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Applications

Presence Check of Steel Sheets on Roller Conveyors by Inductive Sensors with Increased Switching Distances
In the steel industry, the presence of steel plates before and after rolling or punching processes must be checked. For this purpose, the sheets are transported on roller conveyors and reliably detected at their outlet by an inductive sensor with increased switching distance. Height fluctuations of the sheet are compensated by the high switching distance. The sensor with integrated error indicator is ideal for harsh industrial environments thanks to its rugged M18 enclosure and IP67 degree of protection and can be mounted in a few simple steps.

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Safety Inspection of Robots by Laser Distance Sensors Time of Flight
The distance between the robot and the rail system must be continuously monitored during automated storage and retrieval as well as transport of storage containers in block storage systems by robots. For this purpose, two laser distance sensors (time of flight) in miniature design are mounted at an angle of approx. 90° between the wheels for left/right and forward/reverse movement. The sensors continuously measure if the distance to the rail system is correct to ensure that the robot is fully and correctly positioned on the guide rail. Related applications can be found here.

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Track & Trace in the Food Industry with RFID Readers
In the food industry, traceability of products must be ensured at every stage of the manufacturing and processing process. RFID transponders are fitted to food trays for moving the food through the production process. The RFID readers fitted between the roller conveyors register the transponders on the passing trays and read and write new data on them. The plastic sheathing protects the RFID chip from possible damage.

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RFID Recognition and Control of Workpiece Carriers
In special machine construction, workpiece carriers run through various processes in one system. RFID readers are installed at several points in the system so that the workpiece carriers are reliably detected and identified at each station. The transponder mounted on the workpiece carrier is recorded and read by the reader and can be written with new process information to trigger subsequent processes. This ensures the traceability of the processing. Thanks to their compact format, the readers can be mounted in tight spaces or harsh environments.

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Zone Protection During Automated Handling of Plastic Parts Thanks to Safety Light Curtains with Hand Protection
When manufacturing trunk liners for the automotive industry, hazardous areas must be secured with fully automated robot cells to protect people and machines. Safety light curtains are mounted vertically and horizontally at the removal points for zone protection so that it is not possible to intervene or even enter the system. The curtains are designed so that reaching in with a hand leads to an immediate machine standstill. Switching signals can be transmitted quickly to higher-level systems thanks to the built-in IO-Link interface. Related applications can be found here.

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Access Control on Palletizing Systems with Safety Light Curtains with Reduced Resolution
In intralogistics centers, empty wooden pallets are loaded fully automatically at palletizing stations. In order to provide workers with safe access to these zones during operation, a distinction must be made between humans and objects. Horizontal safety light curtains with reduced resolution are installed on the side of the conveyor. The pallet feet are not detected during extension and retraction due to the reduced resolution, the system remains in operation. Only when a worker interrupts the defined number of beams by accessing the area is the palletizer switched off.

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Access Protection on a Stacking Device with Safety Light Arrays
The automated loading and unloading of palletizing stations in the wood industry must be completely secured from all sides for the worker safety. For this purpose, safety zones are defined, which are monitored by safety light arrays with long ranges of up to 50 meters. Entire surfaces can even be secured over corners using deflection mirrors. As soon as a worker enters the zone, the system shuts down immediately.

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Hazard Area Protection on Die Presses via Safety Light Curtain
So-called die presses are used in the metal industry to bend sheets, which apply enormous force to the objects. In order to secure this danger zone for workers during the bending process, a safety light curtain is installed on the side. Individual beams can be deactivated and resolution reduced thanks to the integrated muting and blanking function. Chips or thin sheets are thus not detected and do not lead to unwanted downtimes. Hands or fingers, on the other hand, are reliably detected and lead to an immediate machine stop.

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Door Monitoring on Packaging Lines via RFID Safety Switch
Protective doors or service flaps on packaging machines can be opened manually in the event of a process error and associated machine downtimes, thus reducing system downtimes. The machine can only be started at this point once this movable guard is properly closed again. Safety switches with RFID coding ensure that the doors are properly closed. Equipped with a permanent magnet, they prevent unintentional opening of the doors if vibrations occur.

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Monitoring of Machine Doors via Safety Switch with Locking Function
In order to make areas of machines accessible to workers, but to still provide protection against unauthorized access, safety switches with locking function are installed on doors and flaps. As soon as the internal process is complete, the machine is unlocked and the cover can be opened again to change material, for example. The high locking force, the robust IP69 protection and the high degree of safety offered by performance level e make the safety switch ideal for harsh industrial environments.

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Stepping Behind Protection on Assembly Turntables via Safety Light Curtain with Hand Guard
In industrial production processes, the movement of assembly turntables is a hazard. To secure this area for workers, a stepping behind protection is set up by installing several safety light curtains. Interruption of the safety field automatically stops the system. The turning process cannot be started until the entire zone is free again. Areas are secured over several axes via cascading, i.e. interlinking several light curtains. The high resolution (hand protection) enables short safety distances.

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Hazard Area Protection in Window Profile Production with Safety Light Curtains for Hand Protection
When manufacturing window profiles, mobile system parts such as moving carriages must be able to move as much as possible and be secured at the same time. Zone protection is installed via safety light curtains for hand protection. Thanks to the narrow housings, the protective devices can be ideally integrated into tight systems. You can monitor multiple areas dynamically over long distances. If a safety zone is entered, the system stops. Depending on the number and structure of the areas, the system can continue to operate undisturbed in another zone despite the interruption.

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Websites (4)

Websites

wenglor Expands Product Portfolio with Industrial RFID
With the release of the new industrial RFID readers, the wenglor sensoric group has expanded its product portfolio to include RFID systems. The RFID readers enable reliable and quick identification solutions at close range. Thanks to contactless communication between an RFID reader and an RFID transponder, production processes can be controlled, objects traced and inventory information gathered. Parameters can be changed easily and process data can be transmitted efficiently via the integrated IO-Link interface. Industrial RFID readers emit electromagnetic waves that are picked up by a transponder. The signal returned is interpreted by the RFID reader and the information is processed. RFID systems make contactless data transfer and assignment completely reliable – thanks to a high degree of protection and temperature resistance even in challenging process environments. The portfolio also includes a selection of transponders. High Process Reliability Thanks to Robust Design and Variable Functions The robust design of the industrial RFID readers with a high degree of protection up to IP69K and temperature resistance of –25 °C to +80 °C ensures high process reliability even in challenging process environments. The range includes cubic and metric designs for various applications. RFID readers enable secure data transfer by parameterizing RSSI values. The flexible configuration of alarm modes makes individual application solutions possible, while LED displays visible around them provide user-friendly visualization. Wide Range of Applications for Industry 4.0 The RFID portfolio impresses when reading, comparing and writing data for applications in close range with ranges of up to 78 mm. There are many possible uses for identification solutions with RFID technology. An RFID transponder on the workpiece carrier always contains the current status of a component and thus enables intelligent production control. RFID systems are used, for example, in special machine construction, as they enable production-relevant data to be saved for each workpiece on the relevant workpiece carrier, enabling an efficient and workpiece-specific production process. In the food industry, RFID readers capture and collect production data throughout the production process to ensure batch traceability at all times. RFID systems are also used to monitor the internal flow of materials by enabling data collection of current inventories. The Highlights at a Glance: Reading, comparing and writing data for near-field applications with ranges of up to 78 mm High data transfer speed when writing and reading transponders Clear assignment of data for reliable identification solutions Parameterization of the RSSI value for secure data transfer Configuration of alarm modes for high process reliability User-friendly visualization thanks to LED displays visible all round High degree of protection up to IP69K and high temperature resistance of RFID readers for reliable use in the temperature range from –25 °C to +80 °C Simple operation through parametrization via IO-Link

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Small Format, Large Switching Distances: Inductive Sensors Now in Compact D3 and M4 Housing
wenglor’s product family of inductive sensors with increased switching distances features enhanced performance in miniature design: A total of eight new sensors from the I03 and I04 series in the compact D3 and M4 housing are available for detecting metallic objects in confined systems. Practically no larger than a pin head, the robust sensors in V2A stainless steel housing demonstrate their strengths exactly where space is most limited. The I03 series sensors have a diameter of just three millimeters (D3) and a smooth housing, while the I04 series has an external thread with a total diameter of four millimeters (M4). With both series, the housing is just 22 millimeters long. The almost invisible miniature sensors detect precise switching signals in places where virtually no installation space is available. Increased switching distances of up to 1 mm, a robust PUR cable connection (two meters), a high IP67 degree of protection and a broad temperature range between –25 and +70 °C ensure high performance and long service life. “Thanks to flush mounting, the sensors can be integrated mechanically protected in systems”, explains wenglor product manager Maria Boos. “The optional PNP/NPN and NO/NC variants also enable convenient handling with existing systems. Thanks to the LED adjustment aid, the sensors can also be easily installed. The bright LED shows the status clearly, even over long distances. Eight New Products Expand the Entire Portfolio The introduction of the I03 and I04 series expands wenglor’s product portfolio for increased switching distances by eight new sensors (four per design). In total, there are now sensors in nine different formats in this range, with five connection types and in 15 different housing lengths. “With this wide range of products, we can find a suitable solution for every special requirement. Thanks to the new types, solutions are now also available in areas with very little space, where a reliable switching signal is still required”, says Boos. Small Size Allows for a Wide Range of Applications Thanks to their small size and low weight, the inductive sensors with increased switching distances are ideal for the end position detection of gripper systems in the production of wires and cables, for example. In addition, they can also be flush-mounted in robot grippers in the automotive industry for detecting the gripper opening and closing. The small sensors offer great support in the wood industry in pallet nailing machines. The continuous supply of nail pins can be monitored directly in the dispenser unit. The monitoring of drive shafts in chain conveyor systems in the packaging industry is also one of the key advantages of these sensors. The Highlights at a Glance Small D3 and M4 formats (both housing length 22 mm) Switching distances up to 1 mm Robust housing in V2A stainless steel Connection via PUR cable Outstanding IP67 degree of protection Large temperature range –25 to +70 °C High switching frequency of 3,000 Hz PNP/NPN or NO/NC variants available Bright LED Adjustment aid thanks to flashing LED in the unsafe area

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Safety Technology Protects Man & Machine
Safety light curtains and safety light arrays secure hazardous areas and ensure availability of the respective systems.

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Product Highlights Industrial RFID
The new industrial RFID readers offer a quick and reliable identification solution at close range – even in challenging process environments thanks to a high degree of protection and temperature resistance. Thanks to an IO-Link interface, parameters can be changed easily and process data can be transmitted efficiently.

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Downloads (4)

Downloads

Press Release Industrial RFID (567 KB)

Product Flyer Industrial RFID Identification Solutions (1 MB)

This document contains the product flyer for industrial RFID identification solutions.

Press Picture Industrial RFID (907 KB)

Safety Technology Product Flyer (1 MB)

This document provides an overview of wenglor’s safety technology products.

Technical Glossary (54)

Technical Glossary

3-Stage Enabling Switch
3-stage enabling switches (enabling switch), in comparison to 2-stage enabling switches, have the advantage of always ensuring safe shutdown in emergency situations regardless of individual user operation (release or pressing – in the event of a cramp). Mode of operation of a 3-stage enabling switch:

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AC-DC Switch
An AC-DC switch is a sensor which can be operated with either alternating or direct current.

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Active Switching Zone
The active switching zone is a specified area above the sensing face. The inductive sensor reacts to approaching damping materials which enter this zone, and switches its output accordingly.

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B10d Switching Cycles
The B10d switching cycles gives the number of cycles after which up to 10% of the components fail in a dangerous fashion (for pneumatic, hydraulic and electromechanical components). The MTTFd value and thus the PFHD value of a component can be determined with the help of the B10d values.

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Dark Switching
Dark switching, also called normally closed or NC, is a sensor output mode of operation. The output is activated when the receiver is not illuminated by light from the emitter.

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Effective Switching Distance Sr
The effective switching distance Sr respects manufacturing tolerances and is determined at a voltage within the supply voltage area and the surrounding temperature (23 ± 5 °C). It must lie between 90 % (Sr min) and 110 % (Sr max) of the nominal switching distance Sn. Example: Sn = 10 mm -> Sr min= 9 mm, Sr max= 11 mm See also: Switching Distance

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Emergency Stop Switch
An emergency stop switch is an electromechanical switchgear for the safety of persons at or in close proximity to machines. They are used to shutdown/stop machines and systems in order to avoid or minimize approaching or impending danger for persons, as well as damage to the machine or the goods to be processed.

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Enabling Switches
An enabling switch is a manually operated control device which makes it possible to work in the danger zone of automated production systems in manual operating mode, for example for maintenance and programming work. If the enabling switch is pressed, the system’s safety devices are temporarily deactivated and the system runs in maintenance mode. If the enabling switch is released, the safety functions that protect the machine from unauthorized access during normal operation are reactivated. This operating mode must be defined with a lockable selector switch in accordance with EN 60204, Part 1.

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Inductive Sensors With Increased Switching Distances
Inductive sensors with increased switching distances have switching distances (switching distance) which exceed the requirements specified in the standard EN 60947-5-2. The specified nominal switching distance Sn refers to the standard target.

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Inductive Sensors With Standard Switching Distances
Inductive sensors with standard switching distances work with switching distances (switching distance) specified as a minimum requirement in the standard EN 60947-5-2. The specified nominal switching distance Sn refers to the standard target.

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Intrinsic Safety
Intrinsic safety refers to a sensor’s design features that ensure that no unsafe condition is able to occur in the event of damage or fault. This plays a special role in potentially explosive atmospheres and is defined by the ATEX Directive.

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Light Switching
Light switching, also called normally open or NO, is a sensor output mode of operation. The output is activated when the receiver is illuminated by light from the emitter.

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