Food pressure winner!

A panel of experts from the food processing industry selected the Baumer PP20H pressure sensor as the winner of the Innovations Showcase Award in the dairy product category at the Process Expo in Chicago.

This pressure sensor prevailed among the 17 finalists due to its condensate-resistant silicon measuring cell, exceptional precision across the entire temperature range, and IO-Link interface. 

“An IO-Link interface is the latest trend in the sector and we have incorporated this technology in our PP20H,” says Baschar Al Hammoud, product manager for pressure sensors. However, "in true Baumer style," the company did not settle for that without offering its customers extra benefit – in addition to the digital IO-Link interface, the PP20H also offers an additional analog output. “With this combination, the PP20H offers users more flexibility than any other pressure sensor.”

This way, during commissioning of the sensor, users can benefit from all IO-Link advantages, which considerably simplify sensor parameterization while still allowing process control by the sensor via the 4 ... 20 mA analog output. Furthermore, the IO-Link makes it possible to call up additional process data such as the pressure of the measurement cell or the temperatures of the pressure sensor and the microchip in the central processing unit. Access to this information allows for interesting investigations: for example, whether an unusual temperature rise has occurred in a container, which may indicate a defect or faulty dosage of the ingredients in a tank. As high temperatures may decrease the service life of the sensor or other system components, this may indicate the need for preventive maintenance – one of the promises of Industry 4.0. Of course, the PP20H series offers all the advantages of IO-Link, such as quick parameterization during operation and prior to installation. Even more, a new sensor easily learns the parameters of the old sensor via the master and is immediately ready for operation upon installation. For Baschar Al Hammoud, this is only the first step: “We are planning additional functions based on IO-Link.”

The PP20H also exceeds all standards also in terms of robustness. Its measurement cell is completely sealed even during relative pressure measurement. This prevents the entrance of warm and humid ambient air, which may precipitate with low process temperatures. This is the case, for example, in milk or ice cream processing. At the same time, the sensor must be somehow “open” to the surroundings because the sensor will also determine the difference to the ambient temperature.

The Baumer engineers devised a unique technical solution for this challenge – they placed a barometric pressure sensor in the back of the housing that can measure the reference pressure of the environment via an opening. This way, the actual silicon measurement cell in the front remains hermetically sealed. The PP20H is therefore not only suitable for CIP (Clean in Place) and SIP (Sterilization in Place) processes, but also for sudden changes in process media temperatures.

@ProcessExpo #BaumerElectric #Pauto #Food #MEpax

Effective tool change cleverly designed with inductive miniature sensors.

In modern processing centers, inductive sensors are the components of choice for monitoring the motor spindle clamping process. Integrated into the spindle, they must be exceptionally small and offer high repeatability to ensure smooth tool changing at all times. Baumer offers a high-performance portfolio of miniature sensors for the intelligent design of effective spindle solutions. This can either involve a classic design with three switching sensors or a smart design with one measurement sensor.

Tool change in fully automated processing centers, from removal until the insertion of the new tool in the spindle, takes less than a second. To achieve maximum system effectiveness, this process must function with ultimate reliability. The error-free functioning of the smallest inductive sensors plays a major role in ensuring this. For the processing center to function error-free, the machine control requires the following key information regarding the status of the collet chuck: open and no tool clasped, closed and no tool clasped, or closed and tool clasped. The answer to this challenge are inductive sensors. The task can be handled using either one measurement sensor or three switching inductive sensors.

Largest portfolio, smallest sensors
In drive and clamping solutions, the sensor technology is integrated in the motor spindle. Given this confined space, the sensors must therefore be as small as possible, yet very powerful – characteristics found in the sensors from Baumer. The Swiss sensor manufacturer offers the market’s largest portfolio of miniature and sub-miniature inductive sensors with micrometer measuring accuracy. One example is the inductive proximity sensor IFRM 03 with a diameter of only 3 mm. It is available in various lengths starting at a mere 12 mm. Yet its miniature housing contains the complete evaluation electronics that are responsible for the high-repeatability switching points as well as the precise analog measurement values. In addition, these industrial-grade sensors are robust, EMC-stable, and comply with the protection class IP 67. The sensors remain unaffected by heat, oily environments, and vibrations that normally occur in tooling machines. This is where the decades of experience of Baumer in miniature sensor technology come to play.

Measuring instead of switching
Rather than detecting the three positions of the drawbar with switching sensors, an analog inductive distance sensor offers an alternative solution. It requires a steep angle taper on the drawbar rather than a retainer. With a steep angle taper connected to the drawbar, it is possible for the measuring sensor to detect the position of the drawbar and thus recognize the state of the collet chuck. The distances or the respective clamping values that are evaluated by the control can be allocated to the three positions of the bar. The use of a measurement sensor offers a number of advantages – on the one hand, the sensor requires less space than three individual switching sensors and also less mounting effort. On the other hand, the sensor constantly monitors the state of the tool clamp. This makes it possible, for example, to detect when the tool becomes loose or is not clasped centrally. This may happen if chips fall between the spindle and the tool. It can result in damage to the tool or quality problems of the machined part. The precise sensors from Baumer optimize the repeatability of the tool clamping. This minimizes a potential lack of concentric runout of the used tool or detects it early on. A measuring sensor improves the reliability of the clamping system while ensuring both the quality of the processing as well as system availability, which is reflected in increased overall system effectiveness. This requires micrometer precision of the sensor, a detection range that is as large as possible, and a limited temperature drift. In this regard, AlphaProx, the smallest inductive distance sensors from Baumer, offer the highest performance on the market. The reliable measured values and high precision ensure users a maximum reproducibility for tool tensioning. Baumer has introduced one of the smallest distance measurement inductive sensors on the market – the inductive analog sensor IF08. This product series has a box-shaped housing measuring 16 x 8 x 4.7 mm. Nevertheless, it contains the entire evaluation electronics and a drilled hole for flexible mounting even in confined mounting spaces. Its measuring distance is 2 mm with an output signal of 0 – 10 VDC.

Flexible with IO-Link
Even greater flexibility is offered by the miniature distance measurement inductive sensor of the IR06 series with digital IO-Link interface with a housing that is only 6.5 mm thick and 46 mm long. The standardized interface allows the easy integration of the clamping process into the control. The collected data can be recorded and evaluated via a histogram. This allows the early detection of measurement deviations and facilitates required error analyses. For example, the smallest changes in the process can be detected via the vibration and addressed before the machined part is damaged. The sensor also provides additional diagnosis data, for example, the temperature of the sensor, which the tooling machine designers can use to indirectly recognize the heating up of the spindle. In addition, the sensor offers all the advantages of IO-Link, such as easy parameterization and quick commissioning of a replacement sensor, by downloading the parameters from the IO-Link master based on the parameter server function.

No restrictions with sensors from Baumer
The comprehensive portfolio of miniature inductive sensors offers users maximum flexibility for reliable solutions in the tool clamping process. The customer can choose whether the clamping process is monitored by switching sensors or a measurement sensor – without restrictions or limitations.

#PAuto #Baumer #MePax

Digital and analog interface in one sensor.

Pressure sensor PP20H and conductivity sensor CombiLyz AFI have now been added to the Baumer portfolio of process sensors with digital communication interface

Digital communication opens up many opportunities – but only sensors that reliably deliver precise measured values offer real added value by IO-Link. Well established and appreciated by many users, both pressure sensor PP20H and CombiLyz AFI conductivity sensor excel by outstanding measuring performance and IO-Link interface, but now they offer even more interesting features such as simple and fast parameterization- even during operation. This way, secondary data like different process data output simultaneously or diagnostic data only accessible this way can be communicated from sensor to controller or even retrieved from the sensor memory if required. Further to the digital interface, the sensors also provide one or more conventional analog outputs for maximum user flexibility.

Dual Channel enables analog as well as digital sensor operation or both at the same time - this way, Baumer process sensors such as conductivity sensor CombiLyz AFI and pressure sensor PP20H work both in conventional control topologies and digital IO-Link control environments. In process automation, the proven analog interface is helpful for sensor integration into existing control concepts. Nevertheless, in sensor commissioning, IO-Link advantages such as easy and fast parameterization or access to secondary data are a valuable help. For process control, parallel readout of conductivity or pressure value is enabled via 4... 20 mA analog output.

IO-Link provides access to valuable secondary data: process data including sensor temperature respectively process temperature of PP20H. Such information allow for interesting conclusions, e.g. unusual temperature rise in containers or pipes. And, such data are basic for predictive maintenance. CombiLyz AFI conductivity sensor delivers information on media concentration in addition to media conductivity. By doing so, the medium in process and its concentration is precisely identified. Pressure sensor PP20H delivers ambient pressure information in addition to process pressure. Therefore, the sensor can be deployed for both absolute and relative pressure measurement.

IO-Link allows for mutual and bidirectional sensor communication via the controller. This way, every sensor can utilize the measured values of other sensors to solve complex measuring tasks or for optimization of processes and production flow. Using conductivity sensor AFI for example, transmission of the measured temperature value would reduce response times of temperature compensation to 15 seconds or even completely circumvent them. In level detection in closed tanks, two fusioned pressure sensors enable direct indication of the filling level. The head pressure sensor transmits the measured value to the pressure sensor at the tank bottom for zero point adjustment. This way, the actual pressure is determined.

With CombiLyz conductivity sensors and PP20H pressure sensors now featuring this digital communication interface, Baumer further adds on their portfolio of IO-Link process sensors. And, solutions for flow and level detection using this digital communication standard are also available.

#Baumer #PAuto 

Food sensor innovation wins.

At the Process Expo in Chicago, a panel of experts from the food processing industry selected the PP20H pressure sensor as the winner of the Innovations Showcase Award in the dairy product category.

The pressure sensor prevailed among the 17 finalists due to its condensate-resistant silicon measuring cell, exceptional precision across the entire temperature range, and IO-Link interface. “An IO-Link interface is the latest trend in the sector and we have incorporated this technology in our PP20H,” says Baschar Al Hammoud, product manager for pressure sensors. However the company did not settle for that without offering its customers extra benefit – in addition to the digital IO-Link interface, the PP20H also offers an additional analog output. Baschar Al Hammoud explains, “With this combination, the PP20H offers users more flexibility than any other pressure sensor.”

This way, during commissioning of the sensor, users can benefit from all IO-Link advantages, which considerably simplify sensor parameterization while still allowing process control by the sensor via the 4 ... 20 mA analog output. Furthermore, the IO-Link makes it possible to call up additional process data such as the pressure of the measurement cell or the temperatures of the pressure sensor and the microchip in the central processing unit. Access to this information allows for interesting investigations: for example, whether an unusual temperature rise has occurred in a container, which may indicate a defect or faulty dosage of the ingredients in a tank.

As high temperatures may decrease the service life of the sensor or other system components, this may indicate the need for preventive maintenance – one of the promises of Industry 4.0. Of course, the PP20H series offers all the advantages of IO-Link, such as quick parameterization during operation and prior to installation. Even more, a new sensor easily learns the parameters of the old sensor via the master and is immediately ready for operation upon installation. For Baschar Al Hammoud, this is only the first step: “We are planning additional functions based on IO-Link.”

The PP20H also exceeds all standards also in terms of robustness. Its measurement cell is completely sealed even during relative pressure measurement. This prevents the entrance of warm and humid ambient air, which may precipitate with low process temperatures. This is the case, for example, in milk or ice cream processing. At the same time, the sensor must be somehow “open” to the surroundings because the sensor will also determine the difference to the ambient temperature. The Baumer engineers devised a unique technical solution for this challenge – they placed a barometric pressure sensor in the back of the housing that can measure the reference pressure of the environment via an opening. This way, the actual silicon measurement cell in the front remains hermetically sealed. The PP20H is therefore not only suitable for CIP (Clean in Place) and SIP (Sterilization in Place) processes, but also for sudden changes in process media temperatures.

#Baumer #PAuto #Dairy #Mepax

Process sensors with digital communication interface. #Baumer #PAuto

Pressure sensor PP20H and conductivity sensor CombiLyz AFI now add on the Baumer portfolio of process sensors with digital communication interface.

Digital communication opens up many opportunities – but only sensors that reliably deliver precise measured values offer real added value by IO-Link. Well established and appreciated by many users, both pressure sensor PP20H and CombiLyz AFI conductivity sensor excel by outstanding measuring performance and IO-Link interface, but now they offer even more interesting features such as simple and fast parameterization- even during operation. This way, secondary data like different process data output simultaneously or diagnostic data only accessible this way can be communicated from sensor to controller or even retrieved from the sensor memory if required. Further to the digital interface, the sensors also provide one or more conventional analog outputs for maximum user flexibility.

Dual Channel enables analog as well as digital sensor operation or both at the same time - this way, Baumer process sensors such as conductivity sensor CombiLyz AFI and pressure sensor PP20H work both in conventional control topologies and digital IO-Link control environments. In process automation, the proven analog interface is helpful for sensor integration into existing control concepts. Nevertheless, in sensor commissioning, IO-Link advantages such as easy and fast parameterization or access to secondary data are a valuable help. For process control, parallel readout of conductivity or pressure value is enabled via 4... 20 mA analog output.

IO-Link provides access to valuable secondary data: process data including sensor temperature respectively process temperature of PP20H. Such information allow for interesting conclusions, e.g. unusual temperature rise in containers or pipes. And, such data are basic for predictive maintenance. CombiLyz AFI conductivity sensor delivers information on media concentration in addition to media conductivity. By doing so, the medium in process and its concentration is precisely identified. Pressure sensor PP20H delivers ambient pressure information in addition to process pressure. Therefore, the sensor can be deployed for both absolute and relative pressure measurement.

IO-Link allows for mutual and bidirectional sensor communication via the controller. This way, every sensor can utilize the measured values of other sensors to solve complex measuring tasks or for optimization of processes and production flow. Using conductivity sensor AFI for example, transmission of the measured temperature value would reduce response times of temperature compensation to 15 seconds or even completely circumvent them. In level detection in closed tanks, two fusioned pressure sensors enable direct indication of the filling level. The head pressure sensor transmits the measured value to the pressure sensor at the tank bottom for zero point adjustment. This way, the actual pressure is determined.

With CombiLyz conductivity sensors and PP20H pressure sensors now featuring this digital communication interface, Baumer further adds on their portfolio of IO-Link process sensors. And, solutions for flow and level detection using this digital communication standard are also available.

Miniature-format strain sensors.

Similar to other strain sensors in the Baumer portfolio, the compact DST20 sensors are based on the strain gauge technology with a strain gauge and a strain body. The soft geometry on the inside minimizes hardening of the structure to be measured. This makes the miniature strain sensor suitable for static as well as dynamic applications. Thin structures can also be monitored because of the limited reaction forces on the screws.

The miniature-format strain sensors DST20 complement their portfolio by adding a compact and cost-efficient solution for measuring large forces above 10,000 N even in confined spaces. With their dimensions of 28x12x10 mm, the DST20 miniature strain sensors offer space savings that are unmatched by any other screw-on strain sensor on the market. At the same time, their stainless steel housing and a certification for the IP 65 degree of protection make them excellently suited for use in rough production environments and for a large range of applications, such as mechanical and equipment engineering as well as process automation. The DST20 strain sensor can be integrated into a machine with minimum engineering effort and offers a lasting solution that can serially replace cold bonded strain gauges in limited installation spaces, based on initial tests in the experimental laboratory.

Ex factory the strain is typically measured with an output signal of around 1.0 mV/V, which frequently eliminates the need for calibration with a separate force sensor. This allows users to benefit from simple and quick commissioning coupled with high measurement accuracy in the micrometer range, which saves valuable time in the case of emergencies.

The sensors come in two measurement ranges: 500 and 1,000 µm/m, for different customer requirements in terms of the expected strains and permitted mechanical tension, depending on the steel quality. This way, a single sensor can be used to cover a large number of applications, allowing users to reduce costs and warehouse space.

With the DST20, Baumer rounds off its strong portfolio for force measurement with force and strain sensors. In addition to robust strain sensors for outdoor and industrial applications, Baumer has thus combined robustness and precision with exceptionally compact dimensions, effectively enhancing the scope of application of strain sensors. Users can now also optimize their process safety and quality in areas where the smallest dimensions matter.

#BaumerGroup #PAuto 

Mini-strain sensors.

The miniature-format strain sensors DST20 complement the Baumer portfolio by adding a compact and cost-efficient solution for measuring large forces above 10,000 N even in confined spaces. With their dimensions of 28x12x10 mm, the DST20 miniature strain sensors offer space savings that are unmatched by any other screw-on strain sensor on the market. At the same time, their stainless steel housing and a certification for the IP 65 degree of protection make them excellently suited for use in rough production environments and for a large range of applications, such as mechanical and equipment engineering as well as process automation.

The DST20 strain sensor can be integrated into a machine with minimum engineering effort and offers a lasting solution that can serially replace cold bonded strain gauges in limited installation spaces, based on initial tests in the experimental laboratory.

Similar to other strain sensors in the Baumer portfolio, the compact DST20 sensors are based on the strain gauge technology with a strain gauge and a strain body. The soft geometry on the inside minimizes hardening of the structure to be measured. This makes the miniature strain sensor suitable for static as well as dynamic applications. Thin structures can also be monitored because of the limited reaction forces on the screws.

Ex factory the strain is typically measured with an output signal of around 1.0 mV/V, which frequently eliminates the need for calibration with a separate force sensor. This allows users to benefit from simple and quick commissioning coupled with high measurement accuracy in the micrometer range, which saves valuable time in the case of emergencies.

The sensors come in two measurement ranges: 500 and 1,000 µm/m, for different customer requirements in terms of the expected strains and permitted mechanical tension, depending on the steel quality. This way, a single sensor can be used to cover a large number of applications, allowing users to reduce costs and warehouse space.

With the DST20, Baumer rounds off its strong portfolio for force measurement with force and strain sensors. In addition to robust strain sensors for outdoor and industrial applications, Baumer has thus combined robustness and precision with exceptionally compact dimensions, effectively enhancing the scope of application of strain sensors. Users can now also optimize their process safety and quality in areas where the smallest dimensions matter.

#Baumer #PAuto #MEpax

Measuring energy consumption in dairy.

Dairy cooperative Arla Foods has, for the first time, created transparency over the energy consumed in cottage cheese production at its Falkenberg (S) location. This involves the use of the Baumer Flex-Flow® sensor, which is able to measure the temperature of the medium as well as the flow rate.This cost reductions this could achieve in the future quickly made this a worthwhile investment.

This dairy cooperative produces 20 000 tonnes of cottage cheese every year equivalent to 76.9 tons per day on this site. Arla Foods satisfies almost the entire cottage cheese demand on the Swedish market and also exports to Finland, Denmark and Greece.

Production volumes of this magnitude call for a resource-efficient manufacturing process, and Arla Foods is a forerunner when it comes to sustainability: the dairy cooperative intends to bemaking its products completely CO2-neutral by 2050. A key element of this journey: energy efficiency. Mattias Abrahamsson, Production System Manager at Arla Falkenberg, reports: “In recent years, we have placed an increasingly strong focus on monitoring the energy consumption of our plants. In certain areas, however, we simply didn’t know where exactly the energy was being used.” FlexFlow®, the calorimetric flow sensor from Baumer achieved the breakthrough. Arla installed these sensors at the neuralgic points in the cooling and heating system and used the measurement results to obtain, for the first time, a clear image of the energy consumption. So the dairy producer can now derive concrete measures for reducing energy consumption.

Cooling and heating – these were the tricky points in the energy consumption in the Falkenberg plant. Because of its commitment to sustainability, the food manufacturer had already made a great effort to reduce the energy balance when the plant was designed. It uses to the greatest possible extent, for example, the low external temperatures of the Swedish climate to achieve a cooling temperature of 0.5 degrees Celsius for the cooling circuit, which cools the produced cheese from 60 to 30 degrees Celsius. Yet energy losses that Arla had been unable to localize for some time occurred here as well.

“The potentials of the FlexFlow® sensor,” explained Mattias Abrahamsson, “caught our attention as soon as we heard about them. This sounded exactly like what we had been looking for.”

“Baumer has been collaborating with Arla Foods for many years,” reports Martin Leupold, Product Manager for process sensors at Baumer. “Our partnership dates back to the 1990’s.” The cooperation has seen the development of a new process connection for milk production called Baumer Hygienic Connection, and this has effectively optimized the cleaning times. The temperature sensors from the CombiSeries product range were also created under the close collaboration between Arla and the Baumer Development Center in Aarhus in Denmark. “This close collaboration is allowing us to get to know our customers’ pain points,” explains Martin Leupold. “And we can use that knowledge to develop or suggest products that actually optimize their processes in a sustainable manner.” To solve the problem of monitoring energy consumption, the choice fell to the FlexFlow® sensor because it could easily be integrated into the existing plant and is able to measure both flow and temperature.

The simple installation of the FlexFlow® sensor is down to the symmetrical and centered design with one sensor element ahead of the sensor tip, which allows the sensor to be optimally installed in the process regardless of installation position and orientation. “We want our portfolio to make commissioning as easy as it can be for our customers”, says Martin Leupold. “This allows them to spend their precious time on what actually needs to be done.” The flow sensor has a robust stainless steel housing that accommodates all the electronics, so there’s no need for complex wiring or control cabinet installation.

The FlexFlow® also meets the requirements for protection class IP 68 (Baumer proTect+), making this sensor, together with the materials used, the perfect solution for hygienic applications.

One exceptional feature is its maximum temperature range to 150 degrees Celsius, which also qualifies it for Sterilization-In-Process (SIP) tasks.

Arla has already installed around 15 of these flow sensors in the cooling circuit and heating system. The plan is now to also integrate these sensors into the CIP return line to monitor and optimize the energy consumption there as well.

Mattias Abrahamsson is extremely satisfied: “Thishas proven to be a cost-efficient solution. And because the sensors installed so far are reliably returning the results we need, we will now install more and more of them.” Martin Leupold is also pleased: “This solution is allowing Arla, our long-term partner, to systematically optimize its energy consumption, save resources and deliver on its sustainability promises. We, at Baumer, are working on these very solutions.”

#Baumer #PAuto #Food #MEpax

Point level.

Thanks to their new level switch PL20, the CleverLevel series from Baumer now offers more possibilities for detecting point levels. CleverLevel reliably detects every type of medium, whether liquid, pasty, viscous, or solid, and is therefore the solution for a variety of applications for which standard vibrating forks are used today.

One of its major advantages is the fact that it does not have to be parameterized to a medium as before but flexibly adapts to the medium at hand. This way, even adhesions such as those that frequently occur with pasty materials can be reliably masked. With its optional 4-20 mA analog signal, the PL20 offers a number of additional advantages and true added value for increased efficiency of your production process.

The food and beverage production sector is distinguished by increasingly individual customer requirements. Conventional measurement systems are unable to cope with the different media characteristics involved. The new level switch CleverLevel PL20 makes processes more flexible and eliminates additional efforts – because it no longer matters what is in the tank. The level switch offers true added value, especially when it comes to applications in the food production sector with changing recipes or batch production. The self-learning sensor automatically adjusts to the different media. This ensures maximum flexibility with minimum set-up times. In addition, thanks to its compact design and low installation depth, it has only a minor impact on the process and thus ensures maximum food safety.

Even adhesions such as those that occur with pasty materials and electrostatic charging do not affect the performance of the sensor. In such cases as well, the level switch adjusts the switching level without any type of parameterization, minimizing downtimes that may be caused by faulty switching. With an additional optional 4 -20 mA analog output, the PL20 can help differentiate the media within the process or evaluate the cleaning process. What is more, the graphic evaluation of the measurement results with the help of the FlexProgrammer ensures a transparent process. In addition, the sensor can be easily and quickly integrated in already existing systems via the analog interface. At the same time, the large selection of process connections and adapters allows the flexible and easy integration of the sensor.

#Baumer #PAuto #Food #MEpax

Point level detection.

"The original puts you one step ahead – point level detection has never been this easy and reliable!" 

Thanks to the new level switch PL20, the CleverLevel series from Baumer now offers more possibilities for detecting point levels. CleverLevel reliably detects every type of medium, whether liquid, pasty, viscous, or solid, and is therefore the solution for a variety of applications for which standard vibrating forks are used today. One of its major advantages is the fact that it does not have to be parameterised to a medium as before but flexibly adapts to the medium at hand. This way, even adhesions such as those that frequently occur with pasty materials can be reliably masked. With its optional 4 - 20 mA analog signal, the PL20 offers a number of additional advantages and true added value for increased efficiency of your production process.

The food and beverage production sector is distinguished by increasingly individual customer requirements. Conventional measurement systems are unable to cope with the different media characteristics involved. The new level switch CleverLevel PL20 makes processes more flexible and eliminates additional efforts – because it no longer matters what is in the tank. The PL20 level switch offers true added value, especially when it comes to applications in the food production sector with changing recipes or batch production. The self-learning sensor automatically adjusts to the different media. This ensures maximum flexibility with minimum set-up times. In addition, thanks to its compact design and low installation depth, it has only a minor impact on the process and thus ensures maximum food safety.

Even adhesions such as those that occur with pasty materials and electrostatic charging do not affect the performance of the sensor. In such cases as well, the level switch adjusts the switching level without any type of parameterization, minimizing downtimes that may be caused by faulty switching. With an additional optional 4 … 20 mA analog output, the PL20 can help differentiate the media within the process or evaluate the cleaning process. What is more, the graphic evaluation of the measurement results with the help of the FlexProgrammer ensures a transparent process. In addition, the sensor can be easily and quickly integrated in already existing systems via the analog interface. At the same time, the large selection of process connections and adapters allows the flexible and easy integration of the sensor.

 #PAuto #Baumer #mepax

Coast with the rolls!

In Europe’s biggest roller coaster, the Helix at the Liseberg amusement park in Gothenburg (S), POG 10 HeavyDuty incremental encoders from Baumer monitor the speed of the carrriage's drive as it approaches the start ramp. The HeavyDuty technology guarantees high reliability and precision under extreme environmental conditions – serving up both thrills and reassuring safety for riders.

Liseberg in Gothenburg is Sweden's largest amusement park. The Helix roller coaster is one of the attractions that swirls up an adrenalin kick. With a 1380 meter track, Helix is the longest looping roller coaster in Europe and the second longest in the world. It hurls its riders at up to 90 km/h through six loops and exposes them to up to five times their own bodyweight. This is the first time anywhere in the world where half of the riders, Helix takes up to 28, sit facing backwards, making the ride even more exciting. Before the start, the riders have to be brought to the start ramp at a height of 41 meters. Controlled asynchronous drives with 315 kW of power are used to move the carriages into the start position. The speed of this drive is recorded by the original Hübner Berlin POG 10 HeavyDuty encoder from Baumer. No easy task, as the roller coaster is freely exposed to the elements – heat from the sun, moisture from rain or wind currents. Hence the decision to go for HeavyDuty encoders from Baumer, making sure the riders experience the thrill as a pleasure too.

Reliability is critical
The POG 10 incremental HeavyDuty encoder and its sister model, the HOG 10 with hollow shaft, are among the most versatile product ranges of the Baumer HeavyDuty encoders. They deliver reliable speed data in a host of potential applications and operate under the toughest conditions. As a result, they help prevent failures and maintain the availability of machines and systems. This saves downtime costs in a host of applications. With the roller coaster, it even makes a valuable contribution to the safety of human life – a malfunction in the drive of a carriage would at best be annoying for the riders, and at worst a life-threatening experience.

When is an encoder "HeavyDuty"? "HeavyDuty" is neither a protected expression nor the name of a standard. The HOG 10/POG 10 product range of Baumer Hübner, however, has generally been considered the defining "original" for 25 years now. The features that set this range apart and against which the segment is benchmarked are: • Mechanical resilience: resistance to hard shocks, vibration and forces on the rotary shaft for many years • Impermeability: sealed against dirt, dust and moisture • Electrical resilience: electronic components inside the encoder shielded against electromagnetic fields and powerful output drivers • Precision: reliable signal delivery, allowing a precise open-loop and closed-loop control of drives and generators "HeavyDuty" is an all-encompassing performance promise. It guarantees that an encoder will function reliably and precisely at all times over a prolonged period and under adverse conditions.

The HeavyDuty technology of the POG 10 guarantees high reliability under challenging environmental conditions through numerous specific features. Thanks to solid and generously dimensioned wall thicknesses and a warp-resistant design, the die-cast housings are extremely robust and highly resistant to vibration and shock. Bearings at both encoder shaft ends and the metallic incremental disk offer huge power reserves and unparalleled durability through extreme resilience to axial and radial forces. For outdoor use, in a roller coaster for example, the excellent anticorrosive properties of the CX category of HeavyDuty encoders to EN ISO 12944, achieved through an optimal choice of material and high-resistant coating, are also extremely important. These properties allow the encoders to be used even on or in the ocean, in the Arctic, in the tropics or in the desert.

The combination of labyrinth and shaft seals also protects the inner workings of the HeavyDuty encoders from solid, moist and paste-like contamination. This sealing concept conforms to protection classes IP 66 and IP 67 within a broad temperature range of up to 95 degrees Celsius. Current-insulated bearings ultimately protect the ball bearings of the encoder from current flashovers, and this averts any impairment of the lubricant effect. The result is an almost indestructible full package that effectively prevents potential malfunctions and failures, even during tough continuous use in a roller coaster. This is all the more important as a replacement can get very costly – not because the encoder itself is expensive, but because it is typically mounted in barely accessible locations, as is the case on a roller coaster.

HeavyDuty as an all-encompassing performance promise
HeavyDuty means highly resilient. This is not only about a tight, solid housing and protection against the elements. The intrinsic values have to be right as well. "Of course, it's always the strong ones, so to speak, that are used when the going gets tough, explains Steffen Günther, Head of the HeavyDuty Business Unit at Baumer. "Yet HeavyDuty offers an all-encompassing performance promise: such encoders must, first and foremost, function under extreme conditions at all times. Secondly, however, their signal accuracy must not suffer under these adverse conditions. For an encoder to be called HeavyDuty, it must be absolutely durable, impermeable and precise."

Reliable precision is ensured by the interference-immune scanning function with highly robust, optical circuits (Opto-ASIC). This guarantees optimum electromagnetic compatibility with a burst strength for high-voltage pulses of up to 4 kV. In addition, the Enhanced Monitoring System (EMS) continuously checks numerous encoder functions, swiftly detects connection and encoder errors and transmits the encoder status to the inverter or to the control via an error output. The HeavyDuty encoders achieve the best possible SinCos signal quality through the LowHarmonics technology for outstanding control quality, low drive heat-up and high energy efficiency. The incremental square signal outputs also have short-circuit proof, powerful transistor drivers for peak currents of up to 300 mA. They ensure reliable signal quality even over long-distance transmissions of up to 350 meters.

These features – resilience and precision – make an important contribution to ensuring that the Gothenburg roller coaster riders are brought to the start ramp safely and at the correct speed. A good thing too, since this ascent to 41 meters is thrilling enough without any failures.

Baumer guarantees to keep this all-encompassing performance promise every time with original Hübner Berlin technology through rigorous sample tests and by putting each and every HeavyDuty encoder through a full inspection before it leaves the factory. Resistance to electromagnetic fields, vibration, shocks, dust, hose water, salt spray and much more is ensured on test benches during series production. Detailed quality certificates confirm that these tests have been passed and give the customer the confidence that their encoder won't leave them high and dry.

Baumer's undisputed world leading position as a supplier of original Hübner Berlin HeavyDuty encoders is another such guarantee. The manufacturer can draw on experiences garnered in this encoder class since the 1950s. For 25 years now, the HOG 10/POG 10 product range has been considered the Non-Plus-Ultra in the segment. An original, often copied by the competition, but never equaled, in pursuit of offering more "Beyond the Standard" – more precision, more functionality, more resilience and more benefits for the user. A "more" that can be achieved only through the know-how created from decades of experience with the subject.

It can be assumed that the riders on the roller coaster in the Liseberg amusement park have no idea what's going on. This promise of resilience and precision, however, keeps the operators safe in the knowledge that their ride will never become a roller coaster of feelings for them.

#Baumer #Sweden #Encoder @mepaxIntPR

Strain sensors in concrete pumps.

The trend on truck-mounted concrete pumps is for greater reach with less weight. Technical advances at Schwing are currently making it one of the market leaders in this field. In order to raise operator comfort levels on truck-mounted concrete pumps with large booms, the company has launched an innovative vibration damping system. In partnership with Baumer Electric, the company has developed a new strain sensor with an IP69K protection rating and an exceptionally broad measuring range to provide precise signaling of deflections as they occur in the boom.

Since its formation in the 1930s, they have been designing, constructing and selling pumps, machines and plant equipment for the production, transport and reprocessing of concrete: batching plants, truck-mixers, stationary and truck-mounted concrete pumps as well as recycling plants. Whether concreting a swimming pool in the front garden of a family home or realizing prestigious public projects such as the One World Trade Center in New York (USA), or the third Bosporus bridge in Turkey, the machines and plant are deployed wherever concrete is used to provide permanent stability. With six manufacturing sites and subsidiaries or representatives in more than 100 countries, the company provides efficient, reliable and long-term solutions throughout the world. Extensive in-house production capacity for core components guarantees strict inspection processes and high product quality.

Truck-mounted concrete pumps of various sizes and types are manufactured at sites in Herne (D), Chennai (Ind), and Sao Paulo (BZ). The models with the longest placing booms are manufactured at the Group’s German headquarters. With a new boom drive concept, high-strength steel, less weight, and more operator comfort, they are Schwing’s answer to the market's increasing demands in terms of economics, ecology and ergonomics.

Modern placing booms have a reach of almost 65 meters. With highly efficient twin cylinder piston pumps and a pressure of up to 85 bar, they pump concrete at up to 164 m3 per hour. This obviously causes vibrations in the boom. In order to be able to offer end users improved operator comfort at the end hose, Schwing has developed an innovative vibration damping concept which has included a complete revision of the hydraulic elements. A precision transducer was required which could pick up the elongations from the signal boom caused by movement of the whole placing boom, and which would then transmit the command variables for the vibration damping. A force sensor would have to be mechanically built into the direct flow of forces from the arm and then exactly matched to the machine geometry. It was possible to significantly reduce the development effort by absorbing the movement over the elongation. The effect of a force always produces elongations in a mechanical structure. These elongations depend on the geometry of the structure to be measured and the modulus of elasticity.

“We developed a customer-specific, innovative strain sensor in close collaboration with Baumer Electric AG which comfortably overcomes all the challenges,” explains Reiner Vierkotten, Senior Engineer Control Systems at Schwing GmbH. “The new high-strength steels we have used allow the mechanical stresses and elongations to take place in higher areas than in previously used materials. Conventional strain sensors cannot operate in these areas.”

A completely new set of sensor mechanics was developed using FEM simulations with a measuring range of ± 2000 µm/m. The easy-to-mount sensor with long-term seal functions perfectly in multi-shift operation in spite of the tough conditions on building sites. It is calibrated at the factory which speeds up installation and any possible replacement work. The new sensor, with its on-board electronics, supplies a high-resolution digital CANopen signal directly to the truck-mounted concrete pump’s control system.

Compared to force sensors, which have to be precisely adjusted to the machine geometry, the strain sensor can be easily mounted at the optimum position with just two bolts. This does not affect the structure of the machine, save times in development and makes mounting easy. The robust design of the sensor makes it impervious to shocks, impacts, and other mechanical influences and is therefore ideal for use in the construction environment. At the same time, it is very gentle, reacts quickly, and can accurately detect even the slightest elongation or compression. It is resistant to wind and weather due to its a corrosion-resistant housing. With a certificated protection class of IP69K, its seal is absolutely guaranteed and can be cleaned with high-pressure or steam cleaning systems.

“We are very pleased with our collaboration,” confirms Vierkotten. “The innovative damping system is also available for the latest S 65 SXF truck-mounted concrete pump from SCHWING which was launched at the beginning of 2018 at the World of Concrete trade fair in Las Vegas. Following comprehensive prototype testing and optimization during the development phases, the new DST55R strain sensor was successfully put into volume production by Baumer. We can imagine using Baumer sensors for future projects on our truck-mounted concrete pumps.”

@BaumerGroup #PAuto #Construction

User friendly universal temperature transmitters.

With the new generation of universal temperature transmitters, FlexTop 2212 and 2222, Baumer is expanding its proven range of products. With integrated micro-USB port, automated cable compensation and a fast sampling time of less than 50 ms, it stands out from other commercially available products and is also suitable for demanding applications in a wide variety of areas.

The digital transmitters with 4 ... 20 mA analog outputs are powered through the current loop. The model 2222 also offers HART communication. The sensor inputs can optionally be configured for resistance thermometers, thermocouples, resistance sensors and voltage signals. Depending on requirements, a 2, 3 or 4-wire input can be selected. This makes the transmitters very flexible in their application, keeps stocks low and saves costs. The integrated standard interface allows simple and direct programming at any time and in any place. An additional interface is not necessary.

The multi-colored indicator light provides a visual indication of the status of the measured values. This simplifies diagnostics and helps in troubleshooting. Automatic cable compensation eliminates complicated calculations, reduces the work involved in calibration and guarantees accurate measurements regardless of the length of the cable.

The FlexTops 2212 and 2222 are prepared for direct display connection using UnitCom cables. This allows for comfortable operation on site by touch screen and rules out conversion errors. They are molded in silicone rubber, which makes them insensitive to humid environments.

The two mounting screws with standard 33mm spacing and pressure springs guarantee reliable sensor contact in DIN 43729-compatible heads, even when there are vibrations.

@BaumerGroup #PAuto

Temperature trasmitters with USB port.

A new generation of universal temperature transmitters, FlexTop 2212 and 2222,  announced by Baumer expands its proven range of products. With integrated micro-USB port, automated cable compensation and a fast sampling time of less than 50 ms, it stands out from other commercially available products and is also suitable for demanding applications in a wide variety of areas.

The digital transmitters with 4 ... 20 mA analog outputs are powered through the current loop. The model 2222 also offers HART communication. The sensor inputs can optionally be configured for resistance thermometers, thermocouples, resistance sensors and voltage signals. Depending on requirements, a 2, 3 or 4-wire input can be selected. This makes the transmitters very flexible in their application, keeps stocks low and saves costs. The integrated standard interface allows simple and direct programming at any time and in any place. An additional interface is not necessary.

The multi-colored indicator light provides a visual indication of the status of the measured values. This simplifies diagnostics and helps in troubleshooting. Automatic cable compensation eliminates complicated calculations, reduces the work involved in calibration and guarantees accurate measurements regardless of the length of the cable.

The FlexTops 2212 and 2222 are prepared for direct display connection using UnitCom cables. This allows for comfortable operation on site by touch screen and rules out conversion errors. They are molded in silicone rubber, which makes them insensitive to humid environments. The two mounting screws with standard 33mm spacing and pressure springs guarantee reliable sensor contact in DIN 43729-compatible heads, even when there are vibrations.

@BaumerGroup #PAuto 

Hygienic pressure sensor is safer.

A new generation of hygienic pressure sensors in Baumer's PP20H family closes a gap in its portfolio and also offers an attractively-priced solution for demanding hygienic applications. The sensor has a robust, IP69K-rated stainless steel housing which is designed to handle a variety of applications, and is equipped with a condensate-proof silicon measuring cell.

Its scaled pressure range from -1 to 40 bar and wide range of process connections make it extremely versatile. It is available with 4 ... 20 mA signal and IO-Link. It complies with the strict hygiene requirements in the food and pharmaceutical industries and is CIP and SIP-capable.

Thanks to the hermetically-sealed measuring element, the measuring cell is completely insensitive to condensate, even with extreme temperature fluctuations in damp environments. Together with its excellent temperature and long-term stability and high accuracy, the sensor guarantees demanding hygienic processes are monitored, controlled and regulated safely.

This compact pressure sensor covers the wide media temperature range from -20°C to 125°C without requiring a cooling line, providing space-savings in installation. Additionally, a variety of applications can be covered by just one sensor model. This saves on storage and reduces costs.

Several sensors can be simultaneously configured via IO-Link. This simplifies switching point adjustment for different process stages at start-up or batch changes and saves time. Diagnostic data can be instantly called up and evaluated, which increases system availability.

The modular sensor structure enables shipment within 48 hours after receipt of order (ARO).

@BaumerGroup #PAuto 

Miniature object recognition.

The new O300 miniature laser sensors with IO-Link by Baumer are the specialists for the reliable detection of very small objects and gaps. A laser beam which focuses to within 0.1 mm and the high repeat accuracy of 0.1 mm, ensures that objects can be positioned with high precision and follow-up processes controlled exactly.

Thanks to the extremely short response time of less than 0.1 ms, the sensor reliably detects even closely spaced objects, thus allowing fast processes and high throughput rates. A big advantage is the exact alignment of the laser beam to the fixing holes by design (qTarget).  Detection with pinpoint accuracy can be guaranteed over the entire series.

The new O300 miniature laser sensors with IO-Link by Baumer are the specialists for the reliable detection of very small objects and gaps. Thanks to a laser beam which focuses to within 0.1 mm and the high repeat accuracy of 0.1 mm, objects can be positioned with high precision and follow-up processes controlled exactly. Thanks to the extremely short response time of less than 0.1 ms, the sensor reliably detects even closely spaced objects, thus allowing fast processes and high throughput rates. A big advantage is the exact alignment of the laser beam to the fixing holes by design (qTarget).

Thanks to qTarget, detection with pinpoint accuracy can be guaranteed over the entire series.

@BaumerGroup #PAuto

Detecting tiny objects and gaps.

The new O300 miniature laser sensors with IO-Link by Baumer are the specialists for the reliable detection of very small objects and gaps.

Thanks to a laser beam which focuses to within 0.1 mm and the high repeat accuracy of 0.1 mm, objects can be positioned with high precision and follow-up processes controlled exactly. The extremely short response time of less than 0.1 ms ensures that the sensor reliably detects even closely spaced objects, thus allowing fast processes and high throughput rates. A big advantage is the exact alignment of the laser beam to the fixing holes by design (qTarget). Thanks to qTarget, detection with pinpoint accuracy can be guaranteed over the entire series.

The wear free teach-in method (qTeach) allows easy, user-friendly commissioning of the laser sensor. The weak point of the pushbutton or potentiometer is ruled out with the tamper-resistant teach-in method qTeach, thus offering maximum reliability and system availability.

The O300 laser product portfolio impresses with its great diversity, offering tailor-made solutions for precise detection tasks. Among the five sensor principles to choose from, SmartReflect, the original light barrier without a reflector, must be highlighted. Even reflecting objects with a size of 0.5 mm can be reliably detected within a sensing distance of 250 mm. Stainless steel variants in a rugged washdown and hygienic design extend the typical applications of the O300 laser sensors for packaging plants in the food and pharmaceutical industries.

Thanks to IO-Link integration, the O300 laser sensors are “Ready for Industry 4.0”. IO-Link allows the quick and easy configuration of sensors for all applications using standard network components. In addition, available additional data, e.g. for predictive maintenance processes, can be evaluated.
More information at: www.baumer.com/O300laser

#Baumer #PAuto  #Laser

Level switch with IO-Link.

LBFH and LBFI level switches with IO-Link and ATEX approval are available from Baumer. The IO-Link interface allows the user to automate the configuration of sensors.The inclusion of ATEX also enables the use of commercially available barriers. The sensors are suitable for hygienic and industrial applications.

Thanks to IO-Link integration, the level switches are Industry 4.0-ready. The communication interface enables each application to be configured quickly and easily using standard network components. This ensures error-free duplication of the system and device replacement without the need for additional programming, thereby saving time. Diagnostic data can be called up and evaluated at any time, which increases system availability.

Just like their predecessors, LBFH and LBFI level switches meet the criteria for ATEX categories 1 and 2 for gas and dust. The reduced current consumption of their more advanced electronics means that commercially-available standard barriers can now be used in addition to the Baumer barriers. This increases flexibility in terms of integration even in existing plants, and reduces installation costs.

Two switching outputs make it possible to set independent trigger thresholds. This means two different process steps, such as production and cleaning, or two media groups, such as water and oil, can be monitored with one sensor. Additionally, the two switching outputs facilitate a plausibility check of the sensor. Complementary trigger point setting ensures wire breaks are reliably detected, thus guaranteeing effective monitoring of all programs.

Both variants are suitable for use in temperatures up to 135 °C while the variant for hygiene applications also has SIP capabilities.

#Baumer #PAuto 

Level switch with IO-Link.

Baumer has announced the immediate availability of LBFH and LBFI level switches with IO-Link and ATEX approval. The IO-Link interface allows the user to automate the configuration of sensors.The inclusion of ATEX also enables the use of commercially available barriers. The sensors are suitable for hygienic and industrial applications.

Thanks to IO-Link integration, the level switches are Industry 4.0-ready. The communication interface enables each application to be configured quickly and easily using standard network components. This ensures error-free duplication of the system and device replacement without the need for additional programming, thereby saving time. Diagnostic data can be called up and evaluated at any time, which increases system availability.

Just like their predecessors, LBFH and LBFI level switches meet the criteria for ATEX categories 1 and 2 for gas and dust. The reduced current consumption of their more advanced electronics means that commercially-available standard barriers can now be used in addition to the Baumer barriers. This increases flexibility in terms of integration even in existing plants, and reduces installation costs.

Two switching outputs make it possible to set independent trigger thresholds. This means two different process steps, such as production and cleaning, or two media groups, such as water and oil, can be monitored with one sensor. Additionally, the two switching outputs facilitate a plausibility check of the sensor. Complementary trigger point setting ensures wire breaks are reliably detected, thus guaranteeing effective monitoring of all programs.

Both variants are suitable for use in temperatures up to 135 °C while the variant for hygiene applications also has SIP capabilities.

@BaumerGroup #PAuto #Ex

Clever height measurement.

The measurement of object height is an important aspect in quality control applications. With the PosCon HM light-section sensor, Baumer offers a unique, compact measuring device for this kind of tasks. The smart, pre-configured profile sensor offers five measurement modes for different measurement tasks. An exact positioning of the measured objects is not required.

Smart at-Line quality control of rubber seals 

The PosCon HM provides reliable measurements even on shiny and very dark surfaces. In conjunction with its high measuring accuracy of up to 2 μm, it is suitable for a large number of applications in at-line, off-line and in-line control.

One example is the inspection of black rubber seals for side windows in the automobile industry. In this case, random samples are tested off-line on a special test bench. The seals are fitted into special mounts on a measuring setup. The forms and the curves of the seal may vary, but they must not exceed special limit values. The challenge for the sensors is not only the form, or, to be more precise, the curves, but also the black, light-absorbing material. In the PosCon HM, powerful algorithms analyze up to 600 items of height information per measurement and determine the maximum height of the object, irrespective of its position. Only the PosCon HM makes it possible to carry out this measurement, and it supplies precise, reliable measurement results with a measuring rate of up to 1540 Hz.

The PosCon HM is also the ideal measuring tool for the inspection of metallic, glossy preformed parts, for example the inspection of car doors. The sensors can check the correct form of the car door, for example, by performing measurements at numerous test points. The sensors can also be mounted close beside each other without influencing each other. The PosCon HM provides the measured values directly in mm, thus allowing an immediate OK/Not OK check for each test point.

 #Baumer #PAuto