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Press releases Sensor Technology


670

22.11.2016
Maximum flexibility and minimum delivery time for Sendix incremental encoders.

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Whatever the application, the optimal encoder must both allow easy, error-free and fast installation and have the appropriate resolution and interface. Moreover, the encoders must be particularly robust in order to operate reliably even in harsh environments.

These requirements mean one thing for encoder manufacturers - they have to offer a wide range of variants, so as to prevent the user from making any compromises in its configuration or making himself changes at the encoder.

This requires:
Perfect mechanical connection to the shaft of the application, perfect electrical connection thanks to the right cable, with the right length and the right connector. Without forgetting the right resolution and the right interface.
Offering and manufacturing this range of variants in shortest time poses a great challenge to encoder manufacturers. Otherwise, users must fall back on a few types kept in stock.

Kübler has taken up this challenge and increased significant-ly its range of variants of the incremental Sendix 5000 / 5020 encoders, and even completed this with a unique service - 24one delivery promise.

This makes more variants in terms of flanges, connectors, cables, cables with connectors, resolutions and important options such as e.g. salt spray protection available to the user.
If the user makes use of the 24one delivery promise, the configured incremental encoder is manufactured and made ready for dispatch the same day.

The 24one delivery promise is the result of lean and simplified processes and of the optimization of the organization all along Kübler's order delivery process. All this is backed up by the Kaizen culture practised for many years.

The added value for the user is obvious.
  • Tailor-made encoder for the application
  • More flexibility thanks to minimum manufacturing time
  • More planning security
  • In case of emergency, machine downtime is reduced to a minimum.



671

22.11.2016
For the drive technology Flattest multiturn encoder

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The challenge, in the drive technology, is to develop increasingly compact drives - which nevertheless have to show always higher performance, better dynamics and improved energy efficiency. This leads to new requirements also for the encoders. The new requirement, besides accuracy, robustness and reliability, is "the more compact, the better". To allow designing more compact drives, also the encoder solution must be adapted accordingly.

This is why Kübler developed a totally new product - the Sendix F5883 in the Motor-Line version. An optical hollow shaft encoder with a mounting depth of only 43 mm. Compared with the multiturn encoder Sendix 5883 equipped with mechanical gear, this new version allows saving 27 mm. This is a milestone in an industry that has to house its components even in smallest gaps. This opens up new possibilities when dimensioning the geared motor and installing the encoder in tight mounting spaces.

The Sendix F5883 in the Motor-Line version is based on the mature Sendix platform, which stands for robustness and reliability. Thanks to the Intelligent-Scan technologyTM, this totally optical encoder is highly accurate and 100% insensitive to magnetic fields. This encoder has excellent EMC characteristics.

The wide range of interfaces such as SSI, BiSS, SinCos, RS422 and Push-Pull ensure flexible connection to the frequency converters.
Thanks to its robust bearing structure in Safety-LockTM design, this encoder is particularly resistant to installation errors, shocks and vibrations.

This encoder is available with a through hollow shaft of up to 15 mm and clamping on the A and on the B side. It is therefore the optimal solution for all usual geared motor drive shafts.

The reduced installation depth of 43 mm, combined with a tangential cable outlet, makes the encoder easy to install in tight mounting spaces, and therefore the optimal solution for compact integration. This will contribute to the widespread use of multiturn encoders in geared motors - same installation depths for absolute and incremental encoders now make it possible.



673

22.11.2016
Predestined for tightest installation spaces! Bearingless encoders

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Filippo Zerbo
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What to do if even the installation depth of miniature encoders is too large and if installation space is limited? Which rotary measuring system could fit here? The answer is given by Kübler's bearingless encoders. With a minimum installation depth of 16 millimeters, these particularly compact measuring systems can be mounted quickly and easily in the tightest installation spaces.

Reduced size does in no case mean reduced safety or performance. So, thanks to a non-contact sensor technology, this system boasts a particularly high shock and vibration resistance. The absolute freedom from wear guarantees long service life and safe and durable operation. Expensive machine downtimes thus belong to the past. The sturdy housing and the high protection level up to max. IP69k allow operation even in harsh industrial environments. This combination is totally insensitive to soiling such as dust or liquids.

The absolute measuring system RLA50 allows resolutions up to 16,000 measuring steps per revolution. Versatility is ensured by the push-pull or RS422 interfaces available for RLI20 and RLI50. Regarding performance, rotary speeds up to 12,000 revolutions per minute are possible.

Installation takes place very quickly by slipping and screwing the ring on the shaft and positioning the reading head accordingly. Also solutions for pressfitting are available. The distance between the reading head and the ring has a tolerance of up to 1.5 mm and a maximum lateral offset of +/- 1 mm. The oblong holes provided on the sensor head allow particularly easy sensor adjustment. It can optimally positioned radially and axially.

The measuring system is designed for highest adaptability, offering various ring sizes up to a hollow shaft of 390 mm. Another advantage over encoders with bearings, which allow hollow shafts up to a maximum of only 42 mm.

Various mounting possibilities are available for optimal fastening of the magnetic ring on the drive shaft: press-fit, screwed flange or hub screw ring mounting.

Bearingless encoders are used in the drives technology. Their reduced installation depth allows a slim and compact motor design. The robustness and the technology of the measuring system ensure high reliability and long service life. In brief: High plant availability.

The bearingless encoders portfolio includes incremental (RLI) and absolute singleturn variants (RLA50) with SSI or CANopen interface.



674

22.11.2016
The standard for gearless drives Sendix 5873 Motor-Line encoder

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Filippo Zerbo
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Gearless drives, also known as direct drives, are used in the elevator technology for their high torque at low rotation frequencies and their smooth and silent operation. This leads to specific requirements for the used encoders: short control cycles with high resolution and reliability. Exactly these characteristics make the optical Sendix 5873 singleturn encoders in their Motor-Line version the ideal solution for direct drives.

Highest reliability and optimal travel confort are attributes for every elevator system. The right choice of the sensors is crucial here. The Sendix 5873 Motor-Line encoders convince both in terms of reliability and accuracy.
The tapered shaft with central screw and screw lock ensures a solid connection of the encoder and the drive shaft. These encoders feature a stator or expanding coupling and a tangential cable outlet with an optionally preassembled connector for simple and optimal installation.

The sturdy construction and the robust Safety-Lock™ design bearing structure are the basis of all Sendix encoders. This bearing structure protects against installation errors as well as against shocks and vibrations in continuous operation. This ensures the long service life of the encoder and its reliable use in the elevator system.
These encoders allow simple and fast commissioning thanks to their plug-and-play feature; they are provided with an electronic data sheet and they allow determining the direct drive rotor position thanks to the absolute singleturn information. This has the advantage to allow positioning the measuring system at a predefined position value.
High encoder accuracy is particularly important for optimal travel comfort. The Sendix 5873 Motor-Line encoders score here with their high control quality. Their fully digital BiSS interface with 21-bit resolution or with 17-bit resolution and additional 2048 SinCos periods per revolution ensure best drive control. Alternative product variants are also available for converters with SSi interface.

Advantages of the BiSS interface
The BiSS interface is a fully-digital bidirectional connection for absolute measuring systems. Therefore, BiSS is perfectly suited for dynamic axes with very high accelerations, constant speed control and best positioning accuracy possible.

The great advantage of the BiSS interface is its open source protocol for sensors, inverters and drives, offering e.g. high speeds (data rate up to 10 MHz) and a delay compensation for the optimal operation of the drive system. The selection of the components is not imposed by a licensed interface, but only by the requirements of the application, which results in more flexibility and higher costefficiency.



675

22.11.2016
Combining compactness and standard installation - The advantages of both features in one device.

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Kübler continues expanding its portfolio in the encoder branch. Its characteristics make the magnetic Sendix M58 multiturn encoder a particularly robust and accurate device. Moreover, the reduced mounting depth and the standard installation offer many advantages for very different applications.

This solid shaft encoder is based on the Energy Harvesting Technology, which requires less mechanical components than e.g. a multiturn encoder with gears. This is noticeable in terms of encoder cost-efficiency and reliability. The encoder operates wearfree and therefore durably.

The extremely robust Safety-LockplusTM Design bearing structure includes extra large bearings and an additional shaft seal protection. It thus absorbs shocks, vibrations and installation errors. The advantages for the user are high plant availability and encoder repair costs saving. The IP65 protection level and the wide temperature range of -40°C … +85°C also make this encoder suitable for demanding applications.

The encoder is mounted on a flange with a standard 58 mm size. The mounting depth of 59 mm is ideal for tight installation spaces. This saves installation costs. The Sendix M58 is available in Analog, SSI or CANopen variants. The maximum total resolution is 38 bits.

The scaleable measuring range is another advantage of the Sendix M38. Depending on the application, the analog output can be adapted to the total measuring range. This means e. g. that 0V on the voltage output corresponds to the starting value of the total measuring range (zero position) and 10V correspond to the final value of the total measuring range (max. 65536 revolutions).

The additional limit switch functionality allows setting limit values in the encoder. This allows e.g. achieving simple safety monitoring.

The magnetic Sendix M58 multiturn encoder is used in the following applications: general automation, logistics, metalworking and textile machines.



676

22.11.2016
Undeviating accuracy New generation of inclinometers.

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Filippo Zerbo
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Measuring the horizontal position of a fire truck basket or of a working platform; vehicle leveling for agricultural and forestry machinery; dynamic measurement of the elevation angle of the distributing boom on construction machinery for tunnel and mining and on heliostats in the solar branch - these are exactly the applications where inclinometers are required.

Kübler has been for many years one of the leading position and motion sensor manufacturers in the area of mobile automation. The company now completes its product portfolio for this area with a newly developed inclinometer.

In this area, the demands placed on the sensors always remain the same: accuracy, robustness and long service life. These demands led to the development of the new Kübler inclinometers.

Robustness and long service life: the high protection level IP67 and IP69k, the wide temperature range from -40°C up to +85°C, completed with the high shock resistance up to 100g and vibration resistance up to 10g ensure trouble-free outdoor use. Perfectly suited for the mobile automation and for reliable and longterm use.

Accuracy:
the new inclinometers allow measuring 2-dimensional inclinations of ±85° or 1-dimensional inclinations up to 360°. Their resolution reaches 0.01° and an absolute accuracy of ±0.4° is possible at a temperature of 25°C. The measuring principle is capacitive or MEMS.

Filter settings individually parameterizable via CANopen allow adapting easily the inclinometers to the application. The IN88 inclinometers are equipped with the CANopen interface, which belongs to the usual interfaces in mobile automation. The inclinometers are available in the variants with 1 M12 connector or with 2 M12 connectors. Supply voltage is 10…30 V DC. A Modbus version is also available.

The IN81 inclinometers are an analog variant with preset and teach function. They ensure optimal integration in the application.

Redundancy:
Thanks to their flat construction measuring only 80 mm x 60 mm x 23 mm, these inclinometers are particularly easy to mount, and they can be stacked on each other for use as a redundant solution.

These inclinometers are E1 and UL certified.

Benefits at a glance
  • Predestined for outdoor use thanks to robust construction and high protection level.
  • Highly accurate measurement - resolution 0.01°
  • Flat construction – space-saving
  • Easy installation and possible redundancy



677

22.11.2016
Perfect match Length measuring kit – Limes Kit TB

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Kübler demonstrates maximum flexibility with its linear measurement technology portfolio. A kit system including a spring encoder arm, an encoder, a measuring wheel (pulley) and a timing belt is available now. This allows the users to design their individual solution themselves or together with Kübler experts.

All requirements and needs of any application can be met with the Limes KIT TB measuring system. This is further underlined by the unlimited measuring range and the free choice of the encoder (incremental or absolute). The Kübler encoder used and the robust and temperature-resistant plastic timing belt ensure accurate measurement. The adjustable spring arm is easy to mount (mounting tolerances) and compensates unevennesses in the application, thus guaranteeing reliable and constant measurement. Various pulleys and timing belt variants are available. This makes the kit system the ideal solution whatever the application.

Limes Kit TB is the perfect combination of constant measurement, easy commissioning and long service life. And all this at attractive prices.



678

22.11.2016
Extremely robust and cost-effective Draw wire encoder D120 for outdoor applications. Measuring range 3-10 m

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Filippo Zerbo
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Kübler is known in many branches for its wide linear measuring technology portfolio. Premium quality and flexibility are the main features of this portfolio. In costsensitive branches the selection of the draw wire system is based mainly on robustness and cost-effectiveness. Kübler combined exactly these characteristics and added a new draw wire encoder family to its portfolio.

The structure of these draw wire encoders is both extremely robust and versatile. This is underlined by their high protection level reaching IP69k and their wide temperature range of -40°C ... +85°C. The stainless steel wire with various diameters from 0.5 to 1.5 mm and various wire fastening systems (clip, M4 thread and ring) are further highlights. These features ensure operation in extremely harsh environments. The housing is made of titanium-anodized aluminum. The versatility of these appliances also reflects in the choice of constructions with open, closed housing, or with perforated sheet metal cover. All these features ensure long service life and reliable operation - especially in toughest environments.

The D120 draw wire encoders are designed for a measuring range of 3-10 meters. The high linearity reaching ±0.1 % guarantees high performance …5 V, 0…10 V and 4 … 20 mA analog outputs, a potentiometer output and a CANopen interface are available.

Safety has also been taken care of. All outputs are available as redundant variants, a further advantage of these new draw wire encoders. They thus ensure high plant availability, saving costs and time.

Connection can be chosen, either with a radial cable (IP69k) or with an M12 connector.

The D120 draw wire encoders convince with their extreme robustness and high accuracy at competitive prices.



685

21.11.2016
Directly in the cloud: Industrial Ethernet encoders with OPC-UA interface

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Intelligent sensor networks form the backbone of Industry 4.0. Industrial Ethernet encoders can play here a particular key role, provided they are "equipped" accordingly. The sensors manufacturer Kübler equipped its Sendix F58 industrial Ethernet encoder family with the OPC-UA interface.
OPC-UA is establishing itself as an important interface within the framework of Industry 4.0, in particular for cross-system communication (from machine to machine and from machine to the cloud). OPC-UA can forward machine data and has the distinctive feature of describing these machines semantically in a legible way. It therefore meets an important requirement for Industry 4.0 communication.
Kübler's Sendix Industrial Ethernet encoders can be upgraded additionally with this interface. These encoders therefore also offer the OPC-UA interface in addition to classical industrial Ethernet interfaces such as Profinet, EtherCAT or EtherNet/IP.
The encoder transmits both protocols simultaneously using the same connection, which allows, with a simple switch, sending data to the control as well as e. g. to a web server or to the cloud. This allows sending very easily condition monitoring data such as the temperature, error messages, operating times, voltage supply to the cloud. Intelligent "predictive maintenance" can therefore be implemented very easily in your SCADA concepts. Since every web-capable handheld device can be used to carry out important settings, configuring the encoder through OPC-UA becomes very simple. Service technicians can this way use their smartphone to set e.g. the preset value, the working range, the resolution of the encoder.

The optical absolute Singleturn and Multiturn Sendix F58 EtherNet/IP encoders with a diameter of 58 mm have been designed for time-critical applications. In addition to supporting plant performance and availability, their specific features also greatly contribute to save time and costs.
Equipped with their robust Safety-Lock™ bearing design, these encoders withstand installation errors, shocks and vibrations. Position value transmission is 5 times faster than common market encoders, therefore ensuring more performance. RPI time is only 1 ms. This feature allows operating this encoder in time-critical applications up to a 1,000 Hz update frequency. The fast start-up is another strong point of the encoder. It takes place immediately after applying the supply voltage. Therefore, nothing stands in the way of an increase of plant performance, of plant availability and of the reduction of costsensitive standstills. Cyclic services allow fast and easy commissioning and configuration, saving costs and time.

Thanks to the implementation of DLR (Device Level Ring) a single cable break does not lead to plant stoppage. Ring redundancy is ensured. These absolute Singleturn and Multiturn Sendix encoders are available in solid shaft or blind hollow shaft version. The blind hollow shaft has a diameter of 15 mm. Their IP65 protection level and their wide temperature range from -40°C…+80°C allow operating these encoders reliably also in harsh environmental conditions. Thanks to their optical sensors, these devices are 100% insensitive to magnetic fields. Total resolution is 32 bits. The devices are ODVA-certified.

 



686

21.11.2016
Single-Cable Technology 2in1 – Energy and data transmission Significant costs and space savings.

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Filippo Zerbo
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The communication between the encoder and the processing unit is a decisive factor for the interference-free and reliable control of machines and plants.
This leads to the question of the suitable interface for the application. Safety-oriented interfaces and single-cable technology belong currently to the main innovation trends in the electrical drive technology. Kübler follows this trend with new encoder solutions. This sensors manufacturer early relied for its target branches drive and elevator technology on the fully digital special interface BiSS, predestined by its features for use as a bidirectional motor feedback system for linear and rotary axes. Today the company is convinced that it was totally right, as this open source protocol has in the meantime become integral part of these branches. The "BiSS-Safety" protocol expansions and the brand new single-cable technology allow realizing automation systems that meet all requirements in terms of Functional Safety and in the same time offer hitherto unknown flexibility and cost-efficiency.
Kübler is convinced that the safe transmission technology and the reduction to only one cable for connecting the motor and the drive controller will soon become a sector standard.

Drives technology as a driver for innovation

In Germany, the drives technology is in an enviable position. It has been highly profitable for two decades now and it is still growing above average, even with respect to the - also generally - very successful machinery and plant engineering. The drives technology has been for some time now the driver for innovation that has been initiating the determining optimization steps for many industries and applications.
Two disciplines are fighting together in this changing environment: on the one hand, in order to maintain the global competitiveness at the current high level, machine productivity must constantly be improved further, and the quality of the manufactured products must increase simultaneously. Another trend to be taken into account is the strengthening of environmental and safety awareness: machines must comply with strict safety standards, operate in an ever more energy-efficient way, and their added value must become globally more environmentally compatible. To meet these - partly opposite - requirements, all drive components must be optimized.
However, the real challenge lies with the drives and in the control and measuring technology.

Single-Cable Technology - An innovation offering real cost advantages

Cables and connectors are one of the main cost drivers in every automation architecture. The single-cable technology can contribute greatly to save material costs, installation work and not least space, by achieving power supply and data transmission through one single cable.
The tight mounting space inside of electrical drives requires compact sensors and optimized connection possibilities for their assembly. The single-cable technology allows transmitting energy and data through only one connection line, which leads to the mentioned significant costs saving. But not only the reduction of the costs related to the connector, the cable and the integration makes the single-cable technology so interesting. Space for routing cables is often very limited in the applications. In this case, besides the material costs, requiring only one cable is an advantage.
Kübler's single-cable technology is based on the proven RS485 hardware architecture - this architecture is a widely established standard in many frequency converters.

The interface is fully digital, open-source for the sensor and the drive system, SIL3- capable and perfectly suited for dynamic axes with very high accelerations, uniform speed control and best positioning accuracy possible.
With functions such as the electronic data sheet (EDS), saving of customer-specific application data, condition monitoring and connecting of external sensors, Kübler encoders with the single-cable technology are ready for the basic requirements of Industry 4.0.

Conclusion:
Clearly, in view of the wide range of available interfaces, many users are facing a difficult decision. For Kübler, the future of the electrical drive technology will be greatly influenced by the interface technology. The sensors manufacturer is convinced that, besides the 'Safety' topic, the 'single-cable technology' area will be determining for future applications. The costly and time-consuming routing of two cables to connect the motor and the drive control will in any case very soon belong to the past thanks to encoders with single-cable technology.