Visualisation, control and machine operation at once.

The MATCH product line with a specialised platform for industrial panel PCs that integrates control and operation functions within a single system has been expanded by Wahchendorf Prozesstechnik. The solutions are aimed at machine and plant manufacturers as well as operators of industrial production facilities requiring compact, robust and flexible HMI solutions.

MATCH CONTROL focuses on combining visualisation, control and direct machine operation.

It combines panel PCs with control elements for efficient HMI concepts in machine and plant engineering The panel PCs integrate high-performance computing technology with physical control elements such as push-buttons, switches or emergency stop functions.

The systems are designed for industrial environments and are suitable for direct installation on machines or support arm systems. Various display sizes and form factors enable precise integration.

Like all MATCH products, the devices follow a standardised structure with expansion options. Interfaces, design and functionality can be adapted. This combination of integration, robustness and flexibility reduces development effort and supports efficient HMI concepts.

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New IO-Link encoders.

Maintenance-free, robust, networked.

The portfolio of absolute encoders in the WDGA series from Wachendorff Automation, is being expanded with variants featuring an IO-Link interface. This makes integration into modern automation environments even easier, more efficient, and more future-proof.

The new IO-Link encoders are based on proven EnDra® technology – a maintenance-free multiturn principle without gears or batteries. They offer high resolution of up to 16 bits (singleturn) and 43 bits (multiturn) and are equipped with the fast IO-Link COM3 interface. The devices are ideal for use in packaging machines or roll-to-roll processes.

Technical highlights:

• Smart Sensor Profile (SSP) for easy integration
• Integrated status monitoring (temperature, voltage)
• LED status display for operating states and errors
• Parameterization via IO-Link master possible
• Resolution: up to 16 bits (singleturn), 43 bits (multiturn)
• Protection class: IP65, IP67, IP69K (depending on type)
• Compatible with standard IO-Link masters and unshielded cables
• 64-bit profile available for particularly demanding applications

Precise absolute positioning is crucial in applications such as packaging machines. Wachendorff's IO-Link encoders not only provide accurate position data, but also enable quick adaptation to changing packaging parameters – ideal for short cycle times and high flexibility. Integrated condition monitoring helps to minimize downtime and increase machine availability.

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Industrial PCs.

Panel PCs, web panels, displays and box PCs in a consistent design - attractive for machine and plant engineering.

Wachendorff Prozesstechnik offers a future-proof hardware platform for machine and plant manufacturers with two high-performance series of industrial PCs. The product lines include panel PCs, web panels, displays and box PCs, which are characterized by a uniform and modern design. The design is consistent across all device categories, enabling machine and system manufacturers to implement a clear corporate design right down to the operating and display level of their machines - an increasingly important factor in mechanical engineering and series production.

In addition, the series offers an exceptionally wide range of display sizes from 10.1 inches to 32.0 inches - a spectrum that is rarely found on the market in this range. This allows machine builders to choose exactly the right size for different applications and operating concepts - from compact machine controls to large-format control stations.

The industrial PCs from Wachendorff Prozesstechnik have been specially developed for industrial use: Robust workmanship for 24/7 continuous operation, powerful hardware components for demanding applications and long-term availability for investment security.

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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.

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Compact Ethernet/IP encoder.

Wachendorff is expanding its range of Ethernet-based encoders: Encoders with the EtherNet/IP protocol are now available, including the most compact in the world: the WDGA58F. Wachendorff's R&D team has succeeded in minimising the sensor to an installation depth of just 46.5 mm.

The encoders are certified by the ODVA. The resolution in single and multi-turn can be individually configured via an integrated web server (single-turn 16 bit, multi-turn 43 bit).

The very high environmental data, e.g. temperature range from -40 °C up to +85 °C, shock 1,000 m/s² or vibration 50 m/s² at 10-2000 Hz, allow the use in harsh industrial environments as well as in mobile working machines.

The devices with hollow end shafts eliminate the need for additional couplings and the devices with shafts guarantee a long-lasting and stable connection with their very high bearing loads of up to 400 N.

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Digital lift shaft measurement systems.

Wachendorff’s Silent Move™ series digital shaft copying systems provide highly accurate position feedback to within 0.02 mm and lift speeds of up to 4 m/s and with a measurement range of up to 120 metres. For straightforward integration with lift control and regulation systems users can select incremental encoders with pulsed output or absolute values covering CANopen, CANopen LIFT, SSI or RS485. 

Variohm EuroSensor, Wachendorff’s distribution partner in Britain, fully supports he Silent Move lift monitoring range includeing all necessary components for fast and straightforward mounting in lift shafts used for low-rise residential elevators and home lifts, hydraulic lifts, limited-use/limited-application (LU/LA) systems, cargo lifts, construction site lifts and more.

Silent Move systems are available in two basic design formats: a measuring unit comprising the incremental or absolute encoder on a mounting bracket with pulley wheels and separate toothed belt to attach to a customer designed mounting arrangement – or as a complete measuring system with the measuring unit and all the necessary parts to mount the belt on a standard lift installation (typically including profile rails and clamps, damping spring mechanism and fittings etc.). The toothed pulley measurement unit, which is optionally equipped for a nubbed belt or timing belt, is attached to the lift car and rolls along the belt which is mounted between the shaft head and the bottom of the lift shaft and includes a simple but efficient spring tensioning mechanism. These systems are available with a circumferential (continuous) belt arrangement or an in-line guided belt. Both arrangements offer particularly quiet and smooth running.

Wachendorff Automation GmbH is a developer and producer of rotary encoders, motor feedback devices and complete measuring systems with a strong reputation for delivering highly robust and reliable solutions across a broad range of industries. As part of a comprehensive product range, the German manufacturer combines its industrial grade incremental and absolute encoders with application-specific components as complete digital shaft copying systems for position feedback on elevators and lifts in medium height buildings and structures.

To address the flexibility required for the widest range of lift and elevator applications, Silent Move is available in circumferential and guided formats in a standard range with a nubbed belt and as an extremely quiet “Light” range with a toothed belt. A “Compact” range with a guided toothed belt design provides a solution for particularly tight installation. All these variants are available with optional Wachendorff WDGI 58B incremental encoders with 5000 ppr TTL or HTL quadrature A and B channels, or WDGA 58B absolute encoders offering a wide choice of industry standard protocols. 

Custom tailored variants and redundant encoder versions also available on request. A fourth design variant, the WDGMS, is limited to a lower speed and shorter measurement heights and is based on a round cable rather than a toothed belt (limited to 1 m/s and 53 metres length). This variant includes a WDG 40S incremental encoder.

Silent Move lift monitoring systems are certified by TÜV Germany and like all Wachendorff measurement devices are covered by a 5-year warranty. Designed for compactness and simplicity in operation they offer optimised noise reduction with long working life. Encoders and all components are resistant to typical lift shaft contamination and are essentially maintenance free. A wide choice of electrical output and mechanical configuration options allows lift designers and manufacturers an optimised lift motion profile and gentle acceleration/deceleration performance for maximum user comfort. Installation is fast and straightforward for new or retrofitted systems.

Comprehensive information on the complete Silent Move lift measuring systems range is available on the Variohm EuroSensor website. Variohm EuroSensor supplies and supports the full range of incremental and absolute encoders, and specialist measurement systems from Wachendorff.

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Multi-turn absolute encoders.

Wachendorff’s WDGA series multi-turn absolute encoders are well-proven for their highly precise performance, robustness, and long working life for precision measurement and motion control applications across a broad range of industries. With a single turn resolution of up to 16-bits and a multiturn capability to 43 bits, their EnDra® magnetic encoding technology offers an impressive angular measurement accuracy of +/- 0.09°, coupled with a feedback cycle time up to 50 µsec that suits high performance servo drives. 

The microprocessor-based Hall-effect scanning principle provides a compelling and cost-effective alternative to more fragile linear and rotary optical encoders. Available with full support from Wachendorff’s exclusive British distribution partner, Variohm EuroSensor, the WDGA series’ extensive choice of housing styles, shaft dimensions, safety, and protection levels offers maximum application-matching flexibility, which is further complemented with the wide choice of communication interfacing options including CANopen, CAN SAE J1838, SSI and RS485, PROFINET, PROFIBUS, EtherCAT and a Universal-IP version.

The WDGA series magnetic and non-contacting Endra design offers many significant performance benefits. Unlike competitive multi-turn absolute encoders, the technology does not require a wear-prone gearbox and has a very low current consumption from a regular 10 … 32V DC power supply without the need for batteries. These benefits help contribute to much-reduced axial length dimensions, even when considering an amply designed bearing arrangement that allows significantly high axial and radial shaft loads - ensuring maximum compactness whilst maintaining excellent durability for demanding heavy-duty measurement tasks.

As standard, housings and shafts are IP65 sealed with IP67 and IP68 options through the WDGA series whilst a choice of synchro flange, clamping flange, or blind hollow shaft mounting is available in housing diameters of 36 and 58 mm. The variously available communication options include data output for position, speed and acceleration, encoder cam, plus scaling capability and comprehensive diagnostics - all backed up with commissioning and interfacing software.

With virtually no maintenance required, the WDGA series has an extremely long working lifetime. The confidence Wachendorff has in its product reliability extends to a five-year warranty. Application areas for Wachendorff’s WDGA series absolute, and other encoder product lines and measurement systems include, but are not restricted to, construction and agricultural machinery, wind energy, crane & hoist, AGVs, machine tool, food and beverage, packaging and many more.

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Length measuring systems expanded.

The new Wachendorff Automation LMSCA system is extremely compact and yet extremely robust. The system is just 120 mm long and requires very little installation space! It can be combined with measuring wheels of 200 mm circumference.

With the pre-assembled encoders of the WDGP series, resolutions of 80 pulses per millimeter or 0.0125 mm per pulse are achievable. This proven magnetic sensor technology is now available with ANY pulse count from 1 to 16,384 pulses per rotation.

The inverted signals, TTL and HTL output are also selectable when ordering.

Other important features of the measuring system include adjustable contact pressure from 0 to 20 Newton in 5 Newton increments, as well as a loss-proof central screw.

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Redundant encoders provide cost-effective safety.

Wachendorff has recently launched redundant versions of its well proven WDGR and WDGE series incremental and absolute encoders. Available from Variohm EuroSensor, (Wachendorff’s exclusive
distributor in Britain), the new series combine disparate optical and magnetic measurement principles that are independently correlated yet fully synchronised through separate processing electronics.

Providing true redundancy and utilising as few similar components as possible, Wachendorff see the new products as a compelling and cost effective alternative to expensive Performance Level d or SIL 3 based safety systems - with the two tried and tested measurement principles extensively used across thousands of industrial speed and position feedback tasks over many years.

Two encoder versions are available: the WDGR combines incremental magnetic and incremental optical encoders whilst the WDGE combines absolute magnetic and incremental optical technologies. Both have 58 mm diameter clamping flange mounting with a choice of shafts from 6 mm to 9.525 mm diameter. The resolution for the WDGR is up to 1024 ppr magnetic and up to 5000 ppr for the optical encoder. For the WDGE series the magnetic absolute encoder has a 16 bit single-turn and a 43 bit multi-turn resolution, whilst the incremental encoder resolution is up to 5000 ppr.

The 58 mm diameter WDG series is especially durable with high interference immunity thanks to a magnetically shielded and chrome plated steel housing. A zinc plated connector cover houses a choice of PG cable glands or M12 x1 connectors for each encoder. The entire housing has an IP67 protection rating with IP65 for the shaft assembly where a stainless steel shaft is supported on a pair of precision ball bearings for up to 220 N radial and 120 N axial load ratings. With a maximum operating speed to 8000 rpm, the nominal bearing life is 1 x 10-9 revs. at full load with 1 x 10-11 revs. for 20% load.

The optical sensor technology used in both versions has a wide choice of industrial standard compatible power supply options which are completely separate for the two encoder types – further reinforcing the novel redundant design. Both encoder models have incremental encoders with output options that include TTL, HTL and 1 Vpp sin/cos. The magnetic encoder in the WDGR model has HTL and HTL-inv output whilst the WDGE’s magnetic encoder output is CANopen with a CiA 301 communication profile. Specific details and application support for the new WDG redundant series encoders and Wachendorff’s entire range of sensor products is available from Variohm EuroSensor.

Following the principle that the different sensor platforms would react with differing sensitivities to disturbances and therefore would not fail simultaneously, these new dual redundant encoders offer high reliability with appropriate control systems where, for example, speed detection or loss of position would be problematical.

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Special pricing for absolute shaft encoders.

A new promotional price offer from Wachendorff covers the leading German industrial encoder and precision automation component manufacturers’ wide range of Industrial Ethernet (IE) based absolute shaft encoders. Available to Irish & British customers of Variohm, the unique patented magnetic technology, WDGA series absolute encoders offer exceptionally high-precision position and velocity measurement with extreme durability and long life in single- or multi-turn versions with up to 16-bit resolution single and 43 bit multi turn. A comprehensive choice of industrial interface options includes PROFINET, PROFIBUS, EtherCAT and a recently introduced Universal-IP versions which feature user-selectable PROFINET-IO and EtherCAT protocols.

Wachendorff’s WDGA series promotional offer for industrial Ethernet versions is available for sample orders received up to the 31st December 2019. As a longstanding distribution partner for Wachendorff, Variohm provide comprehensive support for its entire range and promise special promotional pricing for new applications. Interested system integrators and OEMs should contact Sales at Variohm EuroSensor for further details. Customers should provide project application details and projected quantities.

Wachendorff’s high precision and highly dynamic absolute encoders are considerably less sensitive to vibrations in machines and systems thanks to their unique and patented QuattroMag® and EnDra® technologies for single-turn and multi-turn versions. An angular measurement accuracy of +/- 0.09° and a dynamic range of 50 µsec combines with exceptional levels of robustness to outperform optical absolute encoders.

Variohm EuroSensor also supply and support Wachendorff absolute encoders with alternative interfacing including CANopen, SAE J1939, SSI, and RS485 in addition to its comprehensive incremental encoder range.

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Compact encoders offer syncronisation with PLCs.

As a recent addition to its PROFINET IRT protocol variants, Wachendorff’s WDGA 58F absolute magnetic encoder features a minimum bus cycle time of 125 μs which is eminently suited to tightly synchronised multi-axis motion control on the fastest PLCs. Available in Britain from Variohm EuroSensor, the 58 mm diameter encoder is also reckoned to be the world’s smallest PROFINET encoder with a nominal length of only 46.5 mm.

Wachendorff’s WDGA series absolute encoders, are characterised by their single- plus multi-turn functionality and the unique patented magnetic scanning principle that offers exceptionally high-precision position and velocity measurement with extreme durability and long life - without the use of wear-prone gears or batteries. Backed by a five-year warranty, the WDGA is available with a extensive choice of mounting and interfacing options, including CANopen, SSI, RS485, J1939 and PROFIBUS, to ensure flexibility across a very wide range of machine architectures.

The -58F PROFINET IRT version includes a 16 bit single-turn QuattroMag® technology resolution and EnDra® technology multi-turn capability to 43 bits. This translates to an angular accuracy and repeat accuracy of ± 0.0878° (≤12 bit). Programmable parameters include steps or counts per revolution, presets, scale and count direction as well as MRP (Media Redundancy Protocol) specific values for PROFINET IRT to ensure safe operational use.

The WDGA-58F features a clamping flange mount with a choice of 6, 8 or 10 mm shaft diameters (plus a 3/8” option) and is one of five PROFINET IRT models offering mechanical mounting options including synchro flange, hollow bore and other clamping flange variants.

Across the WDGA range generally, the elevated axial and radial shaft load capacity contributes greatly to their high resilience. The durable encoder, available in 36 and 58 mm nominal diameters, has an aluminium housing with IP67 protection class as standard and shaft sealing to IP65 (IP67 optional). Temperature range is typically from -40 °C to +85 °C. Customised interfacing and specification variations are available on request.

Variohm EuroSensor supplies and fully supports Wachendorff’s complete range of absolute and incremental shaft encoders and measurement components.

Plug fest!

CANopen plug-fest for encoders and inclinometers

Plugfest is great and descriptive name coined by CiA here. Hosted by Systeme Helmholz several CiA members connected their CANopen encoders and inclinometers to CANopen PLCs from Systeme Helmholz and ifm electronic.

After establishing SDO and PDO communication as well as Heartbeat, the linked devices were stressed by means of high busload. Other dynamic tests included high-frequently transmitted Sync messages, to which the sensors responded with PDOs (synchronous operation). Just a few minor problems were detected such as not 100 per cent matching electronic data sheets (EDS).

“It is sometimes quite hard to cause the CANopen sensors to send Emergency messages,” said Holger Zeltwanger, CiA Managing Director, “due to the robustness and reliable CAN low layers.”

The companies ifm, Leine & Linde, Mobil Elektronik, Pepperl + Fuchs, and Wachendorff participated in the plug-fest with sensors. These products are used in factory and machine automation as well as in mobile machines. CiA will schedule another plug-fest for encoders and inclinometers in autumn.

Longer warrenty and higher temp for encoders

Reflecting the total confidence in the quality of its wide range of WDG encoders and systems, German manufacturer Wachendorff Automation GmbH has extended its warranty from 3 to 5 years as well as increase the working temperature range of all WDG encoders to those used for military specifications.

They saw the warranty expansion as a logical extension to the positive feedback and extremely favourable returns statistics from many satisfied users.

WDG products include incremental and absolute encoders, guided belt measuring systems and draw wire type linear measurement encoders. In particular, WDG series encoders cover incremental shaft and hollow shaft encoders from 24mm to 145mm in diameter with standard quadrature resolution up to 25000 pulses per rev. WDG series absolute encoders include single- and multi-turn variants with up to 18-bit resolution and output options of SSI, CANopen and Profibus-DP in both optical and highly robust magnetic designs. A wide and flexible choice of mounting styles include synchro-flange, clamp ring and screw-flange mechanical interfacing.

The decision to increase the standard temperature rating places the rugged and durable standard WDG encoder product line in operating temperatures from -40°C to +80°C with storage up to +100°C.

All Wachendorff WDG encoder products and systems are characterised by high reliability and resistance to vibration with IP68 rated housings available for the toughest of environments. Application areas for the product includes cranes, lifts, road marking machinery, agricultural and construction vehicles.

Wachendorff is represented exclusively in Britain by Variohm EuroSensor, which provides complete sales and technical support across the full range of products with stock delivery available on many standard products and the ability to coordinate special custom encoder requirements with Wachendorff.