Low pressure sensor.

STW's modular sensor system is optimized for the needs of mobile hydraulics, and the sensors enjoy wide acceptance and strong demand. To meet increasing demand, the long-standing automation company from Kaufbeuren (D) has optimised the design and availability of its low-pressure sensors.

Large infrastructure projects are fueling demand for modern construction machinery, precision agriculture requires highly automated machinery, and in intralogistics autonomous vehicles are becoming increasingly common. These developments are leading to strong demand for high-performance and robust sensor technology. The data from these sensors form the basis for the assistance systems of modern mobile machines.

In order to meet current high demand for low-pressure sensors, STW has revised the products of the proven M01 series for pressure ranges down to 150 mbar. A new design from the automation specialists from Kaufbeuren enables optimization of the manufacturing processes and significantly increases production capacity. With the M01 sensors from 150 mbar, STW rounds off its comprehensive pressure sensor portfolio with very low-pressure ranges. Low-pressure sensors are used, for example, as reference sensors for absolute pressure measurement in mobile hydraulics, in attachments such as field sprayers, and in many areas of process automation.

The STW modular sensor system for mobile hydraulics offers highly robust products for the detection of temperature, pressure, strain, inclination and angular velocity, and pressure switches, also in functionally safe implementations. All products have CE and the E1 test mark (approval according to the German Federal Motor Transport Authority). The sensors have been developed for use in harsh environmental conditions, including dirt, vibration, heat and cold.

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User-friendly programming for mobile machines.

openSYDE, from the control systems company STW, is a framework and toolset for the implementation, analysis, maintenance and documentation of functions and programs in control systems for mobile machinery. It is characterized above all by its open architecture. It offers the OEM open interfaces to other programs and the possibility to integrate third party components.

It supports machine manufacturers with various tasks around the control system throughout the machine lifecycle, through design, production, and service. openSYDE also supports application programming. Integrated logi.CAD 3 realizes this in a particularly user-friendly way.

The focus of openSYDE is the control system architecture and design, with peripherals. For this purpose, it has the programming environment logi.CAD 3 integrated into the workflow. logi.CAD 3 can be started directly from openSYDE and with openSYDE generated code, automatically takes over the base configuration of the control system for the further programming. This is one part of the development environment’s lifecycle support, which accompanies the machine manufacturer throughout the entire product lifecycle.

With logi.CAD 3, together with the runtime system Micro-Runtime-System µRTS 3, powerful and cost-effective solutions can be realized. logi.CAD 3 offers a powerful ST (Structured Text) Editor and the graphical FBD (Function Block Diagram) Editor. The environment and control system architecture also allows the integration of C and C++ code, and the complete data storage is in ASCII format. In contrast to proprietary binary codes from other suppliers, this makes further processing far simpler - especially in conjunction with the integrated code generator.

logi.CAD 3 utilizes the open source programming environment Eclipse. This means a large number of additional plugins are available, many of them free of charge. One example is support for the source code management system GIT. Using Eclipse as a basis ensures long-term availability and development of both the environment and plugins.

Another advantage of logi.CAD 3, and thus of openSYDE, is the runtime system µRTS 3 of the programming environment mentioned above. µRTS 3 requires around 30 kB of memory. Thus, the machine manufacturer has almost the entire memory of the target controller available for the application. Further, the CAN safety protocol ECeS developed by STW, which is inherently supported by the STW controllers of the ESX family, is also particularly resource friendly. The SIL2/PL d-certified protocol significantly reduces the amount of data on the CAN bus and provides a higher speed of data transfer than the CANopen safety protocol.

openSYDE, logi.CAD 3 and the ESX controller family complement each other in an optimal way. Together they provide manufacturers of construction, agricultural, forestry and municipal machinery, as well as automated guided vehicles and mobile working robots, with a perfect ecosystem for system design, analysis, monitoring and service of their machines.

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Automation research at Munich University.

Training the engineers of tomorrow is a much discussed and complex undertaking. Future machine developers need hardware, software, and programming knowledge. At the Institute of Automation and Information Systems at TU Munich (D) hydraulic test benches are now helping teaching staff provide the required expertise.

The Institute of Automation and Information Systems focuses on the methods used in the automation of machines and plants. This includes hardware, software, and the structured development of intelligent mechatronic systems and automation technology. The focus is on reliability and usability, as well as human-machine interaction in engineering and plant operation. For students, this means a mix of theory and practice throughout their course.

In order to learn about, and better understand, the automation of hydraulic drive systems, the Institute has recently been equipped with two hydraulic test benches, with four workstations in total. The test benches simulate the hydraulic and position control systems of a model sized hydraulic elevator.

Head of the Institute Prof. Dr.-Ing. Birgit Vogel-Heuser explains: "The test benches are used in the bachelor and master degree courses in automation technology. They enable students to test the effects of their software directly on a very dynamic, physical system. In addition, the test stand serves to illustrate to the students that the design of the hardware system and the automation programming are in constant interaction."

HAWE Hydraulik SE provided the test stands. "As a local company, we find it important to support the TU Munich and in particular the Institute of Automation and Information Systems. It's great that hydraulics education is a fundamental part of teaching there," said Axel Schwerdtfeger, CTO at HAWE.

The four control units employed in the test stands are ESX.3cs controllers from STW STW and HAWE have enjoyed a close partnership for several years. "HAWE provides the power, and we provide the intelligence for our customers' machines. Within our cooperation, each partner can access the specialized know-how of the other, and manufacturers, for example of agricultural and construction machinery, benefit from well-coordinated holistic systems acquired from a single source," said Steffen Dieterle, CEO at STW, explaining the advantages of the collaboration.

Therefore, it is only natural that STW control technology is also on board for this project at TU Munich. The ESX.3cs is a compact, robust and powerful control unit. Among other advantages, the control units are suitable for safety-oriented applications up to Performance Level PL d or Safety Integrity Level SIL 2. The application software for the ESX.3cs can be programmed in C or according to IEC 61131-3. For programming applications according to the latter standard, both logi.CAD 3 and CODESYS are available. With logi.CAD 3 - together with the runtime system Micro-Runtime-System µRTS 3 - cost-effective and powerful solutions can be implemented. One of the main advantages of logi.CAD 3 is a powerful ST (Structured Text) editor, which will eventually be used by the students of the TU Munich (As of April 2021, on-site practical courses are suspended due to COVID-19).

With logi.CAD 3, STW customers have the additional benefit that it is integrated into the STW lifecycle tool openSYDE. It can be started directly from openSYDE and through code generation, can automatically provide the configuration basis for control programming. The open approach of both openSYDE and logi.CAD 3 complement each other perfectly. In combination with the hardware advantages of the ESX.3cs, customers - and in this case students - have a powerful, flexible and user-friendly control package.

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Safe, user friendly control applications.

Sensor-Technik Wiedemann (STW) has issued a new safety release for their ESX.3xm and ESX.3xl electronic control units. This new software package enables customers to create functional safety applications on these control units using CODESYS V3.5 with the IEC61131 PLC programming languages. Additionally, these ESX-3 control units have now been integrated in the openSYDE Lifecycle suite.

This new functionality significantly increases the usability of the ESX.3xm and ESX.3xl. Those mobile machine manufacturers and system developers who prefer programming in C can naturally continue to do so, while those that prefer PLC programming languages now have a certified CODESYS solution as a user-friendly option. The control units and the programming suites have been certified for safety relevant applications by TÜV SÜD according to EN ISO 13849 (to Performance Level PL d) and EN 61508 (Safety Integrity Level 2, or SIL2).

Further improvements in this release include support for alternative Flash ROMs, support for Windows 10, and integration of the openSYDE flash loaders. The tried and tested KEFEX flash loader can still be used. openSYDE is the new STW framework and software suite for the implementation, analysis, maintenance and documentation of functions, data and programming in the new generation STW control systems. With the addition of openSYDE functionality for the ESX.3xm and ESX.3xl users have more flexibility and usability throughout the control system lifecycle, and access to a greater range of control units within openSYDE.

The ESX-3 control unit hardware incorporates a second independent processor that supervises the system power supply and program flow in the main processor. When necessary, this processor can turn off all outputs through a second shut-off path, and it can reset the main processor and thereby the control unit. These features help ensure that the hardware can fulfill the requirements of functional safety.

The two control units share the same architectural concept: A robust cast aluminium housing with automotive connector, a fast 32-bit microcontroller with 6 MB Flash and 4MB SRAM, 4 CAN interfaces, a serial port, buzzer and multiple LEDs. Additionally, to CAN and RS232, there are USB, Ethernet and LIN communication interfaces available as options. 

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Inclination sensors.

The inclination sensor SMX.igs-e is the first product of a completely newly developed generation of inclination and gyro sensors by Sensor-Technik Wiedemann (STW), which is based on the use of MEMS sensor technology. This family is part of a new, future-oriented software and hardware platform. In addition, the STW software Toolchain openSYDE is supported, which allows easy integration of the SMX.igs-e into an existing application and which is used during the initial operation of sensors.

The SMX.igs-e is used to measure the inclination angle of an object in relation to the earth's gravity field. The sensor technology used in combination with a compact and robust aluminum housing is ideal for applications in mobile machines and harsh environmental conditions. The measurement values are made available via a CAN interface. This enables easy integration of the sensor into existing systems.

The sensors allow one- or two-dimensional inclination measurements in the range of 360° as well as +/- 90°. The resolution is +/- 0.01°, the achievable accuracy is 0.3°. Internal filter algorithms are available to improve the accuracy of the measured values. This way the influences of parasitic accelerations can be reduced. A robust metal housing with integrated status LED completes the system. At the start of distribution, the sensors will be offered with a CAN interface. The CANopen and SAE J1939 protocol variants will be available at the beginning of 2021. All sensors are factory calibrated before delivery and have CE and E1 approval.

In addition, the STW Toolchain openSYDE is supported, which allows fast and comfortable integration of the sensor into existing and new applications. Preconfigured projects and dashboards support the fast and uncomplicated initial operation of SMX sensors.

The inclination sensors are often used in combination with other STW sensors or control units in the following applications:

• Determination of the inclination for driving and working movements e.g. determination of the position of a digger scoop or a concrete pump
• Ensuring the stability of vehicles with booms, e.g. cranes, lifting platforms, fire department turntable ladders
• Position monitoring/inclination warning for mobile machines to ensure gear lubrication in applications with oil pan lubrication
• Leveling of vehicles and/or attachments e.g. in the agricultural sector for the alignment and adjustment of sieves and threshing units in harvesting machines
• For limiting the steer angle of a vehicle at critical lean angles
• Reduction or avoidance of strong ship fluctuations due to wave movements
• Adaptive adjustment of the brake pressure taking into account the inclination, e.g. in a harvester, to avoid excessive use of the brake system due to high brake pressures.

The SMX.igs-e is part of the STW sensor modular system for mobile hydraulics. It offers various products for the acquisition of physical parameters such as temperature, pressure, strain, inclination and angular velocity, as well as pressure switches also in a functionally safe design. In mobile machines, the measurement values are used, among other things, for monitoring and controlling the drive, the work function or the energy management and can also be made available on the Internet with onboard software and cloud solutions from STW, e.g. for predictive maintenance measures. In addition, STW sensors are characterized by their particular resilience and durability.

The Toolchain openSYDE, which STW makes available to its customers as open source, has been developed for automation specialists for construction machines, municipal vehicles, tractors etc. It is the integrating software with which users can design, develop, configure and service their applications throughout their entire life cycle.

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New version strain sensor.

The Sensor-Technik Wiedemann (STW) strain sensor DMS for measuring deflections, (e.g. of metal arms), has been completely revised and is now available in a new version under the product name SMX.dms-a. The newly developed hardware allows a lower height of the housing. The assembly points are identical to those of the predecessor product, thus enabling the seamless transition in already existing applications.

As on the previous strain sensor DMS, both an analog and a digital output are available. Furthermore, the STW toolchain openSYDE is supported, which allows easy integration into already existing systems and is used for the commissioning of intelligent sensors and electronic control units.

The SMX.dms-a strain sensor is suitable for harsh operating conditions, such as those frequently encountered with mobile machines, and now also has an E1 approval for even easier use in vehicles.

Conventional strain sensors are hard to install and put into operation. Due to its optimized connection technology, the installation of the STW sensor can be very well integrated into the production process of e.g. mobile machines. The sensor is intended either for direct mounting or it can be delivered preassembled with an optional carrier plate. openSYDE enables both easy commissioning of the DMS and software updates.

In case of servicing, the sensor can be easily replaced on site. As the configuration data are adopted, the SMX.dms-a sensor can be put into operation without requiring further alignment, meaning that the system is ready for operation again within a very short time.

By measuring deflections, forces, weights or vibrations are recorded indirectly. This can be used in many different application scenarios, such as presses, hoists, containers, steel beams, connecting rods, bridges, silo stands, railroad tracks, wind power plants, tunnel or mining equipment, airport vehicles, cranes and other mobile machines.
STW strain sensors are often used in combination with other STW sensors or control units in the following applications:

• High-resolution measurements of strain or deflection in critical machine structures • (Indirect) measurement of forces, weights, axel loads or torques • Load detection, torque limitation and load-dependent stroke limitation in e.g. forklift trucks and cranes • Vibration damping of crane arms, ladders or other cantilever structures • Collision detection, e.g. in airport vehicles

The modular sensor system for mobile hydraulics offers various products for the recording of physical variables such as temperature, pressure, strain, inclination and angular velocity, as well as pressure switches also in a functionally safe design. In mobile machines, the measurement values are used, among other things, for monitoring and controlling the drive, the work function or the energy management. They can also be made available with onboard software and cloud solutions. In addition, STW sensors are characterized by exceptional resilience and durability.

The toolchain openSYDE, which STW makes available to its customers as open source, was developed for automation specialists in the field of construction machinery, municipal vehicles, tractors, etc. It is the integrating software with which users carry out the design, development, configuration and service of their application over the entire life cycle.

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Pressure sensors SENT!

A new interface has been added to the Sensor-Technik Wiedemann(STW) modular sensor system for mobile hydraulics. For the pressure sensors of the M01 series, the SENT protocol will be additionally available in the SAE J2716, Rev 2016 variant from Q3/2020. This protocol allows the unidirectional transmission of pressure and temperature values as well as other sensor status information using a cost-effective unshielded three-wire technology, which also enables the power supply of the sensors.

In contrast to analog interfaces, SENT (Single Edge Nibble Transmission) allows several measurement variables, status information and other parameters, such as diagnostic values, to be transmitted via a line which is largely insensitive to electrical interference. SENT is particularly suitable for automotive applications and e.g. mobile machines. As a very simple digital protocol with high data rates, SENT is particularly advantageous in this environment if a connection via field busses is out of the question, but direct digital processing in the control unit is nevertheless required.

STW control units of the ESX device family also support the SENT interface, thus enabling an optimum interaction of the various components.

The modular sensor system for mobile hydraulics offers various products for recording physical variables such as temperature, pressure, strain, inclination and angular velocity, as well as pressure switches also in a functionally safe design. In mobile machines, the measurement values are used, among other things, for monitoring and controlling the drive, the work function or the energy management and can also be made available online with onboard software and cloud solutions from STW, e.g. for predictive maintenance measures. In addition, STW sensors are characterized by their particular resilience and durability.

The ESX control devices family includes robust and efficient safety and non-safety control units. In addition to control units with flexible adaptation possibilities via expansion boards, compact control units with fixed pin assignments are also available. To implement safety applications, the control units are equipped either with a multicore processor (fourth generation) or with a second additional processor (third generation). In both cases, various system voltages and the program sequence are monitored internally. Digital and analog feedback for almost all signal branches allows comprehensive diagnosis of the system including inputs and outputs.

The application software for the ESX control units can be created very efficiently either in "C" or according to IEC61131 (with CODESYS or logi.CAD). Additionally, depending on the control unit, Matlab support packages are available. Numerous comfort functions are already integrated in the programming interface, such as current controller and ramp functions for outputs or frequency averaging for inputs. Various additional libraries, for example for CANopen, J1939 or error handling, simplify the system integration.

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What exactly is digitisation?

The Coronavirus pandemic is forcing companies to go digital. Anyone who does not have a clue when digital jargon such as for example "fog computing" are used, will in future be given regular, easy-to-understand explanations of digitalisation terminology in STW's series "Digital Solutions".

The current situation At STW, the currently unclear and critical situation due to the Corona pandemic is of course viewed with great concern. Long before the current crisis, STW has developed a service that reduces the default risks to a minimum and guarantees long-term availability of STW components through component and obsolescence management. Up to now, STW has not experienced any economically induced delivery difficulties and is able to continue to offer its customers good and reliable service despite adapted working conditions. This means STW remains able to deliver its products.

With more than 30 years of experience in the digitalization, automation and electrification of mobile machines, STW supports customers with customised workshops, the right concepts and suitable system architectures. But what is this digitalisation anyway? What does it mean exactly?

The situation in which we are at the moment is extraordinary in many ways. Life presents each and every one with great challenges, both professionally and personally. Many are forced to find solutions to completely new and unprecedented problems within a very short period of time. The enormously high degree of networking at all levels of society can help create something new in an uncomplicated, fast and pragmatic way. Never before have there been so many new ideas for digital solutions as there are today, the possibilities for implementation are almost unlimited and new ones are added every day.

However, people must first learn to handle the new technologies that they have created and to use them in a sensible, sustainable, but also economically efficient way. Without a new way of thinking and exploring new patterns and structures, however, this will not be easy. More than ever before people are forced to imagine even previously unimaginable things and to put the right things into practice as quickly as possible.

To date, digitalisation is increasing in all economic sectors. But what is this digitalisation? What does it mean exactly? And how can concrete business operations, real products and existing workflows be digitalised and what is the goal of all of this? Questions like these are at the beginning of every digital transformation. Literally, it is precisely these questions that must be answered as accurately as possible before any implementation. Despite all the digitalisation, which is of course what it's all about, there is no need to use digital tools or to specify software or platforms at this stage. All needed here are the traditional pen and paper and the right questions. Customers can benefit from STW's services and many years of experience already at this early stage. The company supports customers with customised workshops, develop suitable concepts and design the appropriate system architectures.

And once an individual digitalization solution has been defined, their digital products also come into play.

With a modular system consisting of modern software, scalable cloud infrastructure, robust hardware and long-term partners, they build prototypes, conduct feasibility studies, provide support during market launch and accompany our customers through the entire life cycle of their digital solution, including system maintenance. All this from one source.

Thanks to the modularity, standardization and open interfaces of their digital product portfolio, they enable customers to cover the entire implementation spectrum between "make-or-buy". This means that a solution can be developed either completely or partially by the customers themselves, or it can be provided by STW as a ready-to-use platform. As a result, customers can focus on their core competence and we take care of the rest.

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Interfaces for safety pressure sensors.

The STW (Sensor-Technik Wiedemann) pressure sensors of the F02 Safety series from the modular sensor system for mobile hydraulics, now can provide the “Deutsch DT04” connector as an additional electrical connection option in addition to a 5-pole M12 connector.

The “Deutsch DT04” connector is mainly used in the automotive sector. With the E1 approval already available, the pressure sensor designed for safety applications can now be integrated even more easily into vehicles. In addition, the sensor now also supports a ratiometric output signal, which changes proportionally to the supply voltage. This signal is less susceptible to interference and can be easily processed in a subsequent analog-to-digital conversion in vehicle wiring systems that can fluctuate greatly, as the supply voltage of the vehicle can be used as a reference.

The F02 Safety is designed for applications, which require a Performance Level PL d or a Safety Integrity Level of SIL 2.

It is based on the proven type M01 and has a thin-film measurement cell made from stainless steel, which is welded together with the pressure sensor, thus guaranteeing high media compatibility. The multitude of available pressure connections, the large supported pressure range, the excellent EMC compatibility as well as the small constructional design offer the greatest possible flexibility in the application or during design-in.

The F02 Safety is part of the STW modular sensor system for mobile hydraulics. It offers various products for the acquisition of physical parameters such as temperature, pressure, strain, inclination and angular velocity, as well as pressure switches in a functionally safe design. In mobile machines, the measured values are used, among other things, for monitoring and controlling the drive, work function or energy management and can also be made available on the Internet e.g. for predictive maintenance measures using onboard software and cloud solutions from STW. Furthermore, STW sensors are known for their particular resilience and durability.

#PAuto #Automotive #Safety @Sensor_Technik @PresseBox

Strategic obsolescence management.

The rapid spread of the Corona virus (Covid-19) puts a massive strain on both the German and international economies. Long before the current crisis, STW has developed a service that reduces the default risks to a minimum and guarantees long-term availability of STW components through component and obsolescence management. This means STW remains able to deliver its products.

As a manufacturer of electronic assemblies for tough and rough operating conditions, the long-term availability of products is essential. The STW product lifetime of more than ten years, for example, is well above the standard in the automotive sector.

Nevertheless, STW, like all other manufacturers of electronic assemblies, is affected by the changes in the electronic component market and – as can be seen currently – unpredictable crises. The ever shorter life cycles and faster innovation cycles of the manufacturers initially stand against the desire for long-term availability. In addition, some component manufacturers change their products over the course of their service lifetime in terms of e.g. color, shape, function, place of manufacture, test site, etc. Some products are discontinued completely and are then no longer available (obsolete). And in extreme cases, companies may have to shut down their operations completely due to drastic economic changes.

Updates on such changes reach STW in the form of PCNs (Product Change Notifications) or PDNs (Product Discontinuation Notifications).

For unprepared manufacturers, discontinuations in particular represent a major challenge. The effort involved in searching for a replacement type, the resulting redesigns or component storage mean high costs.

In order to be prepared for such challenges, STW's "Component and Obsolescence Management" intervenes at a much earlier stage.

Of course, stable processes within STW are indispensable for such a forward-looking approach. Further support includes access to a professional database and membership of COG Deutschland e.V. (Component Obsolescence Group), which has more than 150 members throughout Germany.

This way customers are involved in the life cycle planning of the future product from the initial project phase, where strategic component decisions are made to guarantee a long lifetime of the assembly group. Regular reviews during the product life cycle ensure that the risk of sudden component discontinuation is minimized. STW thus guarantees its customers functionality, quality and the ability to supply the products for years to come.

At STW, the currently unclear and critical situation due to the Corona pandemic is of course viewed with great concern. Up to now, STW has not experienced any economically induced delivery difficulties and is able to continue to offer its customers good and reliable service despite adapted working conditions.

#PAuto  #coróinvíreas #COVID19 #coronavirus @Sensor_Technik @PresseBox