Sensors form the beating heart of many plant operations. Whether deployed on equipment for continuous monitoring or distributed throughout a site to conduct safety-related tasks such as gas detection, sensors are everywhere in the modern engineering environment.
As their numbers have grown, so too have the networking solutions and means of managing the large amounts of valuable data they generate.
Advances on the software and management side continue apace – current trends include the rise in popularity of closed-loop control systems, often enabled by coupling AI tools with distributed sensor networks. A sensor-based, closed-loop system can deliver considerable advantages in terms of process optimisation, energy efficiency and predictive maintenance.
But to achieve those efficiencies on the back-end side requires strong solutions on the hardware side – meaning the sensors themselves. And there is no doubt that suppliers in this field are stepping up to the task of delivering advanced, rugged products that are more easily integrated into control architectures than ever before.
Here, we take a look at recent product launches that illustrate just how much innovation can now be found within these smart sensor solutions.
SAFETY FIRST
One ongoing challenge for engineering applications is the need to work in spaces that are tight or difficult to access. Sensors experts are responding by offering products smaller and more compact that ever before. One new launch here is the ultra-compact RSL 200 safety laser scanner from Leuze, which the firm claims is the smallest one on
the market.
The new safety laser scanner safeguards machines, automated guided vehicles and robots. And thanks to its minimal dimensions, it is very easy to integrate even where space is limited.
Leuze – a company that goes by the nickname “the sensor people” – says that with this launch, it is “setting new standards in the miniaturisation and integration of safety laser scanners. The exceptionally compact size and innovative connection technology allow unprecedented possibilities for sensor integration.”
With its configurable protective fields, Leuze says the RSL 200 is ideal for area guarding and for applications with protective field switchover. In this way, the safety laser scanner detects anyone entering or staying in a machine or system’s monitored area. Thanks to its large scanning angle, it also safeguards two sides of a machine around a corner with just one device.
The configurable protective fields allow the monitoring area to be conveniently adapted to the machine’s contours. In addition to the compact design, the laser scanner’s rotating M12 connection also helps make integration easier, as this standardised connection allows extremely flexible cable routing. Additionally, it reduces the space required and makes commissioning easier.
The RSL 200’s minimal dimensions also make it a solid choice for automated guided vehicles and autonomous mobile robots. The configurable and switchable protective and warning fields enable flexible protection. They allow the monitored areas to be optimally adapted to curved paths, different speeds and various load conditions.
Omnidirectional vehicles can be safeguarded in all directions with the laser scanner: only two diagonally mounted devices are required, thanks to the 275° scanning angle. 32 switchable sets of protective and warning fields enable its speed and direction of travel to be continuously adjusted.
RELIABILITY REWARDS
A fine example of how sensors can improve operational efficiencies is found in the latest launch from Emerson. The company describes its new Aventics DS1 dew point sensor as “the only industrial sensor to monitor dew point, temperature, humidity levels and quality of compressed air and other non-corrosive gases in real time from one device”.
The DS1 can help operators detect and mitigate excess moisture in its early stages and prevent moisture-related equipment damage. By optimising air quality in this way, operators can better control processes, extend pneumatic component life, ensure regulatory compliance, and reduce maintenance and unplanned downtime.
Pneumatic systems power manufacturing processes across the plant floor in many industries, from pharmaceuticals and food and beverage to semiconductor and automotive. Excess moisture in pneumatic systems can cause multiple issues, including corroded components, product inconsistency and erratic processes.
Although most industrial sensors only monitor humidity, the DS1 provides precise dew point monitoring that makes it possible for manufacturers to continuously track critical values, address excess moisture and prevent its negative effects.
Ideal air quality is also critical in instances where compressed air may come in contact with consumer products such as pharmaceuticals or food. Condensate in compressed air can cause discoloration, texture inconsistency and bacterial growth.
“By having greater certainty about compressed air quality and control over moisture levels in compressed air lines, manufacturers of all kinds can prevent a number of common condensate-related issues and their associated costs,” confirms Manuel Goerbert at Emerson.
“The Aventics DS1 dew point sensor allows operators to detect changes in air quality in real time with a single device, so they can quickly make necessary adjustments to optimise production and increase overall process reliability.”
GO THE DISTANCE
Distance sensors are common in many engineering applications, particularly in the manufacturing sector. One recent launch here comes from German sensors expert, Pepperl+Fuchs, which has announced a range of measuring inductive distance sensors featuring IO-Link interface.
The devices are suitable for Industry 4.0 applications and offer not only high-precision measurement capabilities, but also comprehensive information for condition monitoring and predictive maintenance.
The sensors can detect objects at a speed of up to 3m/sec and deliver precise measurement data with a repeat accuracy of 5%. Their measuring range is up to 30mm. The sensors determine the speed and acceleration of the damping element. Two independent switching windows and defined limit values can be individually parameterised.
Adjustable filters allow the measurement speed and accuracy to be adjusted. The high switching frequency of up to 1,300Hz enables very short throughput times, thereby helping to increase productivity.
Additional data, including temperature and operating times and counters, is transmitted via the IO-Link interface. The monitoring of speed and acceleration and the historical values of these variables allow the detailed analysis of sub-processes such as opening/closing for valves and acceleration/braking for absorbing elements.
Detailing how the new sensors make a positive difference to plants, Pepperl+Fuchs says that this monitoring of the machine status facilitates predictive maintenance and prevents unplanned downtimes.
REMOTE WORKING
Remote monitoring capabilities are an attractive addition to sensor products and Bürkert is taking the lead here by providing more diagnostic data to customers. The company is embedding IO-Link and Bürkert büS industrial protocols into its Element Neutrino conductivity and pH sensors for remote diagnostics.
The digitisation of these products allows maintenance and operations to be streamlined thanks to remote monitoring capabilities, supporting process uptime in water quality or chemical applications.
Traditionally, in-line probes in pipework provide signals to controllers, which are then transmitted to PLCs. However, setting up this system requires significant installation work such as wiring the panel – an expensive task.
Another option is compact transmitters, which can offer multiple outputs: usually a switched output and a milliamp output to be used for the primary value such as pH or temperature.
Some designs will feature an integrated display for ease of use, but this still requires operators to be physically at the device to see alarms, min-max values and other parameters. However, the inclusion of IO-Link and Bürkert büS (the latter based on CANopen) into the sensors provides a more capable solution.
First, operators are no longer limited to a couple of outputs, instead gaining access to a wealth of diagnostic data regarding numerous other factors that affect the performance and condition of the sensors.
Furthermore, this can all be accessed remotely. Real-time data can be made available at the PLC, in SCADA systems, on the cloud or in local storage, depending on the preference of the operator. This allows remote monitoring, unlocking a wide range of possibilities for OEMs, system integrators, contractors and end users.
A key benefit is that remote monitoring capabilities streamline maintenance. Diagnostics can be carried out to discern the condition of equipment and the nature of possible repairs before visiting site, allowing the right spares to be readied before leaving the workshop and avoiding multiple trips. This gives OEMs the opportunity to provide products that actively reduce maintenance requirements and cost.
BOX: INCREASED OUTPUT
UK company Sensor Technology has announced an update to its TorqSense SGR521 transducer. In addition to standard digital outputs such as RS232 and USB, the TorqSense SGR521 now features an optional Ethernet output, providing users with enhanced connectivity and data transfer capabilities. This allows for seamless integration with various systems and facilitates real-time monitoring and analysis.
The SGR series transducer uses non-contact technology, effectively eliminating the common drawbacks associated with slip rings, and employs modern strain gauge signal conditioning techniques to deliver an advanced torque measuring solution.
With a range of capabilities, the SGR521 transducer offers torque measurement ranges from 175mNm to 13,000Nm; high accuracy (±0.1%), ensuring reliable measurements; and an impressive 400% mechanical overload capability.