  • Scan rate 10 – 50 s-1
  • Fast Ethernet interface, HTTP, TCP/IP, and UDP/IP (model dependant)
  • Connections – M12x1 4 pin (supply), M12x1 8 pin A coded (multiport), M12x1 4 pin D coded (LAN)
  • Protection rating IP65
  • UL and CCC approval
  • For all models A PACTware device type manager (DTM) is available as a download

 

OBD*OM R2000 LiDAR Switching Sensors for Demanding Field Monitoring Applications

These R2000 LiDAR Switching Sensors have been designed specifically for precise field monitoring of up to 4 fields. With 6 models in the range featuring measuring distances from 10 to 60 metres, 360° scanning angle, high angle resolution and 4 switching inputs/outputs.

These sensors typically utilise an infrared red laser light, however, the OBD10M-R2000-4EP-V1V17 model uses a visible red beam laser.  Defective pallets and protruding products can lead to collisions in high-bay warehouses, the R2000 can reliably detect small components, fragments and broken pallets, avoiding costly damage and downtime.

With a flexible measured data filter and 54k measurements per second means that these LiDAR sensors are ideal for numerous field monitoring applications.

OBD*OM R2000 2-D Field Monitoring LiDAR Sensor Features

  • Field monitoring applications – 4 fields
  • Light source – Laser diode, typically Infrared (one unit uses visible red light) class 1 laser
  • Measuring method Pulse Ranging technology (PRT)
  • Wavelength typically 905 nm (laser sensor is 660 nm), Pulse length 5 ns
  • Measuring speed 54000 measurements per second
  • Detectable shape – Almost anything

 

OMD*OM R2000 UHD (Ultra High Density) LiDAR Measuring Sensors for Complex measuring Tasks and Navigation

The R2000 UHD LiDAR Measuring Sensors provides accurate distance data in dynamic applications such as in the navigation of automated guided vehicles precisely navigating up to 100 m with reflectors as small as 40 mm. With 6 models featuring measuring ranges from 10 to 60 metres, 360° scanning angle, very high angle resolution and operating range.

This range of sensors typically utilise an infrared red laser light (the OMD10M-R2000-B23-V1V1D uses a visible red beam laser). Coupled with a flexible measured data filter and a measuring speed of 250k measurements per second make these UHD LiDAR sensors ideal for industrial navigation applications that demand high precision.

R2000 UHD 2-D LiDAR Sensor Features

  • Designed for complex measuring tasks and navigation
  • Light source – Laser diode, typically Infrared (one unit uses visible red light) class 1 laser
  • Measuring method Pulse Ranging technology (PRT)
  • Wavelength 905 nm typically, (visible laser version is 660 nm), Pulse length 5 ns
  • Measuring speed 250000 measurements per second
  • Filter – Maximum, average, median, reflectivity

See the Range

OMD**M R2000 HD (High Density) LiDAR Measuring Sensors for Object Profiling and Robotic Applications

The R2000 HD LiDAR Measuring Sensors were created for simple industrial position monitoring tasks. With 2 models featuring a 12 metre and 30 metre range respectively, 360° scanning angle, a high angle resolution and operating range.

The R2000 HD sensor is the ideal solution for robotics tasks. With 84k scan points per second and an optimised angular resolution down to 0.043°, the sensor meets the requirements of typical robotic applications.

These sensors utilise an infrared light provided by a laser diode with a PRT measuring method (Pulse Ranging Technology) coupled with a flexible measured data filter make these capable HD LiDAR Sensors ideal for general industrial position monitoring tasks.

R2000 HD 2-D LiDAR Sensor Features

  • Object profiling and robotic applications
  • Light source – Laser diode, modulated infrared light, class 1 laser
  • Measuring method Pulse Ranging technology (PRT)
  • Wavelength 905 nm, Pulse length 5 ns
  • Measuring speed 84000 measurements per second
  • Beam divergence transversal 2 mrad, longitudinal 10 mrad

 

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