Press releases Sensor Technology

Kübler extends its safety products repertoire. With its new safety modules for motion monitoring, the Company presents a further building block in the area of functional safety. Mechanical or plant engineering, process, production, warehouse and conveyor technology – the Kübler Safety modules guarantee safety at the highest level. Thanks to the modular construction, every user can select the best suitable solution fur a safe motion in speed and/or position. Regardless of the drive technology, the Safety-M modules offer all functions required for drive monitoring according to EN 61800-5-2. The modules can be extended from the simple overspeed relay up to a complete safety control. In addition, the devices are freely programmable for the safe processing of light barriers, door monitoring, emergency stop/off pushbuttons, two-hand control units, etc.

The Safety-M modules are available in the following versions:
Safety MS1: Speed, 1 axis
Safety MSP1: Speed and Position, 1 axis
Safety MS2: Speed, 2 axes
Safety MSP2: Speed and Position, 2 axes
Furthermore, several bus modules such as CANopen, Profibus, Profinet and EtherCat are available

The modules achieve the functionality of a complete safe drive controller, and even boast a type certificate released by the TÜV. The graphic programming using symbols has a very simple structure and does not require any specific programming knowledge. After programming, the modules can also be parameterised. This feature is very practical, especially when a module is to be used for several machine types. Machine-specific parameters can be modified during the assembly or on the field, without requiring any software adaptation. Validating the software also is a part of a safe control. For this purpose, the Safety-M modules print out a validation report, which must be checked, ticked off and signed. This relieves the software manufacturer automatically, since he met his obligation to exercise adequate due diligence.

The technical features at a glance:

• Comprehensive library for pre-configured safety sensors and safety command devices
• Parameterisable encoder interface for up to 4 x Inc-TTL/SIN-COS/SSI/resolvers on the front side and 2 x HTL via a terminal connection
• Basic device with 14 safe inputs and 3 safe outputs, among which 1 safe relay output and 2safe digital outputs
• Contact multiplication or contact amplification by means of external contactors in connection with the integrated monitoring is possible
• Comprehensive diagnostic functions integrated in the firmware
• Coded status display by means of a 7-segment display and status LED's on the front side
• Quit/Start/Reset button on the front side
• Extensible up to max. 65 safe I/Os with integrated backplane bus (connector for top hat rail mount)
• Optional fieldbus interface (extension module for CANopen, Profibus, Profinet, EtherCat)

The Kübler Group is one of the leaders in the position and motion sensors branch. Eight group members and 50 sales partners reveal our international orientation. Safety has been for years and still is one of the main focuses of the Company. It is thus no wonder that Kübler is considered today as a pioneer in the area of functional safety. Impressive confirmation: two years ago, this sensor specialist launched the first approved SIL encoder on the market.

This was without any doubt a milestone, but the requirements of the European Directives on machines make increasingly obvious that simply combining approved components does not allow reaching the best safety possible. This subject is much too complex. This is why the users are looking more and more for systems – for systems from one single source. Kübler reacted to these needs and offers today, with the combination of encoders and safety modules, an efficient global package for functional safety that never existed so far in this form.

Safety-M module SP1

There are no limits for the applications: safe motion monitoring in single or multi-axes operation, safe processing of light barriers, monitoring of doors and door locks, emergency stop, 2-hand control units – the Kübler system ensures simple, fast and cost-efficient implementation of any technical safety task.
The modules are characterised by their high safety standards and integration capability. They are suitable for applications up to PLe according to EN 13849 or SIL3 according to EN 61508. This safe, type-tested logic control complies with the Directive on machines 2006/42/EC.

Furthermore, the Safety-M modules include all integrated safety functions for drive monitoring according to EN 61800-5-2. Thanks to a modular structure and to the interface for all common fieldbus systems, they can be used universally and adapted precisely to the specific requirements.

Perfect combination, Safety-M modules with Sendix SIL encoders

The Safety-M modules operate ideally when combined with the encoders for Functional Safety SENDIX SIL of the Kübler Company. Three main encoder variants are available: on the one hand, SENDIX SIL incremental with purely sin/cos signals and, on the other hand, SENDIX SIL absolute singleturn/multiturn with additional absolute information SSI. These encoders are approved for use up to SIL3 or PLe. In order to ensure the highest diagnostic coverage possible, the Safety-M modules monitor the sine/cosine signals with the help of the function sin² + cos² = 1. And, for a safe position information, even after having been switched off, the safety module compares the internal position provided by the incremental signals with the absolute value of the encoder.

Simple and versatile in use

Sendix SIL encoder and Safety-M module SP1 form an effective system for Functional Safety.

The integrated functions for digital signal processing such as sensors, command devices and shut-off channels allow a very comfortable solving of typical safety tasks. But the Safety-M modules offer much more: safe motion monitoring with highest requirements are in no way a problem. And the integrated monitoring functions with many additional practice-oriented functions ensure a simple and transparent implementation of any task. The integrated technology functions of the Safety-M modules ensure a fast and easy implementation of the technical safety tasks.
A comprehensive functions library is available for the pre-processing of sensors (inputs) or actuators (outputs), and it can also be used precisely for safe drive monitoring. A simple combination of the input, monitoring and output functions by means of logic blocks allows a very quick and transparent creation of even comprehensive safety functions. All functions have an open design with respect to the used sensors, drives and actuators. Regardless of the drive technology used, electrical drives with vector or frequency controls, pneumatic or hydraulic systems, the Safety-M modules are the practice-oriented solution for safety management in mechanical and plant engineering.

Safe drive monitoring.

Safety functions for sensor/actuator processing offer a significant simplification in programming. So, for example, no more programming work is required for a logical/time comparison of multiple safety sensor inputs. Instead, the required process is selected quickly and safely with the periphery configuration menu. The programme editor displays every input and output element simply as a function block. They are already reduced to a single logic signal.

Conventional safety controls are restricted to logic processing or reduced word processing of data. A safe drive monitoring as legally required by the European Directive on machines is difficult to achieve this way. In contrast, the Kübler Company placed a particular emphasis with its Safety-M modules on offering devices that will be able to meet future requirements. The safety functions for drive monitoring integrated in the firmware allow for a fast and efficient implementation of new tasks. Regardless of the drive technology used, they offer all functions according to EN 61800-5-2 for drive monitoring and, in addition, practice-oriented function extensions. This applies for single or multi-axes drives, simple converters or high-level servo drives, electrical, hydraulic or pneumatic drives. The safety functions integrated in the firmware are easy to use, whatever the application.

Programming, parameterising and validation made easy

The graphic programming using symbols has a very simple structure and does not require any specific programming knowledge. After programming, the modules can also be parameterised.
This feature is very practical, especially when a module is to be used for several machine types. Machine-specific parameters can be modified during the assembly or on the field, without requiring any software adaptation. Validating the software also is a part of a safe control. For this purpose, the Safety-M modules print out a validation report, which must be checked, ticked off and signed. This relieves the software manufacturer automatically, since he met his obligation to exercise adequate due diligence.

One of many possibilities: Safe motion control with two axes.

Connection possibilities of the Safety-M modules.

Safety plays an absolutely crucial role in the automation branch. Kübler has taken this fact into consideration and continuously develops its products further in this direction. The result obviously have been worth our efforts: our company can now present a combination that has not existed so far. Functional safety and the ATEX approval are combined in one single encoder for the first time. More safety would not be possible!

In potentially explosive atmospheres such as the chemical industry or oil extraction, encoders must comply with special safety regulations, since the smallest spark may have here very serious consequences. Kübler offers now, especially for this kind of applications, new Sendix absolute and multiturn encoders with ATEX approval. The singleturn and multiturn ATEX encoders with "flameproof enclosures" are approved for zones 1, 2, 21 and 22. They can also be used in maritime applications, since the housing and the flange are made of seawater-resistant aluminium.

The shock and vibration-resistant ATEX encoders operate flexibly with a resolution of up to 17 bits (singleturn) and 29 bits (multiturn). With a protection level of IP67 and a wide temperature range of -40°C up to +60°C, the ATEX encoders remain tight even in the harshest conditions and offer a very high safety against breakdowns in the field. The compact design, with its installation depth of only 145 mm, diameter of 70 mm and space-saving cable outlet, rounds off the flexible, diverse application possibilities in areas with explosion hazards.

Sendix SSI/BiSS absolute encoders with additional incremental Sin/Cos output and Sendix incremental encoders in Sin/Cos version are now available with SIL3 / PLe certification. The controller uses the data of the Sendix SIL absolute encoders to obtain safe absolute position information by counting the incremental pulses and comparing the result with the absolute position, which has also been provided by the same encoder. In the incremental Sendix SIL encoders, the controller monitors the validity of the analogue, 90° phase-shifted sine/cosine signals with the help of the function sin²+cos² = 1.

But safety is nor reached only with safe signals, it also requires a safe mechanical connection. The SIL encoders ensure this safety with oversized fixing elements, which guarantee a perfect reliability.

Beyond Functional Safety, the Kübler Sendix SIL encoders offer additional protection thanks to their exceptional robustness, with extra strong bearings in the Safety Lock™ Design and a very high degree of accuracy and a long service life. With their high IP67 level of protection and their magnetic insensitivity thanks to optical scanning, the Sendix SIL encoders offer "All-round Safety".

And, with regard to the requirements of the Machinery Directive 2006/42/EC, Kübler provides now the MTTFd values for its most important standard encoders. This thus enables the user to carry out his own calculations according to DIN EN 61800-5-2 and DIN EN ISO 13849.

The implementation of the BISS-C interface for the Sendix absolute encoders allows Kübler to reach a new level in data transfer. The open BISS-C (bidirectional/serial/synchronous) interface is based on a protocol for achieving a real-time interface for a purely digital, serial and secured communication between a controller and sensors and/or actuators. The BiSS protocol has been designed for industrial applications requiring high transmission speeds, safety (CRC), flexibility and minimised installation work.

The advantages are enormous and apply to all branches, such as technology, quality, costs or logistics. The BISS-C interface is a real-time solution for position and speed that is typically 100 times faster than standard field bus systems. In addition, a preset value can be preset for the encoder via Software (PLC) or via a set button. The interface is fully digital, thus requiring fewer conductors for wiring, and shielding is easier. The bidirectional interface allows an automatic start-up. Being an Open Source Interface, everybody can use the technical advantages of BiSS-C without restriction. About the costs: BiSS-C can be implemented without hardware modifications in usual standard controls.

Another point plays a decisive role among all these advantages: service. Kübler can help you also in this respect, since his own experts will put their know-how at your disposal for the implementation.

Kübler developed an innovative solution for mounting the absolute singleturn encoders on gearless drives (direct drives). Its great advantage with respect to the mounting versions used until now lies in its easy and fast mounting, thanks to an innovative torque stop. A Set button allowing a fast start-up and the open absolute BiSS interface – including an incremental SinCos track – are further highlights of these encoders.

This solution offers the manufacturers of gearless lifts new possibilities for reducing notably the assembly work, as well in production as in operation. The installation is easy, since the encoder is equipped with a tapered shaft ensuring a high-accuracy and direct coupling to the direct drive. The tapered shaft is fastened on the drive shaft by a central screw.
More technical specifics are

• Singleturn resolution up to max. 17 bits with BiSS or SSI interface
• Optional zero point setting button for easy start-up
• SinCos incremental track with 2048 pulses/revolution
• Quick assembly thanks to the innovative torque stop
• Tangential cable outlet for optimal connection

Lift systems have to achieve a fine balance between many differing demands: key amongst these are reliability and a very high level of safety, not forgetting at the same time a long service life, highest profitability and tranquil smooth-running. LM 3 and LM 5 are the names of new - ready-made, pre-assembled - Kübler complete systems for shaft-copying, which make a significant contribution to increased safety and reliability in lift technology, thanks to their innovative bearing design. And which also ensure considerably more "peace and quiet in the shaft" - thanks to an innovative vibration-resistant encoder mounting fixture and a smooth-running toothed belt. They thus offer quiet, smooth-running handling characteristics, which do justice to the lift's claim to be the calling card of the building.

At the heart of the sensor technology: encoders
A lift that has a long service life and requires low maintenance can only be achieved by paying detailed attention to quality. This applies especially to the heart of its sensor technology: the encoders. These control the rotational speed and drive position, offer accurate shaft copying and monitor the speed limiters. Sendix encoders from Kübler offer an appropriate, tailor-made technology for this key function - with proven, extremely rugged quality. Listed among their most important features are the long service life of the devices - due to their high resistance to shock and vibration, their high protection level of up to IP67 and their wide temperature range from -30°C up to +85°C. Thanks to sturdy bearings, short-circuit proof outputs and reverse polarity protection, they are not susceptible to damage during installation.

Double protection via separation of bearing load and sensor technology
The mechanical loading experienced by the encoder within the lift mechanics is quite considerable. And here the prefabricated LM lift systems prove their worth: separating the load and the sensor technology protects the encoder with the aid of additional bearings outside the encoder, thus almost completely relieving the load on the encoder bearings. In this way the innovative design of the LM lift mechanics makes an important contribution to the long life of the whole lift construction. Furthermore, belt pulleys with duplex bearings, smooth-running toothed belts and a vibration-resistant encoder mounting fixture guarantee very quiet, smooth operation of the system. The belt pulley benefits from its own separate bearings within the mounting fixture, which ensures that the mounted encoder is protected from mechanical overloading.

Knowing, when servicing is required: trip counters and hour meters for lifts
Along with its sensor technology Kübler offers an extensive choice of trip counters and hour meters, the combination of which allows for the precise and highly reliable definition of service intervals. There are versions for DIN rails, for use in control systems that have been installed in classic control cabinets. A tip for users: anyone using a counter with a 100% duty cycle can save themselves the generation of pulses or alternatively the time-consuming integration of pulses.

Tamper-proof, compact, economical
Kübler offers compact electromechanical counters that come with a very high level of tamper-proof security, as well as economical LCD counters - also with 230 VAC inputs for direct connection. The electromechanical devices are not only tamper-proof, but also highly noise-immune and have the crucial advantage that the display can still be read even after a fire. This can be of great importance from an insurance aspect. Electronic counters need very little current and generate very little heat, which is particularly relevant when under continuous load with a 100% duty cycle or with overcurrent. An additional advantage of Kübler electronic counters is the wide range power supply of the devices, allowing problem-free use in all countries. The counters do not thus need to be adapted to the conditions of individual countries in line with customers' wishes, avoiding troublesome modifications. In addition counters with control outputs are available, for example to trigger a separate service message.

Experience counts
Without the established presence of Kübler, it would have been difficult to picture the sensor and counter markets - including the lift market. Fast, personal all-round service, as well as customer projects and local sales and marketing are integral parts of the company's philosophy.

The Sendix encoders with CANopen lift interface are available in singleturn and multiturn versions, with removable bus terminal cover for optimal integration in complex CAN networks or with fixed connections - also directly with a SUB-O connector - for the easiest connection possible to the contral.

The CANopen Lift interface (Profile OS 417 Vl.1) allows a particularly simple implementation of the lift control with suitable special functions such as:

• Car Position Unit
• 2 virtual devices: for the position in absolute measuring steps and the position as absolute displacement information in mm
• Lift number programmable
• Independent setting of the node address in conjunction with the CAN identifiers
• Factor for speed calculation (e.g. measuring wheel circumference)
• Integration time for speed value from 1...32
• 2 working areas with 2 upper and lower limits and the corresponding output states Extended error management for position sensing with integrated temperature control
• PDO Mapping of variables in the memory, whether position, speed, acceleration or working area ~the user decides, which information is available in real-time.

Two devices in one:
Multiturn encoder with additional incremental track. The Sendix absolute CANopen field bus encoders are also available with an additional TTL incremental track. This allows achieving simultaneously, with one single encoder, positioning via the CAN network and a direct rotary speed feedback via the incremental track. This saves costs find installation space for a second encoder.
The encoder delivers, in parallel with the CANopen output, an additional TTL compatible signal with 204B pulses per revolution.
For that purpose, the encoder is equipped, in addition to the CANopen output, with a RS 422 interface with the signals A, AI, B, BI.

When choosing the right encoder for functional safety, "togetherness" is the secret, since safety is achieved via the intelligent combination of encoder, controller and actuator. Sendix SSI/BiSS absolute encoders with additional Sin/Cos output and Sendix incremental encoders in Sin/Cos version are now available with SIL3 / PLe certification, which means that they play a key role amongst the components of a safe plant.

The Sendix SIL absolute encoders obtain safe information about the absolute position; here the controller counts the incremental pulses and compares the result with the absolute position, which has also been provided by the same encoder. However in contrast, in the case of the Sendix SIL incremental encoders, the controller monitors the validity of the analogue, 90° phase-shifted sine/cosine signals with the help of the function sin²+cos² = 1.

In addition, Sendix SIL-certified incremental and absolute encoders ensure a safe mechanical connection in the application. Here suitably dimensioned sturdy fixing elements guarantee 100% reliability.

Yet, for Kübler Sendix SIL encoders, safety goes much further. They feature a rugged, reliable interface and an ability to withstand high mechanical as well as electrical loads, thanks to extra strong bearings in the Safety Lock™ Design. The result is a very high degree of accuracy and a long service life. With their high IP67 level of protection and their magnetic insensitivity - thanks to optical scanning - the Sendix SIL encoders offer "All-round Safety". With regard to the requirements of the Machinery Directive 2006/42/EC the MTTFd values for the most important standard encoders from Kübler are also provided.
This thus enables the user to carry out his own calculations according to DIN EN 61800-5-2 and DIN EN ISO 13849.

Industrial Ethernet is becoming evermore widespread as a communications standard. Surveys confirm that in many sectors of industry half of the machines are already equipped with Ethernet. This share will continue to grow and Ethernet TCP/IP as well as the real-time variants will be used. Those who have integrated the latter in their machines will increasingly fall back on the PROFINET profile. EtherCAT is also frequently employed, although experts think that PROFINET will continue to expand on its leading position.

Products from Kübler come equipped for both these interfaces. The multilayered rugged Sendix Absolute family has just been rounded off with new singleturn and multiturn encoders designed for PROFINET. The whole encoder profile according to "Profile Encoder Version 4.1" as well as the "Identification & Maintenance Functionality in Version 1.16" (IM 0, 1, 2, 3 and 4) have been implemented in these devices. The encoders support the isochronous real-time mode, also called IRT mode, and are thus ideal for real-time applications. Through the decoupling of the real-time communication from the standard communication (TCP/IP), the IRT mode also offers a real-time solution for all high-performance applications such as synchronous applications.

The short cycle time of <= 1ms facilitates flexible and versatile use. With the help of the "Ezturn for Profinet" software supplied as standard, the device is really easy to use due to simple plug and play startup. It also allows the encoder software to be updated quickly and easily. The possibility of simply enhancing the features of the encoder with firmware updates without dismantling the encoder also needs to be emphasized. Scaling and preset values and many other additional parameters can be programmed via the Profinet bus. The visualized monitoring of the most important parameters is also included in the Ezturn software list of specifications.

Position, speed, temperature values and other statuses of the encoder can be transmitted as output values.
All parameters can be programmed via the bus for prompt and error-free start-up. The bus cover is equipped with 3 x M12 plugs for prompt, uncomplicated and error-free connection. With singleturn devices, the resolution is up to 16 bit and with multiturn devices up to 28-bit overall resolution.

The "Safety-Lock™" bearing structure enables the Sendix Profinet singleturn and multiturn encoders to guarantee maximum safety. The locked, larger bearing with large spacing ensures stability during vibrations and gives the device a robustness that even withstands installation errors. Machine downtimes and repairs are thus avoided. Thanks to the highly integrative Opto-ASIC technology from Kübler, the electronics and optical sensor technology are reduced to a few components in favor of higher reliability. The stable pressurecast housing with a protection class up to IP67 and the broad temperature range of -40°C to +80°C also facilitates use outdoors.

Visual warning and alarm signals indicate sensor errors, too low a voltage or too high a temperature. Troubleshooting thus becomes substantially easier; the necessary measures for correction can be implemented without delay and lengthy downtimes avoided.

Kübler offers efficient and high-quality draw wire systems for demanding applications from 0.25m up to 40m measuring length for linear measuring technology.

The core of a draw wire device is a drum mounted on bearings, onto which a wire is wound. Winding takes place via a dynamic spring mechanism using a constant force spring, which allows for a high traverse speed of up to 10m/s and high acceleration of up to 140 m/s2; this proves ideal for dynamic applications and offers a longest service life.

The construction is particularly robust and unaffected by environmental influences thanks to its titanium-anodised aluminium housing. The wire is made from stainless-steel and is thus exceptionally hard-wearing. The wire exit is free from wear thanks to a diamond-polished ceramic guide.

The wide temperature range from -20°C to +85°C as well as the optional IP67 protection rating permit use in difficult environmental conditions. The draw wire system is suitable for various sensors and encoders with analog outputs (0 to 10V, 4 to 20mA, potentiometer), incremental (push-pull, RS422), absolute (SSI, BISS) and Field bus (CANopen, Profibus, DeviceNet, EtherCat) interfaces. The systems have a linearity of up to 0.05% and can be supplied on request together with the relevant calibration certificate.

Mounting is effected quickly using just 2 screws. The versatile housing technology allows for various mounting options. Connection is via either cable or connector.

Kübler is setting new standards with the incremental encoders. These versatile devices deliver high performance and offer the customer a wide spectrum of use as per the slogan "more compact, more varied and more sophisticated". The user can address a wide variety of applications using just one type of encoder thus avoiding the extra costs associated with special versions.

The encoders from the new SENDIX 5000 series are just 50mm in diameter and benefit from a compact design that means only limited mounting clearance is necessary. At the same the profile of the flange matches 58mm devices in a ratio of 1:1. The modular construction means the user can select just the right version for his particular application. Production costs are thus reduced whilst performance is increased.

This versatile modular system used in Kübler's 5000 series offers the user even more benefits: plant and machine manufacturers now only require one incremental encoder range to meet a whole host of application requirements. The new shaft and hollow shaft encoders can be modified in so many different ways that they can take care of almost every conceivable application. There is no longer any need for expensive custom versions. So, for example, the through hollow shaft version is designed for diameters of up to 15.87mm and not just for 12 or 14mm. Moreover these new devices are available also in US standard sizes and with all the interfaces commonly used in the US market. Neither is any requirement left unsatisfied when it comes to connection technology - the choice on offer includes competitively-priced M12 connectors, cables tailored to suit, M23 connectors and even MIL standard connectors. In addition the user has a wide choice of options for fixing and mounting.

Kübler's 20 years of experience can be clearly seen in these new SENDIX 5000 series devices. The extensive temperature range, from -40°C up to +85°C, addresses a wide range of applications where very low or fluctuating temperatures are to be found, as for example in vehicles. Increased shock and vibration resistance values (2500m/s2, 6 ms and 100 m/s2,10...2000 Hz) as well as a radial load capacity of 80N - atypically high for this size of encoder - ensure safe operation and a long service life. Even the through hollow shaft version with up to 15.87mm diameter is equipped with extremely sturdy bearings. Here many traditional encoders have had to make do with thin bearings, which demonstrate a much reduced product life. The high IP67 protection rating refers not just to the housing but to the whole encoder, so ensuring that the devices have the best defence against ingress of dirt ,dust particles and liquids. Thanks to highly integrative opto-ASIC technology the electronics and optical sensing are reduced to just a few components, thus providing high immunity to EMC interference. A fast electronic pulse frequency of 300 kHz means dynamic applications are not a problem. Resolution is up to 3600 pulses per revolution.

OptoASICs offer a number of advantages: They are fast, very reliable and feature a high level of integration. Kübler has availed itself of the latest OptoASIC technologies as the basis of its most recent, patented generation of fast and, above all, non-contact, wear-free absolute encoders: the new singleturn and multiturn Sendix F36 impress with their optical patented Intelligent Scan Technology™, which makes highly-accurate determination of position possible - with feedback in real-time - as is required for example in medical equipment, where space is limited.

All the single and multiturn functions of the encoder - which has already won a number of awards for its innovative technology - were first of all combined on to an OptoASIC. Here with the multiturn version the optical sensor technology achieves a very high resolution of up to 41 bits. The same applies to other values, where the technology also outperforms traditional contact measuring methods. The Sendix F36 encoders are characterised by their extreme ruggedness and resilience, a result of the greatly reduced number of component parts and the large, sturdy Safety Lock™ bearings. This is the case even in harsh industrial environments. Moreover, the new patented Intelligent Scan™ technique ensures 100 % insensitivity to magnetic fields, as is called for in applications such as motor brakes. When it comes to its compact size, the Sendix F36 is unrivalled: hollow shafts of up to 10 mm are possible with a flange diameter of only 36 mm. The icing on the cake is provided by the compact dimensions of the tangential cable outlet, for even where installation room is severely limited, the cable connection does not get in the way.

When it comes to flexibility, the Sendix F36 encoders offer an additional advantage with their wide choice of interfaces: together with SSI and BiSS, they are now also available with the CANopen interface, conforming to the encoder profile DS-406/3.1 to CiA Standard DS-301/4.02. The bus parameters are set and monitored by means of the programmed reference values. The read-out values, including position, speed, sensor raw data with CRC (according to the Safety Protocol DS 304) as well as the status of the working area, can be flexibly combined as PDOs using PDO mapping.

The excellent product characteristics of this encoder with no gears are rounded off by the additional incremental outputs SinCos or RS422. They provide the system with high-resolution feedback in real-time and enhance the performance of this compact encoder to that of "two devices in one".

When choosing the right encoder for functional safety, "togetherness" is the secret, since safety is achieved via the intelligent combination of encoder, controller and actuator. Sendix SSI/BiSS absolute encoders with additional Sin/Cos output and Sendix incremental encoders in Sin/Cos version are now available with SIL3 / PLe certification, which means that they play a key role amongst the components of a safe plant.

The Sendix SIL absolute encoders obtain safe information about the absolute position; here the controller counts the incremental pulses and compares the result with the absolute position, which has also been provided by the same encoder. However in contrast, in the case of the Sendix SIL incremental encoders, the controller monitors the validity of the analogue, 90° phase-shifted sine/cosine signals with the help of the function sin²+cos² = 1.

In addition, Sendix SIL-certified incremental and absolute encoders ensure a safe mechanical connection in the application. Here suitably dimensioned sturdy fixing elements guarantee 100% reliability.

Yet, for Kübler Sendix SIL encoders, safety goes much further. They feature a rugged, reliable interface and an ability to withstand high mechanical as well as electrical loads, thanks to extra strong bearings in the Safety Lock™ Design. The result is a very high degree of accuracy and a long service life. With their high IP67 level of protection and their magnetic insensitivity - thanks to optical scanning - the Sendix SIL encoders offer "All-round Safety". With regard to the requirements of the Machinery Directive 2006/42/EC the MTTFd values for the most important standard encoders from Kübler are also provided.
This thus enables the user to carry out his own calculations according to DIN EN 61800-5-2 and DIN EN ISO 13849.

The Sendix Heavy Duty H100 is an extremely rugged family of incremental encoders, available in 3 different versions - as encoders with or without speed switch or as dual encoders. The special HD-Safety-Lock™ construction ensures that extremely high bearing load capacities of up to 300N axial and 400N radial can be achieved.

The typical temporary encoder overloads, caused for exam-ple by axial overload during installation or as a result of high vibration levels, can be tolerated to a large extent. This helps prevent premature damage to the encoder, as well as avoiding failure of the encoder in the field. It is thus ideally suited for heavy industrial usage, such as in steel works or in cranes. Even the harshest working conditions cannot harm the device, as these are exactly what it was designed to cope with. The wide bearing clearance as well as the extra large robust flange bearings increase the load capacity and extend the service life. The floating bearing on the cover-side, in turn, eliminates internal stress. The revolving scan-ning unit ensures constant signal quality with extended tem-peratures; here the sensor unit is mechanically decoupled from the housing.

Not only do the extremely wide temperature range from -40°C up to +100°C, the IP66 protection level and the sea-water-resistant materials all guarantee that the encoder is resistant to harsh environmental conditions, but additional security is provided by the dual seals on the shaft side - a friction seal against humidity and an additional labyrinth seal against dust ingress and to protect the friction seal from wa-ter jets. And finally the feather key shaft slot ensures perfect positive fitting to the application.

However it is not just in the matter of its power of resilience that the Sendix Heavy-Duty encoder H100 more than meets the highest demands made of it, when it comes to functional-ity it also leaves nothing to be desired. The innovative plug-in spring terminal connectors in the terminal box enable simple and fast connection of the cable. This plug-in ability means that mounting of the encoder and electrical installation can be carried out separately.

Not only is installation in the field thus greatly simplified, but also, in turn, so is any replacement of the encoder during servicing. No tools are needed when connecting the cable to the spring terminal. Various simple connection options pre-sent themselves, thanks to the terminal box being pivotable through 180°. This offers a big advantage especially where space is tight, preventing any kinks in the cable. And last but not least, the H100 boasts a wide variety of available resolu-tions and switching speeds.

From the outside it may appear just a pipsqueak, but despite its small 24mm appearance this miniature magnetic incremental singleturn encoder proves to be extremely robust - its non-contact magnetic scanning technology sees to this. Although it does not quite attain the accuracy of optical models, the 24 series excels with a very high repeatability of <= 0.4°.

Naturally, in light of its handy format, it is ideally suited to installations where space is very tight. And furthermore in its small housing many application possibilities lie hidden. The incremental versions of the mini-encoder, with their 5V DC power supply, offer an RS422 interface. The great advantage here lies in the infinitely variable resolution, as all pulse rates per revolution from 1 up to 128, as well as 256, can be (factory) programmed. These encoders are available in both shaft and blind hollow shaft versions.

The singleturn version of the encoder series 2450 / 2470 boasts a new SSI interface, available with the 5V DC power supply variant. Worth noting here is the 12 bit resolution with 4096 different positions for 360°. An extraordinary ability for an encoder of this size. Once again, both shaft and blind hollow shaft versions are available.

It is the largest encoder in the Kübler portfolio, and with it the company is advancing into new application areas. The Sendix H100 heavy-duty encoder is an extremely robust incremental encoder. Optionally, a mechanical speed switch can be integrated as reliable protection against excess rotation speed. The special structure of the HD Safety Lock™ means that an extremely high bearing load capacity of up to 300N axially and 400N radially can be achieved.
The typically temporary encoder loads, for instance due to an axial overload during installation, or high vibrations are largely tolerated. Pre-existing defects or even a failure of the encoder in the field are thus avoided. It is thus ideally suited for applications in heavy industry such as steel works or cranes.
Even the toughest working environments do not affect the resilient device as it has been designed for these very conditions. The wide span and the extra-large and robust flange bearing thus increase the load-bearing capacity and lifetime. The cover-side floating bearing in turn avoids internal tension. The revolving sampling unit ensures consistent signal quality in the event of a substantial expansion in temperature, during which the sensor unit is mechanically decoupled from the housing.

The enormous temperature range from -40°C ... +100°C, the protection class IP66 and seawater-protected material, the double sealing on the shaft-side, a friction sealing against moisture and the additional labyrinth sealing against the penetration of dust and for the protection of the friction sealing against hose water guarantee high resistance to adverse weather conditions. And ultimately the keyway of the shaft guarantees perfect form closure to the application. But the Sendix H100 heavy-duty encoder does not only comply with the highest standards with regard to resistance; it also meets every requirement relating to functionality. The innovative plug-in spring clamps in the connection cover enable the simple and prompt connection of the cable. This plug-in capability means that the installation of the encoder and the electrics can be done separately.
It thus makes installation easier in the field. And that in turn makes the replacement of the encoder substantially easier in the event of maintenance. No tools whatsoever are required to connect the cable on the spring clamp. The connection options can also be simply and variably configured as the connection cover can be rotated 180°. A major advantage particularly with tight space for it prevents a cable being bent. The H100 is also characterized by a large number of resolutions and switching speeds.

New Profinet singleturn and multiturn encoders in the robust Sendix design now complement the multi-faceted Absolut family from Kübler.

The entire encoder profile pursuant to "Profile Encoder Version 4.1" and "Identification & Maintenance functionality in Version 1.16" (IM blocks 0, 1, 2, 3 and 4) has been implemented in the devices.
The encoders support the isochronous real-time mode, also called IRT mode, and are thus ideal for real-time applications.
Through the decoupling of the real-time communication from the standard communication (TCP/IP), the IRT mode also offers a real-time solution for all high-performance applications such as synchronous applications.
The short cycle time of ≤ 1ms facilitates flexible and versatile use.
The possibility of simply enhancing the features of the encoder with firmware updates without dismantling the encoder also needs to be emphasized.

Scalings, preset values and many other additional parameters can be programmed via the Profinet bus. Position, speed, temperature values and other statuses of the encoder can be transmitted as output values.
All parameters can be programmed via the bus for prompt and error-free start-up. The bus cover is equipped with 3 x M12 plugs for prompt, uncomplicated and error-free connection. With singleturn devices, the resolution is up to 16 bit and with multi-turn devices up to 28-bit overall resolution.

The "Safety-Lock™" bearing structure enables the Sendix Profinet singleturn and multiturn encoders to guarantee maximum safety. The locked, larger bearing with large spacing ensures stability during vibrations and gives the device a robustness that even withstands installation errors. Machine downtimes and repairs are thus avoided. Thanks to the highly integrative Opto-ASIC technology from Kübler, the electronics and optical sensor technology are reduced to a few components in favor of higher reliability. The stable pressure-cast housing with a protection class up to IP67 and the broad temperature range of -40°C to +80°C also facilitates use outdoors.
Visual warning and alarm signals indicate sensor errors, too low a voltage or too high a temperature. Troubleshooting thus becomes substantially easier; the necessary measures for correction can be implemented without delay and lengthy downtimes avoided.

It is their versatility that makes the inclination sensors of the IS series so successful in a variety of industries. They are used in particular in vehicle, crane and lifting technology as well as in solar systems and commercial vehicles.
This flexibility in turn is based on a sophisticated technology that is also particularly characteristic of the latest product from this range: The IS60. This sensor for CANopen field bus networks measures 2-dimensional inclinations. Depending on the version, measurement ranges of ±10°, ± 45° or ± 60° are possible.
The sensor has a standardized CANopen interface that ensures simple configuration and start-up. In addition, all the parameters are stored in the internal parameter memory.
The IS60 has an extraordinarily compact and robust plastic housing. This is also documented by the high protection class IP68. Icy temperatures, sweltering heat or other inhospitable conditions do not present any problem for it. The range extends from -40°C to +80°C. Other factors are the pronounced resistance to shocks and vibrations and a high sampling rate and bandwidth. Two M12 plug connectors ensure a secure connection. The ideal goniometer for harsh industrial environments also convinces with its high resolution and precision as well as parametrizable vibration suppression. The calibration accuracy (at 25°) is ± 0.1°.

The requirements that utility vehicles have to comply with are becoming ever more complex. Very often with complex motion sequences proximity sensors are no longer sufficient for determining position. For such cases Kübler offers encoders from its Sendix 3651/3671 magnetic series, which carry e1 certification from the German Federal Motor Transport Authority (KBA). Encoders with this approval are to a large extent unique on the sensor market and offer a real additional benefit to utility vehicle users.

Whenever utility vehicles are working on the public highway then KBA regulations apply. For this application area Kübler now offers encoders from the Sendix 3651/3671 magnetic series that carry e1 approval. The use of certified sensors offers vehicle manufacturers the benefit that devices with this type approval may be used without affecting the type approval of the complete vehicle. This is especially important, if vehicles are being retrofitted with the latest sensor technology. The e1 designation certifies that the device is EMC compatible for error-free functioning with vehicle electronics. The encoder electronics have been adapted to suit the increased demands for EMC compatibility and are therefore ideally suited for use in mobile machines. This also makes approval of new vehicles much simpler. This is an impressive argument, especially with the wide range of models offered by manufacturers of utility vehicles.

The encoders can be powered from the 12V or 24V vehicle electrical supply. They can handle noise pulses of up to 450V without any problem; these can be caused for example by inductances or capacitances in the wiring harness, when the vehicle is switched on or off. The encoder supplies an angle-dependent output signal in the form of a 4 - 20mA current signal. In the voltage range it supplies a 0 - 10V or 0 - 5V voltage signal, each with a resolution of 12 bits. Pre-defined measuring ranges between 0 and 360° can be freely selected; further measuring and voltage ranges are available on special customer request.

The encoders show themselves to be particularly robust, compact and versatile. For, in contrast to potentiometric measuring systems, the non-contact magnetic measuring system does not suffer from wear and guarantees reliability in the application, as well as a long service life. Thanks to their integrated Safety-Lockplus™ and Sensor-Protect™ technology the new encoders are fully protected and ready for harsh outdoor use. Because of the fully-encapsulated electronics and the galvanic isolation of the bearings it has been possible to achieve the very high IP69k protection rating - not only on the housing side but also on the flange side. As a result, steam or high-pressure cleaning, as occurs for example with construction machinery, poses no problems for these sensors. Moreover, the functional safety of the encoders is assured due to the very high level of shock resistance of up to 500g and vibration resistance of up to 30g. Expensive machine downtimes and repairs can thus be eliminated.

The fields of application for these angle sensors in utility vehicles are quite diverse. They are frequently used, for example, to measure the opening angle of pneumatic doors in buses, for positioning the grabs of garbage trucks or also for determining the position of water cannons on fire trucks. Naturally they also find a use in construction machinery, for example for determining the pivoting angle when rotating the superstructure, or in agricultural and forestry vehicles when positioning work devices.

Wind turbines are constantly in use everywhere.
Encoders that are used for pitch and azimuth positioning or for speed measurement in wind turbines are consequently exposed to a harsh working environment. High expectations are placed on the availability of the signals, since downtimes are disproportionately more expensive and replacement far more time-consuming than for most sectors of automation engineering. Kübler encoders and counters measure up to these expectations, providing the required security and offering a high level of convenience. This applies not only to the turbine manufacturers and operators but also to suppliers of components for wind turbines.

There are many encoders on the market for positioning and rotary speed measurement. At first glance they all appear to be similar - or even the same - in their functionality and characteristics. However, as is often the case, the advantages they offer for particular customer applications and areas of operation lie in the details. Encoders from Kübler GmbH boast functionality and features that have been of great benefit to wind turbine manufacturers and system suppliers for many years.

Rugged, accurate Sendix encoders in the pitch drive

Complete system for direct installation onto the pitch or azimuth gear rim.

Using a rugged encoder from the Sendix Absolut series, the angle of the rotor blade in the pitch drive is measured and adjusted via the pitch controller. Variants with additional incremental signals or sine/cosine signals can be used for speed regulation in the frequency inverter.
If even greater safety is required, a resolver that is integrated in the encoder housing can in addition send resolver signals to the frequency inverter, over and above the multiturn signals. These analogue signals are then utilised by the frequency inverter as rotational speed and direction data. The rugged resolver and the accurate encoder represent independent systems. This redundancy increases the availability and means that the blades can be taken out of the wind in the case of a malfunction.
Multiturn encoders from Kübler feature very accurate optical scanning. In conjunction with their proven optical drive they have no need for a battery to store the number of revolutions. They thus provide absolute immunity against the influences of magnetic fields, caused for instance by electromagnetic brakes as are often employed in pitch drives.

Always the right encoder: the application determines the version

Furthermore, Kübler offers singleturn and multiturn encoders, which are mounted either centrically in the rotor blade shaft or eccentrically with a pinion on the blade gear rim. The accessories necessary for installation - such as gearwheels, mounting brackets or protective covers - are pre-assembled and enable fast, safe installation everywhere, including out in the field. Spring-mounted installation systems ensure that the contact pressure of the gearwheel is not too great and that the loading of the encoder bearings cannot be exceeded.
Kübler encoders used for pitch and azimuth measurement can, of course, be reset to the zero position via a reset signal from the controller. For special cases, however, Kübler encoders also have a reset button in the cover. So, during mounting or servicing, the rotor blade reference can be manually set, even in the field. This is very helpful - not least when mounting the components in the restricted environment of the rotor hub.

Better than the norm: maximum sea-water resistance

Kübler offers encoders with a sea-water resistant coating of the housing components. The encoders are suitable for offshore use and are tested to the highest requirements of the IEC 68-2-11 standard: over a time period of 672 hours in the salt-spray chamer.

In order to meet the general requirements for components that are suitable for use offshore, Kübler offers its encoders with a sea-water resistant coating of the housing components. In addition the encoders are tested to the IP67 protection level. They are thus more than able to cope with the damp, salty air they will encounter when used in offshore applications. They comply fully with the requirements for components used in a corrosive environment, such as, for example, with EN ISO 12944-2 Class C3. Here too Kübler goes one step further and tests its encoders according to the highest requirements of the standard IEC 68-2-11: over a time period of 672 hours in the salt-spray chamber..
This test is specified by the automobile industry, although our cars only have to withstand this test for a maximum of 120 hours.
The combination of rugged design and interference-resistant electronics, which ensure reliability and availability, make the Kübler encoders ideally suited for use in offshore applications.

As a matter of principle: braving heat and cold

In contrast to applications in factories and assembly shops, encoders that are installed in wind turbines are operated in a wide range of temperatures. Depending on the location, daytime and night-time temperatures - and also summer and winter temperatures - can vary wildly. However, after a shutdown, the system must be able to be started up again safely and the signals must always be available. For such extreme conditions Kübler offers a working temperature range from -40°C up to +90°C, so the position monitoring or speed measurement neither "freezes up" nor "overheats".
High-temperature versions of the encoders can function in environments, where the temperature is up to 105°C. This can play a decisive role in applications in slip ring housings or in particularly hot locations in wind power plants.

The speed measurement at the generator is an important measured variable for the entire control loop of the plant. Here accurate, high-resolution encoders are necessary for dynamic rotational speed control, supplying the controller with speed information in real time. The harsh operating conditions on the generator B-side are no problem for the Kübler incremental encoders. Shaft currents and the associated damage they do to bearings are avoided by using isolating inserts. A wide diverse variety of accessories and stator couplings enable easy installation without impairing the measuring accuracy. Even a large amount of generator shaft expansion poses no problem here.
In collaboration with our customers we define special product tests, such as for example the Highly Accelerated Life Test (HALT). Here encoders are placed in a chamber and subjected to extremes of temperature, as well as to quick changes of temperature. At the same time they are accelerated in three dimensions.

Well-informed: monitoring the difference between the speed of the rotor hub and the generator

Kübler offers tachometer / frequency displays for the redundant monitoring of rotary speed. They monitor the difference between the speed of the rotor hub and the generator, with safe relay contacts to break the safety chain.

The speed information from the encoders is brought together in the controller, evaluated and then sent from there to the turbine"s control loop. In wind turbines a supplementary, redundant monitoring of the speed is desired. Mostly it is the slow rotor speed that is evaluated and - for wind turbines with gears - the fast speed at the generator. For this purpose Kübler offers tachometer/frequency meters for monitoring the difference between the speed of the rotor hub and that of the generator; the meters offer safe relay contacts to break the safety chain. This means that additional safety can be offered if there is a deviation in the two speeds, or in the case of over-speed. Hour meters display the exact amount of hours during which the plan has produced current on the grid. Thanks to the electromechanical hour meters the information is available at all times, even if no supply voltage is present. Both the speed and the number of hours run can be viewed and monitored by the operator in the tower base - independently of the controller - without having to connect his laptop to the controller.

On top of the world: functioning safely, even at high elevations

Author:
Markus Brunner, Business Development Manager
markus.brunner@kuebler.com, +49 77 20 - 39 03 27

Wind turbines are being erected in more and more locations. Alongside the wind farms that have been planned globally in the seas, mountainous regions and other high areas are now being developed. Even if the logistics and grid connections in these locations are difficult, the advantages are obvious. The lack of population and the high wind speeds are attractive determining factors. These pose new challenges to the manufacturers of the turbines and components. Kübler encoders can be used at altitudes up to more than 3,000 meters above sea-level. The lower atmospheric pressure, as well as the quick changes in temperature, does not cause any problems, either for the electronics or for the rugged, high-quality housing components.

The bottom line: although rotary encoders represent only a very small part of the total wind turbine, it cannot be denied that they carry significant responsibility for the safety, availability and performance of the whole plant.

Fieldbus technologies are increasingly in demand even in hazardous areas. However this trend has been held back by a hitherto very limited choice of suitable sensors with integrated Fieldbus interfaces. To counteract this, Kübler has decided to offer its tried-and-tested Sendix Fieldbus encoder technology in a suitable 'flameproof enclosure'. The singleturn and multiturn encoders are thus approved for use in zones 1, 2, 21 and 22 and come with the latest Fieldbus profiles from Profibus and CANopen.

The shock and vibration resistant encoders operate flexibly and offer a high resolution of up to 29 bits. They offer IP67 protection as well as a wide temperature range from - 40°C up to +60°C. The housing and flange are both made from seawater-resistant aluminium, making them ideal for use outdoors in offshore or coastal applications. The compact design, with its installation depth of only 145 mm, diameter of 70 mm and space-saving cable outlet, rounds off the flexible, diverse application possibilities in areas with explosion hazards.

The most common cause of encoder failures is excessive load on the shaft of the encoder. Kübler has thus developed a new robust bearing unit for those applications in which there is a particularly high level of load on the shafts; this occurs for example with belt measuring systems that are often employed in the lift industry. The system separates the bearing load from the sensor technology and can easily be retrofitted to standard incremental and absolute encoders. Encoders that have been upgraded in this way can handle loads of over 300 N without any problems.

The mounting dimensions of the upgraded encoders remain 100% compatible, with the exception of the installation depth, which is increased accordingly to 84mm. As a result no mechanical adaptation of the system is necessary.

Trying to locate faults is often very time-consuming. Checking that an incremental encoder is correctly connected, checking also that the encoder is functioning properly, finding the zero point of the encoder, ... These are all very important steps that must be followed with the start up of an incremental encoder.
However with the new cordset from Kübler - with its integrated LEDs - the user can accomplish this both simply and quickly. The pre-assembled cable with its standard 8-pin M12 connector can be connected easily to all Kübler incremental encoders that are equipped with M12 connectors.
3 LEDs have been built into the transparent, right-angle housing and display channels A, B and Z of the encoder. In this way it is possible to see the current status of the output channels at all times, as well as when the zero point is reached.
The moulded connector is extremely robust and boasts a protection level of IP67.

Reliable, even in critical situations Kübler Length and Angle Measurement for Mobile Automation

There is an unstoppable trend in the field of Mobile Automation that often goes unnoticed by the public. Automation is continuing to increase and with it sensor technologies too.

The following article provides a general definition of the Mobile Automation sector and the challenges it sets. It then goes on to shed light on the trends for length and angle measurement within these heterogeneous fields of application.

Kübler answers the demands of the sector with the help of its wide-ranging product portfolio. Here the company benefits from more than 50 years experience in machine construction and general automation technology. Magnetic and optical encoders with suitable interfaces, equipped with rugged bearings and housings, as well as with Functional Safety make up a wide range of products especially for the harsh operating conditions to be found in this sector.

The professional, process-oriented service and sales departments at Kübler help support the search for the optimal solution. This is based on a checklist, which illustrates the relevant technical features for each requirement.

Two application examples from the field - "Unflagging service outdoors: Sensors for the Fire Service" and "For warehouses: Automated Guided Vehicle Systems" serve to highlight the comprehensive and flexible Kübler length and angle sensor solutions - outdoors as well as indoors - in harsh everyday environments.

When choosing the right encoder for functional safety, "togetherness" is the secret, since safety is achieved via the intelligent combination of encoder, controller and actuator.
Sendix SSI/BiSS absolute encoders with additional Sin/Cos output and Sendix incremental encoders in Sin/Cos version are now available with SIL3 / PLe certification, which means that they play a key role amongst the components of a safe plant.

The Sendix SIL absolute encoders obtain safe information about the absolute position; here the controller counts the incremental pulses and compares the result with the absolute position, which has also been provided by the same encoder. However in contrast, in the case of the Sendix SIL incremental encoders, the controller monitors the validity of the analogue, 90° phase-shifted sine/cosine signals with the help of the function sin²+cos² = 1.
In addition, Sendix SIL-certified incremental and absolute encoders ensure a safe mechanical connection in the application. Here suitably dimensioned sturdy fixing elements guarantee 100% reliability.

Yet, for Kübler Sendix SIL encoders, safety goes much further. They feature a rugged, reliable interface and an ability to withstand high mechanical as well as electrical loads, thanks to extra strong bearings in the Safety Lock™ Design. The result is a very high degree of accuracy and a long service life. With their high IP67 level of protection and their magnetic insensitivity - thanks to optical scanning - the Sendix SIL encoders offer "All-round Safety".

With regard to the requirements of the Machinery Directive 2006/42/EC the MTTFd values for the most important standard encoders from Kübler are also provided. This thus enables the user to carry out his own calculations according to DIN EN 61800-5-2 and DIN EN ISO 13849.

OptoASICs offer a number of advantages: They are fast, very reliable and feature a high level of integration. Kübler has availed itself of the latest OptoASIC technologies as the basis of its most recent, patented generation of fast and, above all, non-contact, wear-free absolute encoders: the new singleturn and multiturn Sendix F36 impress with their optical patented Intelligent Scan Technology™, which makes highly-accurate determination of position possible - with feedback in real-time - as is required for example in medical equipment, where space is limited.

All the single and multiturn functions of the encoder - which has already won a number of awards for its innovative technology - were first of all combined on to an OptoASIC. Here with the multiturn version the optical sensor technology achieves a very high resolution of up to 41 bits. The same applies to other values, where the technology also outperforms traditional contact measuring methods. The Sendix F36 encoders are characterised by their extreme ruggedness and resilience, a result of the greatly reduced number of component parts and the large, sturdy Safety Lock™ bearings. This is the case even in harsh industrial environments. Moreover, the new patented Intelligent Scan™ technique ensures 100 % insensitivity to magnetic fields, as is called for in applications such as motor brakes. When it comes to its compact size, the Sendix F36 is unrivalled: hollow shafts of up to 10 mm are possible with a flange diameter of only 36 mm. The icing on the cake is provided by the compact dimensions of the tangential cable outlet, for even where installation room is severely limited, the cable connection does not get in the way.

When it comes to flexibility, the Sendix F36 encoders offer an additional advantage with their wide choice of interfaces: together with SSI and BiSS, they are now also available with the CANopen interface, conforming to the encoder profile DS-406/3.1 to CiA Standard DS-301/4.02. The bus parameters are set and monitored by means of the programmed reference values. The read-out values, including position, speed, sensor raw data with CRC (according to the Safety Protocol DS 304) as well as the status of the working area, can be flexibly combined as PDOs using PDO mapping.

The excellent product characteristics of this encoder with no gears are rounded off by the additional incremental outputs SinCos or RS422. They provide the system with high-resolution feedback in real-time and enhance the performance of this compact encoder to that of "two devices in one".

The new incremental magnetic systems RI50 and LI50, with their rugged die-cast housing and their minimal installation depth of just 16 mm, open up a wide spectrum of possible applications. They are thus perfectly suited for all plant and machinery where installation space is limited - and yet they still boast a large hollow shaft of 30 mm.

Thanks to their non-contact sensor technology the systems offer a high level of resistance to vibration and shock. Outdoor use is also possible without problems: this is taken care of by the high IP67 protection rating, the permitted humidity level of 100 percent with condensation, the wide temperature range and the rugged die-cast housing. Moreover, the metallic housing is shielded against electromagnetic interference. The magnetic measuring systems provide the signals of a fully fledged incremental encoders: A, A-, B, B-, as well as 0 and 0-.

Installation is exceptionally easy, due to the large mounting tolerances of up to 1 mm between magnetic ring and sensor head. In addition, a red LED gives a warning signal if the distance from the band or the ring to the measuring head is too great or if the speed is too high. The green light indicates the index pulse. The wide supply voltage range from 4.8 up to 30 VDC further facilitates the installation.

Connection is made using a high-quality shielded PUR cable that can be used in trailing cable (drag chain) installations if required. The measuring head comes with either a push-pull output or an RS422 interface. Resolution is up to 5 µm with quadruple evaluation, the repeat accuracy is +/- one increment and the maximum travelling speed is 25m/s.

In hazardous areas with potentially explosive atmospheres encoders must comply with special protection legislation, as even the tiniest spark can have grave consequences. Positioning tasks arise in many such hazardous areas, whether in the mining and chemical industries or even in oil production. For just these applications that require position values, Kübler now offers its new Sendix absolute singleturn and multiturn encoders with ATEX certification. They are constructed with the "flameproof enclosure" type of protection and are approved for use in zones 1,2,21 and 22.

The shock and vibration resistant encoders operate flexibly and offer a high resolution of up to 29 bits. Thanks to their housing and flange that are made out of seawater-resistant aluminium they are ideal for use in offshore or coastal applications. With a protection level of IP67 and their wide temperature range from -40 to +60°C the Sendix ATEX encoders remain sealed even in harsh everyday use and offer a very high level of safety against breakdowns in the field. The compact design, with its installation depth of only 145 mm, diameter of 70 mm and space-saving cable outlet, rounds off the flexible, diverse application possibilities in areas with explosion hazards.

Lift systems have to achieve a fine balance between many differing demands: key amongst these are reliability and a very high level of safety, not forgetting at the same time a long service life, highest profitability and tranquil smooth-running. LM 3 and LM 5 are the names of new - ready-made, pre-assembled - Kübler complete systems for shaft-copying, which make a significant contribution to increased safety and reliability in lift technology, thanks to their innovative bearing design. And which also ensure considerably more "peace and quiet in the shaft" - thanks to an innovative vibration-resistant encoder mounting fixture and a smooth-running toothed belt. They thus offer quiet, smooth-running handling characteristics, which do justice to the lift's claim to be the calling card of the building.

At the heart of the sensor technology: encoders
A lift that has a long service life and requires low maintenance can only be achieved by paying detailed attention to quality. This applies especially to the heart of its sensor technology: the encoders. These control the rotational speed and drive position, offer accurate shaft copying and monitor the speed limiters. Sendix encoders from Kübler offer an appropriate, tailor-made technology for this key function - with proven, extremely rugged quality. Listed among their most important features are the long service life of the devices - due to their high resistance to shock and vibration, their high protection level of up to IP67 and their wide temperature range from -30°C up to +85°C. Thanks to sturdy bearings, short-circuit proof outputs and reverse polarity protection, they are not susceptible to damage during installation.

Double protection via separation of bearing load and sensor technology
The mechanical loading experienced by the encoder within the lift mechanics is quite considerable. And here the prefabricated LM lift systems prove their worth: separating the load and the sensor technology protects the encoder with the aid of additional bearings outside the encoder, thus almost completely relieving the load on the encoder bearings. In this way the innovative design of the LM lift mechanics makes an important contribution to the long life of the whole lift construction. Furthermore, belt pulleys with duplex bearings, smooth-running toothed belts and a vibration-resistant encoder mounting fixture guarantee very quiet, smooth operation of the system. The belt pulley benefits from its own separate bearings within the mounting fixture, which ensures that the mounted encoder is protected from mechanical overloading.

Knowing, when servicing is required: trip counters and hour meters for lifts
Along with its sensor technology Kübler offers an extensive choice of trip counters and hour meters, the combination of which allows for the precise and highly reliable definition of service intervals. There are versions for DIN rails, for use in control systems that have been installed in classic control cabinets. A tip for users: anyone using a counter with a 100% duty cycle can save themselves the generation of pulses or alternatively the time-consuming integration of pulses.

Tamper-proof, compact, economical
Kübler offers compact electromechanical counters that come with a very high level of tamper-proof security, as well as economical LCD counters - also with 230 VAC inputs for direct connection. The electromechanical devices are not only tamper-proof, but also highly noise-immune and have the crucial advantage that the display can still be read even after a fire. This can be of great importance from an insurance aspect. Electronic counters need very little current and generate very little heat, which is particularly relevant when under continuous load with a 100% duty cycle or with overcurrent. An additional advantage of Kübler electronic counters is the wide range power supply of the devices, allowing problem-free use in all countries. The counters do not thus need to be adapted to the conditions of individual countries in line with customers' wishes, avoiding troublesome modifications. In addition counters with control outputs are available, for example to trigger a separate service message.

Experience counts
Without the established presence of Kübler, it would have been difficult to picture the sensor and counter markets - including the lift market. Fast, personal all-round service, as well as customer projects and local sales and marketing are integral parts of the company's philosophy.

Yet again the new absolute encoder series Sendix F36 has scooped a Design Award. The innovative design of the Sendix encoders was accorded the Design News "Golden Mousetrap Award 2009", in the category "Best Product - Feedback Devices". The jury was highly impressed by the excellent functionality and compact size of the F36 series. Special mention was made of the Intelligent Scan Technology™ and the unique features were rated very highly. The Sendix F36 is the first purely optical multiturn encoder without gears to also be 100% insensitive to magnetic fields. Its compact size, combined with its ruggedness, make it ideally suited to completely new areas of application, where previously there has been no room for encoders.

When it came to performance, this innovative product outshone its rivals with its optimised relations, a 10 mm hollow shaft for a flange size of just 36 mm, as well as the sturdy bearing assembly, which occupies a third of the total constructed space. The appeal of the latest encoder generation from Kübler lies in its slim design: "By omitting mechanical components, Kübler has on the one hand been able to improve the performance and reliability and on the other hand has created a more compact encoder than is otherwise usual in the market," said Contributing Editor Al Presher in the Design News edition of 10th September 2009.

The Design News Engineering Awards have been given out for more than 20 years. They acknowledge and highlight good design, rewarding the engineers responsible. Design News is a leading US magazine for design engineering. It has been published since 1946 and has more than 170,000 readers.

There is a new arrival to the Kübler family of CANopen® encoders in the form of the Sendix F36 series, extremely compact, robust and offering a high degree of resolution. Product characteristics were able to be combined on the basis of the innovative, patented, "Intelligent-Scan-Technology™" platform, so opening up new potential applications, wherever there is a demand for highly compact drives with a long service life. The reason behind this was as follows: for the first time ever, three characteristics could be combined in one device - an option that had been excluded previously. The Sendix F36 devices are purely optical, have no gears and in addition are 100% resistant to magnetic fields.

As a result of the reduced number of component parts the Sendix F36 series offers a very high level of immunity and reliability. The 10 mm blind hollow shaft with a flange diameter of 36 mm may possibly be a record. Thanks to the tangential cable outlet, the connection is never in the way, even where installation space is very tight. At the heart of the new encoder series is an OptoASIC with a new scanning technique. This technology platform also guarantees the magnetic insensitivity, which can be the deciding factor, for example, in applications involving motor brakes.

The Sendix F36 devices conform to the encoder profile DS-406/3.1 according to CiA Standard DS-301/4.02. The bus parameters are set and monitored by means of the programmed reference values. The read-out values, including position, speed, sensor raw data with CRC (according to the Safety Protocol DS 304) as well as the status of the working area, can be flexibly combined as PDOs using PDO mapping. The baud rate and node address can be set and configured to CIA Profile DS305 V2.0 by means of LSS services. In addition, selective commands are given via the respective attributes of the Identity Object (1018h).

The maximum 32 bit overall resolution ensures compatibility with the CANopen® profile. It results from the combination of a programmable multiturn encoder that has been tailored to suit market needs, with up to 66 thousand turns and a very accurate singleturn with a resolution of up to 16 bit. The encoders of the new F36 series thus afford particular versatility that opens up a wide range of new application areas. In addition to CANopen with the latest profiles, the Kübler Sendix F36 encoders are also available with SSI and BiSS interfaces.

Steel can suffer, no question about it. Over the course of time strong detergents or acids can cause it to corrode. That is, unless we are talking about stainless-steel. Because the refining of steel not only brings with it a whole raft of beneficial mechanical properties but also a very high level of material resistance and consequently an almost unlimited service life. The new Kübler Sendix 5006 incremental encoder in stainless-steel incorporates all these advantages and is thus ideal for use in demanding application areas that require long-term durability. Sectors that can profit from this latest development include, for example, the food industry, which has to use aggressive substances, not only because of strict hygiene regulations but also due to foodstuff ingredients such as brine or lactic acids; the packaging and utility vehicle sectors will benefit in a similar way, especially from the specific power spectrum.

A sizeable contribution to the durability of the stainless-steel encoder is made by its high-grade Viton seals. These ensure impermeability, even when subjected to aggressive substances or variations in temperature. The high IP 67 level of protection as well as the wide temperature range go one stage further in protecting against breakdowns in the field. The Sendix 5006 incremental encoder can easily handle large fluctuations in temperature, from -40° C up to + 85° C. The tried and tested bearing assembly, with its sturdy Safety-Lock™ design, provides additional protection against vibration or installation errors.

When it comes to high demands it is well worthwhile looking at the stainless-steel version of the Sendix incremental encoders from an economic point of view, i.e. as an especially high-quality encoder, which quickly pays for itself thanks to its long service life and minimal follow-up costs.

The compact revolution. Kübler presents the first optical multiturn encoder without gears and with 100 percent magnetic insensitivity.

Kübler introduces a little technological revolution. Technology companies do this quite frequently, however in this case the term is fitting. A new encoder technology, developed with the new Kübler Sendix F36 series, aims to spur on applications in the future; whilst getting rid of technological disadvantages such as wear and ageing or magnetic sensitivity. All the advantages on one chip - this is the motto.

In the new patented, optimised design there is room enough only for the essentials. Even functional "accessory parts", such as the battery - traditionally accommodated within the housing - had to give way, in order to afford extra space for the impressive Sendix-style bearing assembly. This bearing assembly alone - guarantor for extreme ruggedness and long service life - takes up two-thirds of the overall depth of the compact encoder. Thanks to the non-contact optical technology in the F36 series, no other product of this size is going to be able to quickly match this encoder when it comes to service life. This is because, for the first time, the proven Sendix ruggedness can now find sufficient space in such compact dimensions. It is probably also a record that an 8 millimetre hollow-shaft or a 10 millimetre blind-hollow shaft can be offered within the overall size of just 36 millimetres.

There is no doubt that the product philosophy of concentrating on the essentials, which forms the basis of this new technology, makes a crucial contribution to the insensitivity and the reliability of the devices. This includes the considerable reduction in the number of component parts compared with conventional encoders. This means, in a nutshell: giving up the gears in order to benefit service life and also doing without a battery, so as to offer exceptionally compact dimensions. Compact dimensions, by the way, where the tangential cable outlet provides the icing on the cake.

A state-of-the-art OptoASIC lies at the heart of the new F36 Sendix series; here the information threads come together; here lies the intelligence for singleturn and multiturn functions.

With a total resolution of up to 41 bits, which results from the combination of a requirement-based programmable multiturn encoder with up to 16 million revolutions and a high-precision singleturn with up to 17 bits resolution, the new F36 encoders feature a particular wide choice of options, which opens up numerous areas of application to them. The Kübler Sendix F36 series thus provides the ideal basis on which to build customer-specific solutions in demanding applications. Wherever drives need to be especially compact and economical, or in sectors that demand particularly flat solutions, such as drive engineering or medical technology, then the advantages offered by the large 8 mm hollow shaft or the 10 mm blind hollow shaft become evident. It is now rare to hear arguments in favour of using potentiometers: the new Sendix F36 generation of encoders must surely now make them a thing of the past.

Tough nuts to crack: The Kübler SAE J1939 solution for commercial vehicles.

Although from the outside they look like big bruisers, they are really high-tech products on wheels: construction and agricultural machines or trucks and buses. Thanks to electronic control units their regulations and safety applications have become ever more complex. The high quality demands found in the sector result not least from the harsh environments encountered - whilst at the same time the piece quantities involved are very small and the variety enormous.

In short: Kübler has answered the demands of the industry for communication systems suitable for their applications by implementing the standard protocol of the Society of Automotive Engineers SAE J1939 for commercial vehicles and ships, railway vehicles, construction and agricultural machinery. This has been achieved primarily on the basis of CANbus and by networking system components on a standardized basis, whilst at the same time offering manageable costs, flexible communication options and compatible components.

SAE J1939 was integrated in the proven Kübler magnetic absolute CAN encoders types M3658 and M3678 and ensures a smooth-running exchange of information between individual sub-systems - whether it is a matter of current rotational speeds in construction machinery or of idling speed under load for lifting platforms.

The Kübler Sendix encoders with the SAE J1939 interface and 14 Bit resolution support virtually all common requirements of the special protocol and make an essential contribution to the overall system diagnostics or to the quick localization of failures. In accordance with the protected Kübler Safety-Lock plus™ technology, the encoders boast especially sturdy bearing assemblies with interlocked bearings. Furthermore the Sensor-Protect™ technology with its fully encapsulated electronics and separate mechanical bearing assembly ensures the very high protection rating IP69K. SAE J1939 combines all the incoming signal data into specific parameter groups (PG), which means that Kübler Sendix encoders can be adapted to virtually all customized applications that have an integrated J1939 protocol.

Weathering the stiffest breezes: tests confirm that Sendix series is resistant to seawater.

Encoders are increasingly being used outdoors; this is becoming progressively more popular in coastal and offshore projects. Kübler GmbH has now added seawater resistant Sendix encoders to its product portfolio in order to address applications in this demanding environment.

The Sendix family of devices already has a proven history when it comes to harsh applications and has now in addition been certified to IEC 68-2-11 for its resistance to the effects of salt-spray for a period exceeding 672 hours - the highest test level. This encoder family thus guarantees tested safety and reliability - not only for the magnetic Sendix range but also for the high-precision optical Sendix absolute encoders and their numerous Fieldbus versions. The choice ranges from compact encoders with a size of 36 mm diameter up to 58 mm standard devices. The high certification level for the Sendix encoders attests not only to particularly good corrosion-resistance, but also to their excellent aging properties.

As Sendix had already been designed for use in demanding outdoor conditions, the particularly high protection rating - up to IP69K - as well as the wide temperature range from -40 up to +85°C count amongst the plus factors of the new device versions. In addition these rugged encoders place the emphasis, both mechanically as well as electronically, on outstanding safety and accuracy, incorporating Kübler's latest patented technologies, such as Safety-Lock™. Consequently they are ideal for use in commercial vehicles, wind energy, dockside cranes or offshore installations.

Everything but self-explanatory. During the expert forum at its 2008 Customer Days, the Kübler company grasped the hot potato of the wide diversity of standards in the field of "Safety in Automation".

"Finding ways through the maze" - so promised the ambitious sub-heading of the expert forum, which was held in English in homage to the many international guests present. Within the framework of the Kübler Customer Days on the 10th and 11th October 2008, over 100 experts, customers and illustrious guests from the fields of research and politics gathered at the company's headquarters in Villingen-Schwenningen, where the recurrent theme of Innovation and Safety ran through the fully-booked series of events. A new 2500 m² large facility that includes an R & D centre was inaugurated; "SIL", Safety Integrity Level - Safety in Automation - was one of the central themes of the festivities. A podium discussion on the afternoon of the 10th October was specially dedicated to this, with six highly-distinguished experts from industrial organisations and businesses. The first team selection of experts on the podium promised concentrated professional know-how that could shed light on the darkness surrounding regulations and standards. Thomas Steffens from the TüV Rheinland Group gave a comprehensive introduction to the IEC 61508 standard - seen from the Inspection Authority's point of view - and the resulting criteria and requirements applicable to the development of plant and systems. "Implementation in practice and applications" was the title of the subsequent talk by Gerhard Bauer, Managing Director of the BBH Products company that specialises in technical safety systems. Bauer illustrated the theoretical principles outlined by the previous speaker with many practical everyday examples from industry of how these are implemented. Meanwhile Arnold Hettich, Product Manager at Kübler, rounded off the essential facts by specially highlighting the "Kübler Way" where functional safety is concerned and giving a preview of the safe absolute encoder "Sendix Safety SIL 3", scheduled for launch in 2009.

The remaining speakers on the podium comprised Ralf Moebus, technical spokesman for the company Safety Network International e.V., Rainer Apfeld from the BG-Institute for Occupational Safety and Health, known as the BGIA, and Lothar Kübler, Managing Director of Kübler GmbH. Moebus picked out as his central theme the wide diversity of standards and guidelines - from IEC 61508 and IEC 61511, VDI/VDE 2180, through to ISO 13849 and EN IEC 62061. His conclusion was that each standard has its own specific focus and this therefore, within certain parameters, explains the rationale behind it - though this is not to say that its existence is justified: "Whilst the 13849 standard addresses more the area of architecture and mechanical systems, EN IEC 62061 focuses on complex systems." Apfeld also clearly confirmed the wide array of standards, which could definitely lead to uncertainties in the application, though he was however sure that the current multiplicity of standards would be considerably reduced starting from next year: "In the near future there will be just one clear standard."

Time to act ...

There is a growing trend for Safety in Automation and this is given top priority at management level within Kübler. Lothar Kübler had already made this point very clear in his welcoming speech, when he drew a comparison between the Safety Integrity Level "SIL" in the field of automation and the routine safety precautions that are taken for granted today. He concluded: "Just as no-one today would think of driving a car without wearing a seatbelt or letting his children ride a bicycle without wearing a safety-helmet, then functional safety in an industrial environment will take hold and grow to become the accepted standard."

Gerhard Bauer, the representative of BBH Products, also reminded us again that "now is the time to act". His speech clearly stressed one point: the new Machinery Directive 2006/42/EC from the European Parliament will come into force without fail on the 29th December next year. "Every business that is well advised will be preparing and planning for this." This new directive reminds all manufacturers of plant and machinery (or of separately driven safety components) of their obligations. For Bauer one element is key for businesses, when it comes to keeping the costs and effort involved in these new tests and approvals manageable: "It is all a matter of finding the right partner!" He was emphatic in pointing out that good advice not only keeps costs in check, but also eliminates unnecessary measures and action-taking right from the start.

... in three steps.

According to Bauer, three vital steps should be observed when implementing any safety project: 1) First of all it is important to have the right support when selecting the functional safety system configuration and in the validation process. Qualified manufacturers of components, which in turn are suitable for functional safety applications, come into consideration here. 2) Here only logic controllers that have been tested in accordance with Appendix IV of the Machinery Directive, or alternatively centralized or decentralized controls with integrated safety functions according to DIN EN 61800-5-2, should be used. The manufacturer himself determines the necessary values for validation according to DIN EN 13849. 3) If moreover only such components are used, which for their part are suitable for functional safety systems, then nothing more stands in the way of a safe new system and its approval.

Safety is a 4-level system

"SIL" - the much cited Safety Integrity Level - classifies the safety-related performance or reliability of electronic or electrical control systems fundamentally into four levels. With SIL the so-called safety-chain stands in the foreground of the assessment - this is also known as the SIF "Safety Instrumented Function." Behind this lies simply the functional combination of controller, actuator and sensor. Once the decision has been made to develop the functional safety to the latest levels of technology, the question often arises, when and how should I sensibly introduce the existing standards? For the field of encoders Thomas Steffens from TüV saw a clear need for action - and that Kübler are on the right path when it comes to their efforts concerning safety. "Encoders are an integral part of the safety chain and in the future will be certified ever more frequently SIL 2." This trend was confirmed by Ralf Moebus: "In the future more and more products will communicate more intensively, and will also become more intelligent. This development points clearly to a growing demand for safety communication. I can see here growth rates of around 25 percent per year."
As well as this there is the question of product liability: safe is safe. Steffens concedes that the application of and compliance with the EN 61508 standard is and will remain on paper voluntary. It constitutes however an important basic principle in the context of product liability and sets forth here clear-cut requirements.

Opinions were divided on the question of intelligent encoders

The question of how far encoders are affected by the safety issue was quickly resolved amongst the experts. Gerhard Bauer put forward the simple but sensible statement: "Wherever there is motion, then encoders are not far away. When it comes to safe motion then encoders are definitely involved."
However - taking it for granted that encoders are an important component part of a safe system - how much intelligence do they really require? Or to put in another way: could not the system or plant control assume the intelligent part and relieve encoders of the 'awkward tasks' ? Florenz von Guttenberg, Product Development Manager at Kübler GmbH, asked pointedly: "Do we have to give the encoder itself the safety function, or could this not simply be taken over by the control within the safety chain?" A question which led to an evident difference of opinion on the podium: Safety Network International representative Moebus made the case, along with Thomas Steffens of TüV Rheinland, that each member of the safety chain - including the sensor - needed to have a high degree of communication capability in order to be future-proof, whereas Gerhard Bauer of BBH Products granted intelligent encoders an extravagent amount of redundancy - even though this had to be combined with a particular level of reliability for the total system: "The encoders of the future do of course need to be safety-tested in order to exist in the market, but they do not need to be intelligent. The intelligence itself will remain in the control system, in the so-called 'Safety Kernel', which is the real heart and core of the safety chain. Chips however - not least on cost grounds - will remain outside of the encoder." Of course, systems as well as components must continue to be more price competitive, Gerhard Bauer went on, yet at the same time development continues in the direction of ever cheaper components.

In practice however, the outlay for certification can be kept within limits, as whole product families can be tested together, added Lothar Kübler during the discussion on costs and expenditure. As with the principle of killing two birds with one stone, it is important during the certification process that an agreement is reached with such bodies as the PTB or Apex regarding "exactly what modifications can be made to a product, so that it does not need to be re-tested." The experts were all agreed that certification leaves room for flexibility, but the key question that needs to be explored is how and in what areas can we be flexible?

The experts on the podium were agreed that Safety in Automation must be driven by the principle of avoiding accidents - and not just meeting the demands of some regulatory standard. Thomas Steffens gave a good example of this in his speech with a highly topical quotation from the year 1880: "The prevention of accidents should not be regarded as a requirement of the law, but rather as an act of human obligation and economic sense." A beautiful - and actually simple - concept from Werner von Siemens, the well-known German inventor and industrialist - and original founder of the famous Siemens company.

As a result of technical innovations, ever increasing demands are being made on machines and motors when it comes to accuracy in rotary motion. At the same time the trend towards ever more compact designs continues endlessly. This has given rise to an area of application for rotary encoders that is constantly growing in importance: utilization where space is tight.

Thanks to a new magnetic measurement principle, Kübler's singleturn encoders 2450 and 2470 require just 24 mm diameter installation space to measure both reliably and extremely accurately.

Despite their space-saving dimensions, these compact encoders are comparable with significantly larger variants with regard to accuracy and ruggedness and are thus able to satisfy the highest quality standards. Furthermore, the non-contact technology underlying the magnetic measurement principle offers the benefits of no wear as well as resistance to ageing, meaning that plant and equipment can be operated reliably and safely for considerably longer periods. These advantages quickly pay for themselves, especially in installation locations that are difficult to access.

Just as with larger devices, the Kübler 2450 and 2470 models are designed to cope with significant fluctuations in temperature and remain fully functional at temperatures between -20°C and +85°C. Moreover, the particularly high resolution of 12 Bit with 4096 different positions at 360 ° ensures outstanding repeat accuracy.

Even the cable outlet on this little space-saving miracle has been designed to offer an optimum level of robustness: the multiple clamping guarantees high strain-relief, ensuring smooth operation and offering reliable protection against failures.

These Kübler singleturn encoders 2450 and 2470 - both solid and hollow shaft versions - really are the specialists for handling applications where space is at a premium, especially where the combination of the following two properties is key: the minimum possible space requirement combined with the maximum possible reliability.

The new generation of Kübler singleturn encoders, Sendix M3658 and M3678, was designed and developed particularly with a regard to their special areas of expertise - from extreme, demanding outdoor applications through to heavy construction machinery. These encoders offer all-round protection even in harsh environments, thanks not least to the integrated Safety-Lockplus™ and Sensor Protect™ technologies. The Sensor Protect™ Technology, with its fully-encapsulated electronics and separate mechanical bearing assembly, ensures a very high protection rating of IP69k. There is an additional plus point here: the IP69k protection is guaranteed not only on the housing side but also on the flange side. This means that high-pressure water or steam cleaning can be carried out, as is common with construction machinery, without the ingress of moisture or humidity.

Alongside the robust bearing assemblies with their interlocking bearings, one of the key quality attributes of the absolute encoders is the mechanically protected shaft seal. This will tolerate installation errors and offers additional protection - even against stone-chipping. Furthermore their high resistance to shock and vibration safeguards the reliable functioning of the devices and above all ensures one thing: that machines and motors run reliably and safely, without losing time to repairs or unnecessary shutdowns.

In addition to their ruggedness these new singleturn devices boast a high resolution of up to 14 Bit. Their non-contact measuring system does not suffer from wear, ensuring a long service life with continuous reliable operation.
With their wide temperature range from -40° C up to +85° C and their high resistance to humidity, the series M3658 and M3678 encoders are well equipped to deal even with outdoor applications with large fluctuations in temperature.

The new encoder series is also very user-friendly when it comes to status indication. Here the two-colour LED located on the rear indicates the operating or fault status, as well as the status of the internal diagnostics.

Very often it is the dimensions that decide where the products can be used: thanks to their very compact design the new M3658 and M3678 encoders can be installed even where space is tight - opening up new areas of application, where up till now absolute encoders could not be accommodated.

Kübler is now offering its proven Sendix absolut CANopen® Fieldbus encoders with an additional incremental track. 
Parallel to the CANopen® output this encoder outputs an additional TTL compatible signal with 2048 pulses per revolution. As well as the CANopen® output, the encoder is also fitted with an RS422 interface, which outputs the signals A,/A, B,/B.  This means it is possible to implement simultaneously both positioning via the CAN network and direct feedback of the speed - all in just one encoder. This saves on the costs and installation space that a second encoder would have entailed.

The device is equipped with the latest profiles with many extra functions. 
Using the variable PDO Mapping in the memory the user can decide which information is to be available in real-time. Intelligent functions, such as the transmission of speed, acceleration or exiting the work area, ensure fast data availability while reducing the load on the bus and controller. 
The real-time position acquisition of the expanded CAN Sync Mode enables genuine time-synchronous position detection of several axes.

The Sendix technology, with its sturdy Safety-LockTM bearing construction, high IP67 protection rating and wide temperature range from -40°C up to +80°C,  facilitates use in harsh industrial environments - even outdoors.  The devices offer a very high level of reliability thanks to the OptoASIC technology with the highest integration density (Chip-on-Board); this reduces the number of components and connection points to a minimum.
The removable bus terminal cover  -  with integrated galvanically isolated fieldbus nodes -  enables simple integration into the CANopen® network. Start-up is easy, either directly at the unit thanks to easily-accessible DIP switches, or quickly and error-free by programming via the bus.  

With the LIMES LI20 and LI50 Kübler is presenting a new generation of measuring heads in a particularly solid die-cast housing. Used in conjunction with its magnetic bands with their stainless-steel covering, the resulting linear measurement system stays sealed even in harsh industrial environments and offers security against failures in the field. The magnetic rings offer the user a remarkably compact measurement system for rotary applications where installation space is very tight. Installation depths of only 16mm are possible with a large hollow shaft of 30mm. The combination of rings and bands plus Kübler's flexible manufacturing facilities open up a wide spectrum of different geometries that can be scanned, such as for example pitch circles or curves.

The non-contact technology ensures high vibration and shock resistance. The products can also be used outdoors, thanks to the high IP67 protection rating, the permitted 100% humidity with condensation, the wide temperature range and the weatherproof die-cast housing. The metal housing also offers improved shielding against electromagnetic interference. 

Installation can be carried out very easily due to the large permitted tolerances of up to 1mm, which apply not only to the distance from band to sensor head but also for lateral misalignment, as well as to the built-in LED, which gives a red warning signal if the distance from the band to the reading head is too great or if the speed is too high. A green light shows the index pulse. The wide supply voltage range from 4.8 to 30 VDC likewise facilitates installation. The connections are made via a high-grade shielded PUR cable that is also suitable for trailing cable applications.

The sensing head is available either with a push-pull output or an RS422 interface and supplies two channels plus a periodic index with the corresponding inverted channels. The resolution is up to 5 mm with quadruple evaluation and the repeat accuracy is +/- one increment. The maximum traversing speed is 25m/s

With its new 2450/2470 series, as well as with the Sendix 3651/3671 and M3658/M3678, Kübler is expanding its range of compact absolute singleturn encoders as far as a more compact 24mm design, higher resolution up to 14 bit and interfaces with analogue output (0 to 10 V, 4 to 20 mA), SSI or CANopen® are concerned. There is a measuring range suitable for each application: either 45°, 90°, 180° or 360°.

The encoders prove to be particularly rugged, compact and versatile, as the non-contact magnetic  measuring system is not subjected to any wear and ensures reliability in the application as well as a long service life.

The encoders are fully equipped to handle harsh everyday industrial environments, thanks to the Safety-LockplusTM and Sensor-ProtectTM technology.
Sensor-ProtectTM technology offers fully-encapsulated electronics and a separate mechanical assembly, providing a very high protection rating of IP69k together with an extremely high level of shock resistance (> 500g) and vibration resistance (> 30 g), which ensure the functional safety of the encoders and avoid expensive machine downtime and repairs.
The Safety-LockplusTM technology from Kübler also makes possible the very high level of protection IP69k, not only on the side of the housing but also of the flange, so permitting pressurized-water or steam cleaning, as is required for example with construction machinery. A further notable feature of Safety-LockplusTM is the robust bearing assemblies with interlocking bearings as well as the mechanically protected shaft seal, which tolerates installation errors and also protects against stone-chipping.
The wide temperature range from -40°C to 85°C and a particularly high level of resistance to humidity and condensation enable the encoders to be used in outdoor applications where there are large fluctuations in temperature.

Installation where space is limited is no problem, thanks to the compact format and a blind hollow shaft up to 10 mm and the encoders can be mounted on a tight radius even with large shafts . Individual fixing can be effected using the appropriate torque stop and stator coupling. Connection can be made either via a cable or with an M12 connector.

A further plus is offered by the green LED display, used for reference point recognition. This makes start-up considerably easier.  A red LED display warns of error conditions, simplifying diagnosis during maintenance.

The CANopen® versions offer the latest encoder profiles with many additional functions. Whether position, speed or working area, the user decides which information will be available as process data, thanks to variable PDO mapping in the memory.
Thanks to LSS services for configuration of the node address and baud rate via CIA DS 305 V2.0, start-up is fast and error-free, with no need to set switches. The node address, baud rate and termination can be programmed via the bus.

The compact method of construction and the technical characteristics of the new devices allow users to use these devices in areas where up till now absolute encoders were not employed. Moreover the encoders boast an attractive price/performance ratio, ruggedness and long service life.

The inclinometer IS40 from Kübler permits 2-dimensional inclinations to be measured. Different versions are available for the measuring ranges ±10°, ±45° or ±60°. The compact, rugged construction, high degree of shock resistance, high IP67 protection rating as well as the wide temperature range from -30°C to +70°C all make this sensor the ideal angle measurement device in harsh industrial environments, especially for vehicle technology, solar installations, cranes and hoists and commercial vehicles. 

The small design, just 30mm x 20mm x 50mm, requires a minimum of installation space and can thus be mounted easily virtually anywhere. Connection is fast and error-free via an M12 connector.

The resolution is up to < 0.05° and the repeat accuracy is from < 0.2 % of the measuring range. The sensors have either a voltage output of 0.1 to 4.9 V or a current output of 4 to 20 mA.

The  new high-quality draw wire systems from Kübler expand on their proven economical standard draw wire systems with solutions for demanding applications from 0.25m up to 40m measuring length.

The core of a draw wire device is a drum mounted on bearings, onto which a wire is wound. Winding takes place via a dynamic spring mechanism using a constant force spring, which allows for a high traverse speed of up to 10m/s and high acceleration of up to 140 m/s2; this proves ideal for dynamic applications and offers a long service life of approx. 2 million complete cycles.

The construction is particularly robust and unaffected by environmental influences thanks to its titanium-anodised aluminium housing. The wire is made from stainless-steel with a diameter of 0.5mm and is thus exceptionally hard-wearing. The wire exit is free from wear thanks to a diamond-polished ceramic guide.
The wide temperature range from -20°C to +85°C as well as the optional IP67 protection rating permit use in difficult environmental conditions.
 
The draw wire system is suitable for various sensors and encoders with analog outputs  (0 to 10V, 4 to 20mA, potentiometer), incremental (push-pull, RS422), absolute (SSI, BISS) and Field bus (CANopen®, Profibus, DeviceNet, EtherCat) interfaces.

The systems have a linearity of up to 0.05% and can be supplied on request together with the relevant calibration certificate.
Mounting is effected quickly using just 2 screws. The versatile housing technology allows for various mounting options. Connection is via either cable or connector.