Efficiency inside: sensors with integrated Ethernet

Leuze electronic Pty Ltd
By Ingo Baumgardt, Director, Auto ID and Machine Vision Product Center
Thursday, 01 June, 2023


Efficiency inside: sensors with integrated Ethernet

Integrated connectivity means that all relevant industrial Ethernet interfaces are integrated in the sensor, making it possible to access all central device functions.

It sounds simple, but is not standard on the market. Instead, sensor manufacturers frequently offer devices without an industrial Ethernet interface, so that the interface needs to be provided via a gateway. Integrated Ethernet connectivity provides system operators with multiple benefits, ranging from commissioning (device management) to machine monitoring (condition monitoring) to process optimisation.

Leuze offers devices with integrated interfaces for Profinet, EtherNet/IP and EtherCAT. The significant advantage that can already be gained during commissioning is demonstrated using an illustrative system design with and without integrated connectivity. First a system with barcode readers without integrated interfaces: here, every scanner must be connected to a separate gateway, which means an additional gateway with its own power supply for each barcode reader. As a result, the installation effort and the number of cables are double what would otherwise be required. The parameterisation is also significantly more complex. Also, because of the gateways required, there are significantly more devices in the system that can cause a malfunction and need to be checked should this occur. In comparison, the same system with an integrated industrial Ethernet interface means that separate gateways are superfluous. Most importantly, the system layout is significantly clearer and fewer cables are required. Lastly, errors can be eliminated more quickly as fewer devices have to be checked.

Leuze sensors with integrated connectivity also have an additional feature that contributes to particularly efficient commissioning: the devices have a switch as standard, which means they have both an Ethernet input port and output port. As a result, system operators do not need an external switch. It is also much easier to connect several devices, for example in a ring or linear topology. With linear wiring, the system operator connects one sensor to the next using the integrated switches. Only the last sensor in the row is connected to the control system. Again, the benefits are the simplified system design and reduced number of cables. Devices without an integrated switch, however, require an external Ethernet switch. Users must also connect each individual sensor to the switch using a star topology and then connect this to the control system.

Figure 1: The implementation of a linear topology for each integrated switch reduces the cabling requirements, saving time and money.

Figure 1: The implementation of a linear topology for each integrated switch reduces the cabling requirements, saving time and money.

Integrated connectivity also means that users can work in the usual control environment. This is possible because the entire device parameterisation is integrated in the GSDML file (Generic Station Description Markup Language) of Profinet, for example. In contrast, many other Ethernet-based devices generally have to be parameterised via a web server. This is complex, as every manufacturer supplies their own web server version with its own user interface. Users have to familiarise themselves with new interfaces every time and find the corresponding functions. For devices without Ethernet that are connected via a gateway there is frequently the need for product-specific manufacturer's software for parameterisation. This in turn can cause problems regarding compatibility with the hardware used if the sensor manufacturer no longer updates the software after several years.

The advantages are:

  • Users stay in their usual control environment
  • Installation of manufacturer’s software and associated familiarisation are not necessary
  • Access to a web server is not required
     

Leuze devices with integrated connectivity are very easy to parameterise. The GSDML file only has to be downloaded from the Leuze website and copied once into the company’s own engineering software. The modules are then available in the hardware catalog. A meaningful description of the device functions is also included, making it very easy to parameterise and use, and a sensor and manual is not required in most cases.

Figure 2: The barcode readers from Leuze (here the BCL 300i) are equipped with integrated connectivity.

Figure 2: The barcode readers from Leuze (here the BCL 300i) are equipped with integrated connectivity.

A look at the device profile of sensors with integrated connectivity illustrates additional ways in which programming is made easier. For example, for the AMS and BPS positioning sensors, Leuze not only supplies positioning values, but also a calculated speed value. Users requiring this system save time as they do not have to carry out their own calculations. Without integrated connectivity, the control must be used to filter for specific barcodes. In the case of the Leuze BCL barcode readers, it is possible to prefilter according to specific criteria. Only codes which correspond to the required pattern are transferred.

The option to duplicate Profinet devices in the engineering tool is also a time-saver. Users only have to specify the parameters once and can then copy the settings as needed. Integrated connectivity even helps when a device is exchanged: if a damaged sensor has to be replaced, the system automatically transfers all the parameters stored in the control system to the new device and the sensor is ready for use straight away.

Integrated connectivity not only provides support during commissioning, but also with condition monitoring. For efficient operation, system operators need to answer questions such as whether the system is running without errors when scheduled maintenance is needed.

The answers are provided by the integrated interface: via industrial Ethernet communication, it not only transmits the actual process values, but also diagnostic data as well. As a result, all identifying data can be read out via a barcode reader to manage the device. This includes the serial number or the software/hardware version of the sensor. Moreover, there are quite a number of diagnostic parameters, such as the number of OK and NOK readings. In particular, the system provides a quality marker for each individual code reading in a plant with barcode readers, providing information on the quality of the readings. The value is generally between 90% and 95% and can be monitored to detect deviations during operation, for example caused by contamination or mechanical damage.

Remote monitoring can also be implemented as an additional communication channel via OPC UA. The control system can be used for this purpose, but Leuze sensors provide an easier solution by accessing them directly via OPC UA. As a result, system operators can monitor their devices in parallel to the ongoing process. This gives them real-time information on the performance of the system. If required, this data can also be transferred to a cloud service.

How can processes be optimised based on the collected data? This is demonstrated by two practical examples using barcode readers.

  1. The scanning window of the sensor can become contaminated. In some systems this does not happen for years, in others it occurs more quickly. Data evaluation via OPC UA can be used to quickly determine which sensor is contaminated. Using the data, a software program records the read quality of each individual decoding process. For barcode readers with impaired reading performance, it indicates that maintenance is required.
  2. The label itself can also cause problems, for example if the code is damaged or not completely printed. In this case, it is not enough to monitor an individual sensor to determine the error. Instead, the faulty label has to be traced along different measuring stations to identify it. This makes it possible to detect similar evaluations and use the identification number to determine the label involved.

Top image caption: Integrated connectivity offers advantages during commissioning and processes can be optimised, making it possible to achieve optimum system operation.

Related Sponsored Contents

Pacific Automation announces Microsonic partnership

Pacific Automation has announced its latest partnership with Microsonic, a pioneer in specialised...

Standardised, easy-to-use, efficient application software for robot control

The MOVIKIT Robotics software module enables easy universal control of a wide range of serial and...

Industry 4.0 technologies as enablers in the fluid power industry

Industry 4.0 technologies enhance and advance condition monitoring using historical machine data...


  • All content Copyright © 2024 Westwick-Farrow Pty Ltd