Near field communication replacing cables & boxes.

During the development of a machine, there comes a time when the individual sensors need to be fine-tuned. Uncertainty often arises about the number of pulses required for optimum application. Effort and frustration are therefore inevitable. Choosing the right adaptors, tools and parameterization boxes for sensor adjustment usually doesn't go as smoothly as expected. The problems continue when the required cable is unavailable. Without the right cable, the set configuration can't be changed or adapted. To facilitate this development phase, Wachendorff Automation has developed an intelligent and simple solution. Instead of relying on the usual adapter cables and parameterization boxes, the company decided to use NFC - Near Field Communication - as the configuration interface when developing the new incremental encoder.

Wachendorff is a medium-sized, owner-managed company with headquarters near Frankfurt am Main (D). The company, which specializes in the development and production of encoders has developed the world's first incremental encoder that can be individually configured using a smartphone. The individual characteristics can be created and saved to a smartphone application. These settings can now be uploaded to the encoder via NFC. NFC is a powerless and contactless transmission technology. The WDGN series has been equipped with an NFC chip to transfer this established communication technology to the encoder.

"The aim of our WDGN series is to offer our customers new options for their encoder configuration," says Robert Wachendorff.

A reliable and high pulse rate is generated by the specially developed encoder sensor technology. At the same time, it is so flexible that any pulse rate down to one pulse per revolution can be set. The devices are based on patented magnetic sensor technology with high accuracy and resolution. Highly accurate measurements can be realized in a small installation space with up to 16384 pulses per revolution and a compact design starting from 36 mm.

The flexible parameter setting via the app allows the customer to configure the device on site by himself. This provides greater flexibility in machine development and commissioning. Different controllers or frequency converters can be tested variably. The exchange of the devices on the machine is possible in a very flexible way. This reduces storage and transport costs as less stock is required. Incorrect ordering is reduced to a minimum. Different encoder configurations can be stored directly in the application.

The generic software, specially developed by Wachendorff, can be used regardless of the sensor type. Functionality can be adapted to other sensor and actuator systems, such as enabling features or exchanging data.

The Flutter software, which is compatible with both Apple and Android, was used as the basis for the app's technology.

NFC technology has been successfully adapted for harsh industrial conditions. The encoder series, with typical diameters of 36 mm and 58 mm, consists of shaft encoders and hollow shaft encoders. Depending on the product type, a shaft load of up to 300N is possible. Reverse polarity and short-circuit protection are provided for the full voltage range from DC 4.75V to DC 32V. All common industry mounting options are available. The encoders can be supplied with an M12 connector or cable outlet, in both radial and axial versions. The robust stainless-steel housing provides IP67 and IP69K protection, depending on type, and IP65 or up to IP67 at the shaft input. High resistance to vibration and shock is available, as well as an operating temperature range of -40°C to 85°C, making them well suited to use in very harsh industrial environments. The new alloy used for the cover provides better shielding against magnetic influences and makes production even more environmentally friendly.

Data transmission security is also guaranteed. Configuration of the encoder is only possible with the correct password. The communication of the encoder is encrypted, and the different levels of access rights are protected by PINs for the end user. There are several memories in the encoder. The current configuration is stored in the microcontroller's internal memory and in the NFC memory.

If the values are valid, the configuration in the NFC memory can be overwritten with the desired one and will be transferred to the internal memory after a power reset. If the data in the NFC memory is invalid, it is reset to the last valid values in the internal memory. By using the NFC memory, configuration data can be read and sent even when the device is switched off. This is essential for easy and secure deployment. All data is protected and encrypted by the PIN, even when the device is switched off.

Compared to Bluetooth and WLAN, NFC has a shorter range and communicates in the near field. The longer range of WLAN and Bluetooth makes them more susceptible to interference and potentially easier to attack. Both are active radio standards where transmission can only take place when power is applied. With NFC, parameter configuration can be performed directly on the machine, ensuring limited access. As the NFC module communicates passively, there is no interference during operation. NFC allows wireless and voltage-free parameterization directly on the machine, making it safer and less complicated to use.

The antenna design has been tested with several functional prototypes. For further testing and optimization, several antenna designs were created and procured in production quantities. These were tested for reception quality, distance between smartphone and antenna, and robustness of communication. The best possible ratio between range and space requirement of the antenna was identified.

The solution developed provides sufficient memory for current requirements and sufficient reserves for future expansion. The antenna layout has been optimized to fit on a 20mm x 17mm circuit board while still providing reliable transmission over the maximum distance.

This board is connected to the sensor board via a ribbon cable and special locking connectors. This locking is necessary for high mechanical robustness.

The WDGN is an optimal and simple alternative for customers where the otherwise widely used IO-Link communication standard is not suitable.

The newly developed WDGN series is available in two versions. The Basic version has the standard channels of an incremental encoder (A, B, N) and the inverted channels. The Advanced version is more advanced. Here, four channels can be configured independently.

The new technology easily saves costs and time and increases sustainability.

@mepaxIntPR #wachendorff-automation #PAuto #Communication

Rotary angle measurement.

Variohm EuroSensor are supplying Contelec's Vert-X 79 magnetic rotary encoder designed for high accuracy angular measurement on construction machines and heavy-duty mobile vehicle applications where extreme conditions call for the highest levels of durability.

With the convenience of straightforward application adaptation through its MH-C and MH-C2 technology, output interfaces include 0.1 to 10 V, 4 - 20 mA and CANopen with optional half and fully redundant versions available. The Vert-X 79 series has a 0 … 360 degree continuous range with a choice of 12- to 16-bit resolution depending on the output type with independent linearity down to 0.1% of the measuring range. Contelec’s contactless magnetic measuring principle ensures long life whilst the robust aluminium housing with IP68 / IP69K protection ensures maximum durability for extremes of humidity, dampness, dust, and vibration.

The compact sensor has an outer diameter of 79 mm with overall height of just 50mm and electrical interfacing is via an M12-m connector. Series options include special characteristic curves, factory programmed electrical angle within a range of 30° to 360° as well as support for field-programmable direction, range and index points. The CANopen version also offers custom bit-rate to 1000 Kbits/sec. Other customisation options include shaft and housing modifications, and alternative electrical connection.

The Vert-X 79 can be supplied with a driving disc that can be used as a coupling element for the rotating drive mechanism. This connection method allows precise measurements even under radial impact and can tolerate a high level of axial misalignment.

@Variohm #PAuto #Contelec

Safety encoder.

In 2015, the Safety Communication Layer of BiSS Safety was confirmed by TÜV Rhineland for suitability for safety-relevant communication up to and including SIL3. In the future, Hengstler will offer this protocol for its rotary encoder portfolio in order to meet the steady growth in safety applications.

Since 2007, Hengstler has been offering encoders which use the open communication standard BiSS C. A continuous data connection to the bus participants, high transmission rates and free licenses are to be mentioned as clear advantages. The newly introduced BiSS Safety Protocol is 100% based on BiSS C. Hengstler GmbH, based in Aldingen (southwest Germany) has an enormous experience of countless successful applications in which their encoders play a reliable role.

Hengstler sees enormous potential in the field of functional safety in combination with ever-increasing machine guidelines, increasing number of safety applications. For this purpose, the internal system structure of the encoder is expanded by a combination of available blocks. The Safety Communication Layer of BiSS Safety has been certified according to IEC 61784-3: 2010 ans IEC 61508 Part1-7:2010. It is therefore suitable for safety-relevant communication up to SIL3.

This means that BiSS Safety, combined with Hengstler rotary encoders, will combine positive effects from two worlds. As a customer, one can be sure that Hengstler will successfully extend the encoder portfolio with BiSS Safety, thanks to its decades-long BiSS experience. On the other hand, users benefit from different providers, which offer a manufacturer-independent protocol for secure data transmission.

@Hengstler_GmbH #PAuto @tuvrheinland

Robust, non-contact distance measurement!

A new bearingless encoder for linear distance measurement has been introduced by Baumer. The MIL10 comprises a sensing head and an adhesive magnetic tape.The non-contact magnetic sensing method is wearfree and hence provides virtually unlimited service life.

Magnetic tape encoding is by poles of 2mm width. Signal processing integrated in the sensing head allows for resolutions up to 5 µm. The fully encapsulated magnetic sensor provides IP 66 and IP 67 as standard protection. Used in conjunction with a masking tape of stainless steel, the system is even up to demanding environments with a high degree of soiling by dust, chippings, splints or oil. Operating temperature may range from -40°C to +85°C.

Sized 10 x 15 x 45,5 mm, the sensor is extremely compact. It withstands shocks and vibrations up to 500 respectively 30 g. The Polyurethan cable capable of flexible carriers and frequently changing bending radii is shielded and twisted in pairs - and in conjunction with the sensor’s robust metal housing the ultimate protection against electromagnetic interference.

The output frequency of max. 350 kHz allows for travel speed up to 25 m/s. MIL 10 is available with 5 VDC supply and TTL / RS422 compliant line drivers and as a 10…30 VDC variant with push-pull. Both output two inverted channels with 90° shift and generate an additional pole-periodic inverted index pulse.

IECEx Standard compliant encoder!

EEx HOG 161 is the youngest Baumer HeavyDuty incremental encoder in explosion-proof design with IECEx certifcation in device category 2 G.

The encapsulated, pressure-proof device for enhanced safety is compliant to both ATEX Directive 94/9/EG for potentially explosive atmospheres (II 2 G Ex d e IIC T6 Gb) and IECEx scheme (Ex d e IIC T6 Gb) and this way allows for deployment in anyone of the 30 countries worldwide that have adopted the IECEx standard. In particular manufacturers of export-oriented equipment benefit from the international certification.

The encoder operates on the optical sensing technique and depending on the product variant provides 250 to 2.500 impulses per turn. Inner through-hollow shaft diameters from 30 to 70 mm, high bearing load capacity of 650 N radial and 450 N axial ensure maximum service life. The robust housing will reliably protect the encoder against adverse ambient conditions and the large terminal box enabling four different mounting positions will considerably ease electrical installation.

Heavy duty encoder is compliant to IECEx standard

EEx HOG 161 is the youngest Baumer HeavyDuty incremental encoder in explosion-proof design with IECEx certifcation in device category 2 G.

The encapsulated, pressure-proof device for enhanced safety is compliant to both ATEX Directive 94/9/EG for potentially explosive atmospheres (II 2 G Ex d e IIC T6 Gb) and IECEx scheme (Ex d e IIC T6 Gb) and this way allows for deployment in anyone of the 30 countries worldwide that have adopted the IECEx standard. In particular manufacturers of export-oriented equipment benefit from the international certification.

The encoder operates on the optical sensing technique and depending on the product variant provides 250 to 2.500 impulses per turn. Inner through-hollow shaft diameters from 30 to 70 mm, high bearing load capacity of 650 N radial and 450 N axial ensure maximum service life. The robust housing will reliably protect the encoder against adverse ambient conditions and the large terminal box enabling four different mounting positions will considerably ease electrical installation.


The Baumer Group is an international leading manufacturer and developer of sensors, encoders, measuring instruments and components for automated image-processing. Baumer combines innovative technology and customer-oriented service into intelligent solutions for factory and process automation and offers a uniquely wide range of related products and technologies.

With more than 2,500 employees and production plants, sales branches and agencies in 36 subsidiaries and 18 countries, the family-owned company is always close to the customer. Industrial clients in many sectors gain vital advantages and measurable added value from the worldwide consistency of Baumer’s high quality standards and its enormous innovative potential. For further information, visit www.baumer.com on the internet.