Explore Industry 4.0 optimization with this ebook: master multi-protocol I/O hubs, choose the right sensor technologies, leverage sensor fusion for AMR efficiency, and discover how remote I/O devices enhance automation control systems.
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Industrial Sensors | Volume 13
Optimizing industry 4.0 Communication architectures using multi-protocol I/O hubs and converters Sorting through proximity and distance sensor technology choices How sensor fusion enables AMRs to maneuver around factory floors efficiently Remote I/O devices optimize automation control systems
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Optimizing industry 4.0 communication architectures using multi-protocol I/O hubs and converters
How to select and apply radar for sensing in harsh environments
Sorting through proximity and distance sensor technology choices
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Things to consider when selecting an industrial photoelectric sensor
How multi-sensor asset monitoring can improve performance in industry 4.0 factories and logistics and in datacenters
How sensor fusion enables AMRs to maneuver around factory floors efficiently
How safety laser scanners can protect people and machines
Remote I/O devices optimize automation control systems
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Editor’s note Welcome to the Industrial Sensors eMagazine, where we dive into the cutting-edge technologies that are transforming the world of industrial automation and communication. This issue will delve into some of the most crucial advancements that are optimizing efficiency, reliability, and flexibility across the industry. As Industry 4.0 continues to revolutionize manufacturing and automation, the focus on optimizing communication architectures takes center stage. We explore how multi-protocol I/O hubs and converters are streamlining data exchange, making systems more agile and interoperable. This technology is crucial for building smart factories capable of seamlessly integrating diverse devices and protocols. We also take a close look at proximity and distance sensor technology, breaking down how these sensors are evolving to meet the demands of modern automation. Whether it's enhancing machine vision or improving precision, these sensors are playing a pivotal role in applications ranging from robotics to quality control. A key area of growth in automation is the integration of sensor fusion, which is enabling Autonomous Mobile Robots (AMRs) to navigate factory floors with unprecedented autonomy and efficiency. In this issue, we discuss how combining multiple sensor types can provide AMRs with the real-time data they need to maneuver safely and effectively in dynamic environments. Finally, we examine how remote I/O devices are optimizing automation control systems, allowing for enhanced control, reduced downtime, and greater flexibility in operations. These devices are critical in ensuring that automation systems stay connected and responsive, even in the most challenging environments. Whether you’re an industry veteran or newcomer, this issue offers actionable insights and the latest developments to keep you ahead. We welcome your feedback as we continue exploring technologies shaping the future.
Optimizing industry 4.0 communication architectures using multi-protocol I/O hubs and converters
By Jeff Shepard Contributed By DigiKey's North American Editors
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Communication protocols are important in supporting real- time data transfers and control in Industry 4.0 and Industrial Internet of Things (IIoT) networks. Sensors, actuators, motor drives, and controllers all have specific communication needs. There’s no “one size fits all” communication protocol. While no single protocol suits every application’s requirement, diverse devices often need to be linked. Sensors must be linked to controllers, and controllers must connect with various system
elements that use different protocols like IO-Link, Modbus, and multiple forms of Ethernet. In many instances, the entire machine needs to connect with the Cloud. That results in complex communication architectures with a myriad of protocols. To address that challenge, machine designers can turn to multi-protocol input/output (I/O) masters, hubs, and converters. This article begins with a review of common Industry 4.0 communication protocols and where they fit into the networking hierarchy. It
then presents a series of I/O masters, hubs, and converters from Banner Engineering, reviews their operation, and discusses how they can facilitate complex Industry 4.0 and IIoT communication architectures. What is the OSI seven-layer model? Network communication protocols are often described in the context of the Open Systems Interconnection (OSI) seven- layer model. The model starts with three media layers that deal
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Optimizing industry 4.0 communication architectures using multi-protocol I/O hubs and converters
with hardware considerations, such as physical, data link, and network connections. Data addressing is the focus of the next three layers, which include the transport, session, and presentation processes. The seventh level of the model is the application layer, which provides the interface between the user and the network. Protocols like Modbus and PROFINET reside in this layer. The OSI model is more loosely related to other protocols like EtherNet/IP. In the case of EtherNet/IP, the application layer includes processes like web access (HTTP), e-mail (SMTP), file transfers (FTP), etc. The three Host layers implement the Transmission Control Protocol/Internet Protocol (TCP/IP) processes for establishing sessions, making error corrections, etc. The Media layers include the physical 10 Base-T connection and the implementation of the Ethernet data link and network connections (Figure 1). Where does IO-Link fit in? IO-Link is a single-drop digital communication interface (SDCI) for small sensors, actuators, and similar devices. It extends bidirectional communications down to individual devices on the
factory floor. It’s specified in IEC 61131-9 and is designed to be compatible with industrial network architectures based on Modbus, PROFIBUS, EtherNet/IP, etc. IO-Link uses a Master device to connect IO-Link devices to higher-level protocols like Modbus
programmable logic controllers (PLCs), human-machine interfaces (HMIs), a cloud data service (CDS), and so on. At the lowest level, IO-Link uses Hubs to aggregate multiple devices and feed the data up to a Master device. In addition, an analog voltage to the IO-Link Converter can be used to add analog sensors to the IO-Link network (Figure 2).
that provide connections to data-consuming devices like
Figure 1: How EtherNet/IP relates to the OSI seven-layer model.
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The data collection and communication capabilities of IO- Link provide increased visibility into the operation of individual sensors, as well as dispersed sensor networks, and speed the data up to a PLC and the Cloud.
How do you combine Modbus and IO-Link?
One of the first tools to consider is a hybrid I/O Modbus hub like the 8-port bimodal to Modbus R95C- 8B21-MQ. This discrete bimodal to Modbus hub connects two discrete channels to each of the eight unique ports, providing access to monitor and configure those ports via Modbus registers. Hybrid I/O Modbus hubs are available with four configurable analog inputs (voltage or current) and four analog outputs, plus eight configurable PNP (sourcing) or NPN (sinking) discrete inputs and outputs for increased application flexibility. DXMR90-X1 industrial controllers can be used as a platform for IIoT solutions. They can consolidate data from multiple sources for local data processing and accessibility. The DXMR90 contains individual Modbus clients supporting simultaneous communication to up to five independent serial networks.
Figure 2: IO-Link converters, hubs, and masters can collect data from field devices and push it up to data consumers like PLCs, HMIs, and CDS. (Image source: Banner Engineering)
Increased factory automation and expansion can be facilitated using a gateway that supports both IO-Link and higher-level protocols like Modbus TCP or EtherNet/ IP and can function as a bridge between a field-level sensor network and an industrial network communications backbone. IO-Link increases operational efficiency by providing a standardized, uniform configuration process for all sensors, and it can be used to replace defective sensors automatically when an identical model is used.
Why combine IO-Link with other protocols? Mass customization and flexible production processes are distinguishing characteristics of Industry 4.0. Combining IO-Link with other protocols can increase the flexibility and versatility of Industry 4.0 factories. Beneficial characteristics of IO-Link include: Modbus has limited support for analog devices like certain sensors, while IO-Link is compatible with both digital and analog devices.
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Optimizing industry 4.0 communication architectures using multi-protocol I/O hubs and converters
The DXMR90-X1 includes one female M12 D-Code Ethernet connector and four female M12 connections for Modbus master connections. Other DXMR90 models are available with two female M12 D-Code Ethernet connectors and four female M12 connections for Modbus client connections or with one female M12 D-Code Ethernet connector and four female M12 connectors for IO-Link master connections. All DXMR90 controllers also include one male M12 (Port 0) for incoming power and Modbus RS-485 and one
female M12 for daisy chaining Port 0 signals. Additional features of the DXMR90-X1 include (Figure 3): ■ Converts Modbus RTU to Modbus TCP/IP, EtherNet/IP, or Profinet ■ Internal logic driven by action rules for easy programming, or MicroPython and ScriptBasic for developing more complex solutions ■ Support for Internet protocols, including RESTful and MQTT ■ Well-suited for IIoT data analytics, condition monitoring,
predictive maintenance, overall equipment effective (OEE) analysis, diagnostics, and troubleshooting
What is multi-protocol support? The DXMR110-8K 8-port IO-Link master is a compact, multi- protocol smart controller that consolidates, processes, and distributes IO-link and discrete data from multiple sources. Connections include:
Figure 3: The DXMR90-X1 controller can be used in conjunction with the R95C hybrid I/O Modbus hub. (Image source: Banner Engineering)
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Figure 4: The DXMR110-8K 8-port IO-Link master is a multiprotocol smart controller. (Image source: Banner Engineering)
■ Two female M12 D-Code Ethernet connectors for daisy chaining and communication to a higher-level control system ■ Eight female M12 connections for IO-Link devices ■ One male M12 for incoming power and one female M12 for daisy chaining power The DXMR110 supports cloud connectivity and includes advanced programming features. ScriptBasic and action rules programming can be used to
create and implement custom scripts and logic for optimized automation processes. The internal processing power of the DXMR110 can be used to move data processing to the edge, minimizing the need for hardware in the control cabinet and eliminating I/O cards on a PLC. Integrated cloud connectivity can make data accessible from anywhere in the world. Finally, the IP67 housing simplifies installation in any location by eliminating the need for a control cabinet (Figure 4).
There’s more The devices presented so far are not the only options for implementing multi-protocol industrial communication solutions. Machine designers can employ a range of Banner Engineering's remote I/O blocks to optimize system design, space efficiency, and performance. Banner offers in-line converters and masters with over-molded designs that meet the ingress
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Optimizing industry 4.0 communication architectures using multi-protocol I/O hubs and converters
performance (IP) demands of IP65, IP67, and IP68. The R45C series in-line converters and masters provide a gateway for connecting IO-Link devices to an IIoT network or system controllers using the Modbus RTU protocol. Model R45C-2K-MQ connects two IO-Link devices to a Modbus RTU interface. When analog signals are required, designers can turn to the R45C-MII- IIQ Modbus for a dual analog in-line I/O converter. Functions include: ■ Analog in. When the converter receives an analog input, it sends the numerical representation of the value to the corresponding Modbus register. It can accept analog inputs from 0 to 11,000 mV or 0 to 24,000 µA.
Figure 5: Examples of the form factors and configurations of Banner’s remote I/O solutions for IO-Link integration. (Image source: DigiKey)
■ Analog out. The converter outputs an analog value corresponding to a numerical input. Analog outputs can range from 0 to 11,000 mV or 0 to 24,000 µA. ■ Process data values outside the valid range (POVR) can also be detected and processed, and the converter sends a signal to the system. When a single analog input needs to be converted to an IO-Link signal, designers can use the S15C- I-KQ. This cylindrical analog current to IO-Link converter connects to a 4 to 20 mA current source and outputs the corresponding value to an IO-Link master.
Banner offers a variety of Modbus RTU I/O blocks that support connections of multiple analog and discrete devices connected to a Modbus or IO-Link network. They can be mixed or matched to support flexible system designs and interoperability (Figure 5). Can wireless protocols be integrated? Banner’s Sure Cross DSX80 Performance wireless I/O network solution enables wireless connectivity. It can be used independently or connected to a host PLC using Modbus or a personal or tablet computer.
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Figure 6: Banner’s Sure Cross DSX80 Performance wireless I/O network solution includes a gateway and one or more sensor nodes. (Image source: Banner Engineering)
The basic system architecture comprises a Gateway and one or more Nodes (Figure 6). Implementing a Sure Cross DX80 Performance wireless network involves three elements: the network topology, master and slave relationships, and the time division multiple access (TDMA) architecture. A star topology is used where the master maintains a separate connection with each node. If the connection between a node and the master fails, connectivity with the rest of the nodes is unaffected. A gateway like the DX80G2M6- QC is the master device and initiates all communication with the slave devices. A gateway that uses a Modbus RTU RS-485 connection acts as a slave to a Modbus RTU host controller. A single wireless network can include up to 47 slave nodes.
Slave devices can be wireless nodes like the DX80N9Q45DT dual thermistor temperature sensor node, the DX80N9Q45PS150G pressure sensor node, or vibration and humidity sensors. Slave devices can’t initiate communication with the gateway or communicate with each other. A serial data radio like the DX80SR9M-H can be added to extend network coverage to accommodate physically large installations. TDMA is the key to combining robust connectivity with minimal energy consumption. The TDMA controller in the gateway assigns each node a specific time to send and receive data. The gateway always has device ID number 0. Nodes may be numbered in any order using device IDs 1 through 47.
Setting specific communication times for individual nodes optimizes efficiency by eliminating the possibility of conflicts between nodes. It also enables nodes to enter a low-power state between communications, only waking up at the assigned time. Turning off the radio between transmissions conserves power and extends the operating life of battery-powered nodes.
Conclusion
Access to multiple communication protocols, like IO-Link, Modbus, EtherNet/IP, and so on, is necessary to support the efficient operation of Industry 4.0 and IIoT networks. Banner Engineering provides designers with a comprehensive selection of IO-Link hubs, converters, and masters in various form factors to support optimized communication solutions.
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How to select and apply radar for sensing in harsh environments
By Kenton Williston Contributed By DigiKey's North American Editors
Outdoor and industrial applications and other rugged environments present conditions that can interfere with remote sensing technologies such as ultrasonic sensors. Inclement weather, dust and debris, and complex sensing environments are some issues that can impact standard sensors. Radar sensors can address these challenges, detecting moving and stationary targets in various ambient conditions. This article reviews the scenarios where radar can outperform alternative options. It examines several types of radar sensors from Banner Engineering, their applications, and design considerations to remember when selecting a sensor.
Why use radar sensors? Radar is robust in the face of rain, dust, and other common airborne substances, works equally well in bright and unlit spaces, and is unaffected by temperature variations and wind. It can detect surfaces with a wide range of finishes, geometries, and colors, and also penetrate non-conductive materials, allowing radar sensors to peer inside containers. In addition, radar can be used over relatively long distances while also being resistant to crosstalk, giving it advantages for short-range applications where sensors are in close proximity.
How radar works
Radar works by bouncing electromagnetic waves off target objects, determining distance based on the time it takes for a signal to return. Radar sensors use two main technologies: frequency-modulated continuous wave (FMCW) and pulsed coherent radar (PCR). FMCW radar emits a constant stream of radio waves, allowing for uninterrupted monitoring of moving and stationary objects. PCR sensors send radio waves in pulses, typically using low-power transmitters. This makes PCR sensors better suited to short- range applications.
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How to select and apply radar for sensing in harsh environments
Range and material sensitivity are also heavily influenced by the operating frequency. Lower frequencies are better for long-range detection and work well with materials that have high dielectric constants, such as metals and water. Higher frequencies offer greater accuracy and are better suited for detecting smaller objects and a wider variety of materials. Beam patterns and sensing zones Radar sensors can be optimized to focus on specific areas of interest and track one or multiple objects. Key parameters include the beam pattern, sensing zones, and dead zones.
Radar sensors emit radio waves in a specific pattern, defined by horizontal and vertical angles. Narrow beam patterns offer precise detection and longer range, while wide beam patterns cover larger areas and better detect irregularly shaped objects. Many radar sensors allow the configuration of multiple sensing zones within their beam pattern. This feature enables more complex detection scenarios, such as setting different parameters for near and far zones in collision avoidance applications. The dead zone is the area immediately in front of the sensor where detection is unreliable. Higher-frequency sensors generally have shorter dead zones.
Identifying the optimal radar sensor: start with the basics There are numerous factors to consider when selecting a radar sensor. In addition to the basic operating parameters, radar sensors have various features that impact their cost, durability, and ease of use. Figure 1 provides a flow chart that illustrates some of these decision points using radar sensors from Banner Engineering as examples. The Q90R series from Banner Engineering is a useful starting point. These FMCW sensors operate at 60 gigahertz (GHz) to balance range, accuracy, and material detection capabilities. They have a sensing range of 0.15 meters (m) to 20 m, a dead zone of 150 millimeters (mm), and two configurable sensing zones.
Figure 1: Shown is a flowchart that illustrates the process of choosing a radar sensor. (Image source: Banner Engineering)
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Figure 3: The T30R series operates at 122 GHz, has a beam of 15° x 15°, and offers precise detection. (Image source: Banner Engineering)
sensor from the T30R series (Figure 3) is a good choice. The sensors have a beam pattern of 15° x 15° or 45° x 45°, an operating frequency of 122 GHz, a sensing range of 25 m, a dead zone of 100 mm, and two configurable sensing zones. With its narrow beam pattern and high operating frequency, this sensor family offers precise detection in specific areas. For example, they can be used to monitor levels within narrow containers. The T30RW version comes in an IP69K housing suitable for high- pressure, high-temperature wash- down environments such as car washes. It has a sensing range of 15 m and a beam pattern of 15° x 15°.
An example use case for these sensors is detecting when trucks arrive at a loading dock. Here, the relatively wide 40° x 40° beam pattern makes it easier to find a mounting location that keeps the dock in view. The Q90R2-12040-6KDQ (Figure 2) builds on these capabilities with a wide, configurable field of view (120? x 40?) and the ability to track two targets, allowing them to tackle more complex sensing scenarios. Selecting radar for narrow beam applications In some applications, radar needs to pick out a small target. Here, a
Figure 2: The Q90R2-12040-6KDQ FMCW radar sensor operates at 60 GHz, can track two targets, and has a wide, configurable field of view. (Image source: Banner Engineering)
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How to select and apply radar for sensing in harsh environments
Key specifications for the K50R series include an operating frequency of 60 GHz, a sensing range of 5 m, a dead zone of 50 mm, two configurable sensing zones, and beam patterns of 80° x 60° or 40° x 30°. Selecting a long-range radar sensor For applications that require sensing over longer distances, radar operating at 24 GHz is often the best choice. These lower-frequency devices, such as the QT50R series, have a sensing range of 25 m that is valuable for applications such as collision avoidance for mobile
Selecting a radar sensor for visual feedback While radar sensors typically integrate into larger automation systems, having an at-a-glance status indicator can be helpful. At an electric vehicle (EV) charging station, for example, a visual display can help drivers correctly position their vehicles. For applications like these, the built-in LEDs of the K50R series play a valuable role. Particularly noteworthy are the Pro models, like the K50RPF-8060-LDQ (Figure 4), which offers a colorful, easy-to-interpret display.
Figure 4: The K50RPF-8060-LDQ incorporates LEDs for visual feedback. (Image source: Banner Engineering)
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equipment. The series also has one or two configurable sensing zones and a beam pattern of 90° x 76°. Its dead zone measures 400 mm for moving objects and 1000 mm for stationary objects. A notable feature of the QT50R is its ability to be configured through DIP switches. This enables simple setup in the field. However, some applications call for more sophisticated configurations. For example, the Q130R sensor (Figure 5) is designed for applications requiring sophisticated detection
capabilities and advanced configuration options. It operates at 24 GHz, has a range of 40 m, a beam pattern of 90° x 76° or 24° x 50°, a dead zone of 1000 mm, and provides accurate detection of moving and stationary objects. Notably, the Q130R employs a PC-based graphical user interface (GUI) for complex setup and fine- tuning. For example, it can be used for positioning feedback in a busy rail yard. In this application, the sensor can be configured to ignore trains parked in the background on one track while recognizing other trains as they pass in front.
Conclusion
Radar sensors are uniquely capable of operating in a wide range of outdoor and harsh environments. To maximize the benefits of radar technology, it is essential to analyze the application requirements and select a sensor with the right operating frequency and beam pattern, among other specifications. With a well-chosen radar, many challenging remote sensing applications can be addressed.
Figure 5: The Q130R radar sensor is designed for applications requiring sophisticated detection capabilities and provides accurate detection of moving and stationary objects. (Image source: Banner Engineering)
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Sorting through proximity and distance sensor technology choices
By Jeff Shepard Contributed By DigiKey's North American Editors
Using proximity and distance sensors to detect the presence and location of items without physical contact can be an important aspect of controlling industrial processes like material handling, agricultural machinery, fabrication and assembly operations, and food, beverage, and pharmaceuticals packaging. These sensors are available using a variety of technologies including photoelectric, laser, inductive, capacitive, magnetic, and ultrasonic. When determining the best choice for a given application, factors like range, size, accuracy, sensitivity, resolution, and cost need to be considered. A key factor in many applications is the material of the object to be detected. Some sensors behave differently with hard versus fibrous surfaces, and other sensors can be affected by the color or reflectivity of the object.
This article reviews commonly available non-contact proximity sensor technologies, looking at how they work, their basic performance characteristics and exemplary sensors from SICK, along with some intended applications.
Photoelectric sensors
Photoelectric sensors, like the W10 photoelectric proximity sensors from SICK, are simple to use and install and are available with a range of features suited for numerous applications. The sturdy design of the W10 sensors makes them suitable for precise object detection in challenging environments. The integrated touchscreen speeds parameter setting and sensor deployment (Figure 1). Figure 1: The touchscreen on these photoelectric sensors can speed commissioning and deployment. (Image source: SICK)
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Sorting through proximity and distance sensor technology choices
Available teach-ins enable designers to adapt these sensors to specific application requirements. In addition, integrated functions like speed settings, standard and precision measurement modes, and foreground and background suppression mean a single sensor can be used in an array of applications. The sensor series includes four variants, which differ in their operating distances and mounting options.
All objects between the sensor and the sensing distance (set to the background) are detected. To ensure reliable sensing, the background needs to be relatively bright and should not vary in height. When objects are on a reflective surface like a white or light- colored conveyor belt, foreground suppression can improve detection. Rather than detecting light reflecting from the object, the sensor detects the object by the absence of the light reflected by the conveyor belt. Retro-reflective In a retro-reflective sensor, the emitted light hits a reflector, and the reflected light is evaluated by the sensor. Errors can be minimized by using polarizing filters. Stretch films and plastic wrappings that are transparent can interfere with these sensors. Reducing sensor sensitivity can help overcome those challenges. In addition, the replacement of standard IR light emitters with lasers can enable longer sensing ranges and higher resolution. Retro-reflective sensor performance can be improved using a lower- than-normal switching hysteresis. In these designs, even minimal light attenuation between the sensor and reflector, for example, caused by glass bottles, can be reliably detected. SICK also offers a
monitoring system called AutoAdapt that continuously regulates and adapts the switching threshold in response to the gradual buildup of contamination that could lead to failure of the sensing system. Through-beam In contrast with retro-reflective sensors, through-beam sensors use two active devices: a sender and a receiver. Through-beam sensing enables longer sensing ranges. The replacement of IR emitters with laser diodes can further enhance sensing distance while maintaining high resolution and precise sensing.
Background suppression
Photoelectric proximity sensors with background suppression (BGS) use triangulation between the sending and the receiving elements. Signals from objects behind the set sensing range are suppressed. In addition, SICK’s BGS technology ignores highly reflective objects in the background and can handle difficult ambient lighting conditions. Background suppression is especially useful when the target object and the background (like a conveyor belt) have similar reflectivity or if the background reflectivity is variable and can cause interference with detection. Foreground suppression Photoelectric proximity sensors with foreground suppression (FGS) can detect objects at a defined distance.
Fiber-optic
Fiber-optic sensors are a variation on through-beam designs. In a fiber-optic photoelectric sensor, the sender and receiver are copackaged in a single housing. Separate fiber optic cables are used by the sender and receiver. These sensors are especially suited for use in high-temperature applications and in hazardous and harsh environments. Photoelectric sensor arrays The RAY26 Reflex Array family of photoelectric sensors like the model 1221950 enable reliable object detection of flat objects as
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Figure 2: Photoelectric sensor arrays can detect objects as small as 3 mm in a 55 mm high field. (Image source: SICK)
well as fast commissioning. When combined with a reflector, the photoelectric sensors also detect small, flat, transparent, or uneven objects as small as 3 mm. Within a 55 mm-high uniform light array, the sensors detect the leading edge of the object. This means that even perforated objects can be reliably detected without complex switching (Figure 4). Laser distance sensors Designers of applications like level monitoring in storage containers, position detection of objects on conveyors, XY position of the axis in automated forklift systems, vertical positioning of cranes in warehouses and overhead conveyors, and diameter monitoring during coil winding can turn to the DT50 Laser Distance Sensors. These sensors support time of flight (ToF) distance
measurements up to several meters using reflected laser light to provide immunity to ambient lighting, and precise and reliable operation. For example, the DT50-2B215252 has a range of 200 to 30,000 mm and several special features, including: ■ Rugged housing with an enclosure rating of IP65 and IP67 ■ Can provide up to 3,000 distance measurements per second ■ Minimum response time of 0.83 ms ■ Compact housing supports a range of applications from industrial robots to measuring fill heights of storage containers
High-res measurements using statistics High-definition distance measurement plus (HDDM+) is a high-resolution ToF measurement technology that can be used in laser distance and light detection and ranging (LiDAR) sensors. In contrast with single-pulse or phase correlation sensing technologies,
HDDM+ is a statistical measurement process.
The sensor software statistically evaluates the echoes of multiple laser pulses to filter out interference from sources like panes of glass, fog, rain, dust, snow, leaves, fences, and other objects to calculate the distance to the intended target. The resulting distance measurement can have a high level of certainty even under challenging ambient conditions (Figure 5).
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Sorting through proximity and distance sensor technology choices
Figure 3: SICK’s HDDM+ software uses a statistical evaluation process to eliminate “noise” from items like glass panes, fog, rain, dust, snow, leaves, and fences. (Image source: SICK)
Figure 4: A basic inductive proximity sensor consists of an LC circuit that produces an alternating field, a signal evaluator, and an amplifier. (Image source: SICK)
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Typical applications for HDDM+ technology include distance measurement for quality control in electronics production, LiDAR multi-dimensional object detection and position determination in mechanical and plant engineering, and determining the position of industrial cranes or vehicles. The sensing range of HDDM+ sensors is up to 1.5 km on retro- reflective tape. For example, model DT1000-S11101 has a range up to 460 m with a typical measurement accuracy of ±15 mm for natural objects and an adjustable resolution from 0.001 to 100 mm. Inductive Inductive proximity sensors like the IME series from SICK can detect ferrous and non-ferrous metal objects. These sensors consist of an inductor-capacitor (LC) resonant circuit that generates a high-frequency alternating electromagnetic field. The field is dampened when a metallic object enters the detection range. The dampening is detected by the signal evaluation circuit and an amplifier that produces the output signal (Figure 4). Two important specifications for the sensing distance of several proximity sensor technologies are the nominal sensing distance (Sn) and the secured sensing
Figure 5: In a capacitive proximity sensor, an oscillating circuit produces an electrostatic field that changes characteristics when the target to be sensed enters the field. (Image source: SICK)
distance (Sa). Sn does not consider manufacturing tolerances or external influences like operating temperature. Sa takes into consideration both manufacturing tolerances and variations in operating conditions. Sa is typically about 81% of the value of Sn. For example, for the model IME08- 02BPSZT0S inductive sensor, Sn is 2 mm and Sa is 1.62 mm.
When an object enters the electrostatic field, the amplitude of the oscillations in the resonant circuit change based on the dielectric properties of the material. The signal evaluator detects the change, and an amplifier produces the output signal (Figure 5). Like inductive proximity sensors, there are several specifications related to the sensing distance of capacitive proximity sensors including Sn, Sa, and a reduction factor. For example, the model CM12-08EBP-KC1 has an Sn of 8 mm and a nominal Sa of 5.76 mm. The object to be sensed must be at least as large as the sensor face and the sensing distance varies with the reduction factor of the material. Reduction factors are related to the dielectric constant
Capacitive sensing
Like inductive sensors, capacitive proximity sensors use an oscillator. In this case, an open capacitor is used where the active electrode in the sensor produces an electrostatic field relative to ground. These sensors can detect the presence of a wide range of materials including metallic and non-metallic objects.
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Sorting through proximity and distance sensor technology choices
of the material and can vary from 1 for metals and water to 0.4 for polyvinyl chloride (PVC), 0.6 for glass and 0.5 for ceramics. Magnetic Magnetic proximity sensors respond to the presence of a magnet. Magnetic proximity sensors from SICK use two detection technologies: ■ Giant magneto resistive (GMR) sensors are based on resistors that change their value in the
presence of a magnetic field. A Wheatstone bridge is used to detect the change in resistance and produce an output signal. The MZT7 cylinder sensors, like the MZT7-03VPS-KP0 designed for use with T-slot cylinders, use GMR technology to detect piston positioning in pneumatic drives and in similar applications. ■ LC technology uses a resonant circuit that resonates with a small amplitude. If an external magnetic field approaches, the resonant amplitude increases.
The increase is detected by a signal evaluator and an amplifier produces the output signal (Figure 6). The MM08- 60APO-ZUA has an Sn of 60 mm and an Sa of 48.6 mm.
Ultrasonic sensors
For objects up to 8 m away, designers can turn to ultrasonic sensors like the UM30 family from SICK. These sensors have integrated temperature compensation to improve
Figure 6: In a magnetic proximity sensor, the field probe can use GMR or LC technology. (Image source: SICK)
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measurement accuracy and provide color-independent object detection, immunity to dust, and operation up to +70°C. They measure distances based on time-of-flight technology where the distance is equal to the speed of sound multiplied by the total acoustic time of flight (t 2 ) with the total divided by 2 (Figure 6). Ultrasonic sensors like model UM30-212111 are suited for applications like empty tote monitoring. An internal temperature monitor produces a measurement accuracy of ±1%. These color- independent sensors can detect hard to distinguish objects even in the presence of dirt and dust. Conclusion The good news is that there’s a wide range of proximity and distance sensor technology choices. That means there’s a solution for every application requirement. The challenge is sorting through the many choices and finding the optimal solution for detection of specific materials under actual application and operating conditions.
Figure 7: Ultrasonic sensors can measure distance based on the total time of flight (t 2 ) of the sound waves. (Image source: SICK)
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Article Name
Things to consider when selecting an industrial photoelectric sensor
By Eric Halvorson
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Simply put, sensors are the eyes and ears of industrial automation. Regardless of the application, without sensors automation is simply not possible in today’s manufacturing process. There are many different ways in which we measure our environment through sensors. Whether that is vibration, object detection, temperature or humidity, speed, strain, or a hundred other different sensing technologies, sensors enable the
world of industrial automation. One of the many different sensor technologies that we will be talking about here is photoelectric sensors. Photoelectric sensors are utilized in industrial applications to detect object presence. There are three types, Through-Beam, Retroreflective, and Diffused. They can be used to detect materials such as wood, plastic, metal, and glass depending on the sensor
type. Through-Beam sensors utilize a transmitter node and a receiver node. The transmitter will be on one side of the beam, the receiver on the other. These two must be in alignment without any obstruction to the beam to work. With Retroreflective, the sensor contains both the transmitter and receiver in the same unit. The sensor emitter projects the beam to a reflector. The reflector is aligned to reflect the beam back into the receiver.
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Things to consider when selecting an industrial photoelectric sensor
bracket, and required cabling for power and connectivity? What are the environmental conditions in the area where the sensor(s) will be mounted? What level of ingress protection will the sensors need? 2. Beam Size. Select a sensor with a beam size that is appropriate for the size of the target you are looking to detect. The target must be big enough that it will break the beam and trigger detection. 3. Sensor Output. There are two- wire sensors and three-wire sensors. Each provide different outputs. In a two-wire sensor configuration, the sensor acts as a switch and will toggle the output on or off. With three-wire configurations, logic is required. In this case, the sensor triggers an event with a connected PLC using sourcing or sinking currents (PNP vs. NPN). 4. Output configuration. You will need to determine whether
In a diffused reflective sensor, the sensor again contains both transmitter and receiver in one unit, but instead of needing a reflector to return the beam to the receiver, the sensor is directed at an object and the light returns to the receiver. There are advantages and disadvantages to each sensor type. With Through Beam, longer range, reliability, and higher accuracy can be achieved. Areas such as wide door openings like a garage door or wide conveyors. This is due to light only needing to travel in one direction. There are some disadvantages as well. For example, cost is higher due to the need for multiple components, being able to detect through thin clear objects due to light refraction. With the need for two modules, set up can be more difficult as well. Things like mounting space requirements, cable management, and alignment prove to be a challenge depending on application. With retroreflective, cost is lower, and setup is easier having only one module and a reflector. There is no need for additional cabling and power, alignment is easier, but distance becomes shorter. Applications for retroreflective include baggage conveyors at airports, vehicle detection at toll gates, as well some material handling applications. Disadvantages of the retroreflective photoelectric sensor are at the
reflector. In situations where the object being detected is highly reflective, the sensor may fail to read the object. This can be avoided by adjusting the angles, but it is something to be aware of. With the beam being bi-directional, detection distance is also shorter. When looking at the diffuse photoelectric, cost is again lower, and there is only one point of installation. However, detection distance is much shorter. Rather than relying on a reflector to bounce back the beam, the sensor relies on objects passing in front of the beam. The other downside is depending on the material and color of the object being detected, the sensor may struggle in detection.
Considerations
When selecting your photoelectric sensor there are a number of things to consider before deciding on one type of photoelectric over another. Here are a few points you will need to look at. 1. Location. The location of the sensor plays a significant role in the type of sensor technology you can use. What is the detecting range for your application or to put it simply, how far with the object to be detected be from the sensor? Is there sufficient mounting space for the sensor module,
your sensor application would require a Light-on, Dark-on, Light-off, or Dark- off configuration is the next step. Depending on the needed configuration will help to select the proper sensor. Circuit function will help to identify the type of
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d. Moderate Contamination – Milling Operations e. High Contamination – Heavy particulate, extreme washdown environments f. Extreme Contamination – Coal bins Photoelectric sensors are indispensable tools in modern industrial automation, offering reliable and versatile object detection capabilities. Understanding the nuances of Through-Beam, Retroreflective, and Diffused sensors is crucial for selecting the optimal solution for specific applications. By carefully considering factors such as location, beam size, sensor output, output configuration, and excess gain, engineers can ensure the successful integration of photoelectric sensors into their automation systems. The judicious choice of these sensors contributes significantly to enhanced efficiency, productivity, and quality control in various industrial settings.
sensor you need. Through- beam, retroreflective, and polarized retroreflective sensors are all capable of Light-Off and Dark-Off output configurations whereas Diffuse Reflective sensors are capable of Light-On and Dark-On configurations. 5. Excess Gain. Excess Gain is the measure of the minimum light energy needed to ensure proper triggering of the sensor. When selecting your sensor, you need to ensure there is sufficient excess gain to allow for proper detection. This will be especially important in dirty industrial environments. When researching your sensor options, most manufacturers will provide an excess gain curve chart
for both non-polarized and polarized sensors. These charts will provide maximum distance vs. maximum receiver gain based on a clean environment. There are levels to consider based on the cleanliness of air in which the sensor will be operating. Here are some examples to help explain the level of air contamination and how they impact sensor operation and object detection. a. Clean Air – Ideal Conditions, perfectly clean air.
b. Slightly Dirty Air –
Non-industrial areas
c. Low Contamination – Warehouse, light manufacturing
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How multi-sensor asset monitoring can improve performance in industry 4.0 factories and logistics and in datacenters
By Jeff Shepard Contributed By DigiKey's North American Editors
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Monitoring machines for parameters like vibration and temperature can provide real-time data on machine performance and health and give manufacturers the data needed to schedule proactive maintenance, reduce downtime, and improve productivity. Humidity and temperature monitoring in logistics facilities or during transport can improve operational performance and preserve goods like vaccines or fresh produce. Environmental monitoring systems with wired and wireless connectivity are available to suit various applications, including enterprise and Cloud data centers. Monitoring vibration can be beneficial for identifying potential machine problems before they occur. International Organization for Standardization (ISO) 10816 can be an important reference. It provides guidance for evaluating vibration severity in motors used for pumps, fans, compressors, gearboxes, blowers, dryers, presses, and similar machines that operate in the 10 to 1000 Hz frequency range.
This article presents some key considerations for selecting between wired and wireless connectivity for monitor systems and how using wired and wireless networks is not an either/or choice. It then examines the four classes of vibration severity as defined in ISO 10816. It concludes by discussing various options for implementing both wired and wireless condition monitoring systems, including using multiple sensors for monitoring vibration, temperature, humidity, and representative applications. Banner Engineering offers a choice of equipment health monitoring (EHM) gateways that provide easy access to the EHM network data. Industrial EHM designers can choose between the company’s SNAP ID wired gateway solutions with a local display for sensor readings or an optional Cloud dashboard and the CLOUD ID wireless gateways designed to connect with a Cloud dashboard (Figure 1) directly. Common features of these two choices include: ■ A range of sensors to select from to optimize EHM operation
■ Rapid deployment supported by automatic recognition of connected sensors without additional programming ■ Sensor data readily available for adjusting equipment or for scheduling needed maintenance to minimize downtime and maximize productivity ■ Cloud connectivity support by both systems ■ Preconfigured dashboards available and customizable for optimal data visualization Wired or wireless EHM gateway? While they have some common features, there are essential differences between the wired and wireless EHM gateways. The AMG- SNAP-ID asset monitoring gateway (AMG) supports commissioning, monitoring, and alarms for up to 20 sensors and converters. It supports Modbus and Banner’s SNAP SIGNAL connectivity and scans for individual
Figure 1: Banner’s SNAP ID wired (left) and CLOUD ID wireless (right) EHM gateways have several common features. (Image source: DigiKey)
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How multi-sensor asset monitoring can improve performance in industry 4.0 factories and logistics and in datacenters
sensors or converters, auto-detecting model information. Users can change and assign Modbus server ID numbers to build and commission custom EHM solutions. Connected devices can be grouped, and alarms can be assigned thresholds individually. The alarm status is visible on the touchscreen and by the color of the light on the top of the enclosure. When reaching directly up to the Cloud is required, EHM system designers can turn to the DXM1200-X2 IIoT gateway to connect up to 200 devices from both Banner and third parties to deliver performance and machine health data. It can automatically detect and connect with sensor nodes
wireless architectures often include wired connectivity.
and deliver data to the Banner Cloud software. Developers can choose between simple or complex programming tools. The IIoT gateway can process information on the edge and then send it via both Ethernet and cellular networks to be monitored anywhere in the world with an intuitive Cloud dashboard (Figure 2). Wired and wireless EHM architectures Wired and wireless EHM architectures are not mutually exclusive. Wired systems can have wireless elements, and
For example, a basic wired EHM architecture can include several junction boxes connected to multiple sensors like the 4-port R50- 4M125-M125Q-P and the 8-port R95-8M125-M125Q-P. Banner’s Sure Cross R70SR serial data radios, like the 900-MHz R70SR9MQ and the 2.4-GHz R70SR2MQ, can extend network range without additional cabling. Features of these radios include (Figure 3): ■ RS-485 serial interface ■ Support for star and tree network topologies ■ Support for self-healing, auto- routing radio frequency network with multiple hops to further extend network range ■ Frequency hopping spread spectrum (FHSS) technology for reliable data transmissions In a large facility, numerous systems can be spread out over a wide area, including: ■ Air compressors ■ Pumping systems ■ Conveyor systems ■ Numerous electric motors and machines ■ Gearboxes ■ Air filtration systems ■ Level measurement and monitoring in storage tanks
Figure 2: The wireless (left) and wired (right) IIoT sensor network gateways include several common features. (Image source: Banner Engineering)
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Figure 3: Basic wired asset monitoring topology (left) with example of a wirelessly connected remote sensor cluster (right). (Image source: DigiKey)
In these cases, EHM system performance can be improved by combining wired and wireless technologies. The DXM1200-X2 wireless IIoT gateway mentioned above includes Modbus wired connectivity. If Ethernet is needed, designers can turn to the DXMR90-X1. The DXMR90-4K can implement IO-Link master/ controller functions. In addition to the choice of Modbus, Ethernet, and IO-Link, designers can use the R709 serial data radios to provide wireless connectivity to physically dispersed assets (Figure 4). ISO 10816 vibration severity ISO 10816 is an important standard for EHM systems. It quantifies vibration severity for machines
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