Heavy cranes

Kübler pulses for the heavy industry. Reliable and sturdy.

On oil platforms and offshore plants, in open-cast or underground mining machines, in crane installations and in steel plants - Kübler encoders operate reliably in heavy machinery in the harshest environmental conditions with dust, moisture and extreme temperatures and mechanical stress. Usually, in these unfriendly environments, high-accuracy sensors reach their limits.
This is not the case with Kübler - With its wide-ranging products portfolio, the Company boasts more than 50 years of experience in mechanical engineering and automation technology. Heavy Duty encoders and rugged compact encoders equipped with particularly robust bearings, wit the most modern housing technologies and many various communication interfaces (from analogue up to the real-time Profinet interface) are part of our wide heavy industry-specific products range.
Encoders for functional safety and optical fibre modules for the secure optical transmission of encoder signals over long distances complete the Kübler product range for these application fields.

Positioning and speed measurement for heavy cranes: Availability 24 hours a day

Gantry crane, container loading bridge crane, stacking crane... the requirements for automation and safety are increasing. Sendix encoders measure the position at the rope hoisting gear, at the trolley, both on rails and on tyres, and at the spreader. Only these robust and safe measuring devices allow the automatic positioning of the containers.

The lifetime and availability of the used sensors is of outmost importance for plants with high operating costs. For decades, Kübler sensors provide highest performances for gantry cranes in harbours and for underslung cranes in production lines or steel plants.

1. Trolley position
Sendix F36XX CANopen

2. Hoist speed
Sendix Heavy Duty H100

2. Hoist speed
Sendix Heavy Duty H120

3. Boom angle / end position
Sendix M3658 CANopen

5.-7. Spreader control system
Sendix 58XX CANopen

8. Travel speed
Sendix 5000/5020 Incremental

Sendix F36
Sendix Absolute Singleturn F3653 and F3673,
F3658 CANopen and F3678 CANopen.

Sendix Absolute Multiturn F3663 and F3683,
F3668 CANopen and F3688 CANopen.

Sendix F36XX CANopen

  • Safety Lock – Rugged bearings construction in a compact shape, 36mm
  • Highly accurate optical encoder without gear, insensitive to magnetic fields
  • 17 bit singleturn + 24 bit multiturn = 41 bit total resolution
  • Interfaces: SSI, CANopen, BiSS, additional incremental outputs RS422 and Sin/Cos
  • Optional: seawater-resistant

Sendix Heavy Duty H100 (shaft)

  • HD-Safety-Lock™ bearing construction for an extremely high bearing load capacity
  • Seawater-resistant material
  • Feather key fitting ensures positive fitting to the application
  • Safe overspeed protection by means of mechanical speed switch
  • Guaranteed availability thanks to the optional double encoder (twin encoder)
Sendix H120
Sendix Incremental H120.

Sendix Heavy Duty H120 (hollow shaft)

  • Bearing isolation up to 2,5 kV
  • Extremely high resilience (Dual protection of the shaft, IP66/67)
  • High shock (200 g) and vibration resistance (15 g)
  • Fastening arm on the flange or cover (device can be flexibly mounted)
  • Cable, plug-in connector, terminal box or optical fibre connection
  • Incremental encoder with up to 5000 ppr
  • Through hollow shaft up to Ø 28 mm
Safety-M basic modules.

Safety-M extension modules.

Safety-M safety modules

  • Compact safety control with integrated drive monitoring for up to 2 axes
  • Freely programmable for the safe processing of drive-related safety functions as well as of EMERGENCY STOP switches, two-hand operator controls, light barriers, ...
  • Complex motion monitoring tasks possible
  • Graphical programming interface
  • Optional fieldbus interface
Sendix M3658
Sendix M3658 CANopen.

Sendix M3658 CANopen

  • Compact singleturn encoder, diameter 36mm
  • Fully encapsulated electronics for outdoor applications in moist environments
    (-40°C, IP 69k)
  • Magnetic scanning for a high shock and vibration resistance
  • Status display·
  • Optional: seawater-resistant
Sendix 5858
Sendix 5000.

Sendix 58XX CANopen

  • Up to16 bit singleturn and 12 bit multiturn resolution
  • Safe operation with moisture and dirt
    (-40°C ... +90°C, IP 67)
  • High accuracy, insensitive to magnetic fields thanks to optical scanning
  • Status display and reset button in the cover
  • Optional: seawater-resistant
Sendix 5000
Sendix incremental 5000 und Sendix 5020.

Sendix 5000/5020 Incremental

  • Compact and rugged incremental encoder
  • Rugged Safety Lock™ bearing construction
  • Safe operation with moisture and dirt
    (IP67, -40°C ... +90°C)
Sendix SIL
Sendix Incremental 5814 FS2 / 5814 FS3 and 5834 FS2 / 5834 FS3.

Sendix Absolute Singleturn 5853 FS2 / 5853 FS3 and 5873 FS2 / 5873 FS3.

Sendix Absolute Multiturn 5863 FS2 / 5863 FS3 and 5883 FS2 / 5883 FS3.

Sendix SIL

  • Singleturn and multiturn absolute encoders and incremental encoders for functional safety with SIL3 certification
  • Interlocked bearings for high robustness, accuracy and long lifetime
  • IP67 protection level
  • Insensitive to magnetic fields thanks to optical scanning

Sendix Heavy Duty – technology for heavy industry

Thanks to the special HD-Safety-Lock™ construction, the Sendix Heavy Duty encoders are ideally suited for applications in heavy industry, such as steel works and cranes.
Resistant materials, wide temperature ranges and a high protection level ensure they remain unaffected by the harshest environmental conditions.
Their innovative connection technology enables simple quick installation.

Sendix Heavy Duty – The product family

Thanks to their special HD-Safety-Lock™ construction the Sendix Heavy Duty devices are an extremely rugged incremental family of encoders that are offered in a wide variety of models:
shaft, hollow shaft, with mechanical speed switch, as double encoder and with optical fibre module interface.
With their wide choice of connection options and fixing solutions, the encoders of the Sendix Heavy Duty family can be used in numerous application areas.

The Sendix Heavy Duty family at a glance

Sendix H100

Sendix Heavy Duty H100 H100 H100
Incremental shaft encoder Incremental shaft encoder with mechanical speed switch Incremental double shaft encoder

Sendix H120

Sendix Heavy Duty H120 Sendix Heavy Duty H120 Durchgehende Hohlwelle  
Incremental hollow shaft encoder Incremental hollow shaft encoder for connection to optical fibre modules  

A wide variety of versions for every installation situation

Fixing solutions H100

EURO RE0444 Flansch Welle ø 11 x 30 mm mit Passfederverbindung EURO RE0444 flange
Shaft ø 11 x 30 mm with feather key fitting

Fixing solutions H120

Sendix Heavy Duty H120 Konus-Hohlwelle mit Zentralbefestigung

Tapered hollow shaft 1:10
with central fixing – for highly accurate direct connection to the application shaft.

Sendix Heavy Duty H120 Zylindrische Sacklochhohlwelle

Cylindrical blind hollow shaft
Ø 12 mm or 16 mm with central fixing – the standard mounting solution for generators.

Sendix Heavy Duty H120 Durchgehende Hohlwelle

Through hollow shaft
from Ø 16 mm to 28 mm – the flexible mounting solution for all cases.

H100 Befestigungsarm Fastening arm
70, 100 or 150 mm
H100 Klemmkasten-Anschluss Stator coupling

Connection options H100

Terminal box connection
with plug-in spring terminal connectors (connection cover rotatable through 180°)

Connection options H120

H120 Kabelanschluss Cable connection
for space-saving mounting – the economical solution
H120 Steckeranschluss Plug-in connectors
for fast and error-free connection of the encoder
H120 Klemmkasten Terminal box connection
with plug-in spring terminal connectors (connection cover rotatable through 180°)
H120 Klemmkasten Optical fibre connection
highest degree of security, even over very long distances

Solutions for safety technology

Safe single components alone do not fully ensure a safe global application. Only the optimal interaction between safety sensors and safety monitoring modules offers reliable solutions, which will meet the necessary safety requirements.
The optimal combination of Kübler's Safety-M modules and Sendix SIL encoders allows the easy implementation of a safe drive monitoring system.

Safe monitoring of hoist and trolley position

krane Safety functions
  • Speed monitoring on the hoist
  • Monitoring of working areas on the main hoist or the auxiliary hoist
  • Safety relays instead of limit switches
  • Two-axis synchronisation monitoring in tandem operation
  • Positioning of crane and cross travel (anti-collision)
  • Monitoring of the whole drive train, comprising motor, drive, coupling and cable winch (speed ratio, gear backlash when reversing direction of rotation)
  • Safe relay outputs as replacement for cam switches or limit switches
  • Safe speed switch
Functional description
  • 1, 2 or 4 encoder inputs, absolute signal (SSI), incremental signal (Sin/Cos, HTL, TTL) or resolver signal
  • 14 safe digital inputs for further safety sensors (Emergency-stop, door switches, overload, etc.)
  • 2 safe analogue inputs for monitoring additional process variables
  • Modular expansion up to 58 safe digital inputs, 22 safe digital inputs/outputs, 9 safe relay outputs
  • BUS modules for communication with the main controller via PROFIBUS, PROFINET, EtherCAT, CANopen or DeviceNet
  • Simple graphical programming and parameterization during installation or in the field
  • Minimal space requirement, simple integration into existing control systems
Main advantages
  • The combination of encoder and safety module is certified for PLd / PLe applications
  • Using certified components for speed and position monitoring can reduce overall costs by eliminating redundant or multiple sensors
  • Using certified components and systems will dramatically simplify the safety assessment of the overall machine
  • Integrated load and position monitoring
  • By using certified encoders and controllers, limit switches (for drives) can be dispensed with and no mechanical adjustment of the limit switches is necessary

Complete encoder family for safety technology

Incremental SinCos Encoders
Sendix 5814 FS2 / 5814 FS3 (shaft)
Sendix 5834 FS2 / 5834 FS3 (hollow shaft)

Absolute Singleturn SSI / SinCos Encoders
Sendix 5853 FS2 / 5853 FS3 (shaft)
Sendix 5873 FS2 / 5873 FS3 (hollow shaft)

Absolute Multiturn SSI / SinCos Encoders
Sendix 5863 FS2 / 5863 FS3 (shaft)
Sendix 5883 FS2 / 5883 FS3 (hollow shaft)

In order to achieve safe incremental information with the encoder, the controller must monitor the validity of the analogue, 90° phaseshifted sine/cosine signals with the help of the function: sin² + cos² = 1.

In order to obtain safe information with the encoder regarding the absolute position, the controller counts the incremental pulses and compares the result with the absolute positions also provided by the encoder.

A 100% reliable mechanical connection is required for a safe function in the applications. Suitably sturdy fixing elements can help eliminate the risk of faults.

Complete family for safety drive controllers: Safety-M modules

Safe motion control for speed or position monitoring in multiaxis operation – the Safety-M modules allow you to implement your safety technology tasks in compliance with the Machinery Directive 2006/42/EC.

Independently from the drive technology, the Safety-M modules offer all functions according to EN 61800-5-2 for drive monitoring (as, for example, safe reduced speed, safe direction of rotation or safe position monitoring) and, in addition, practice-oriented function extensions.

The Safe PLC software offers user-friendly graphic programming with function chart and block functions.
A parameter editor allows simple parameterising by the end user. It could not be easier: the software generates a specific report for validation purposes.

Technologies for the heavy industry

Innovations from tradition. Kübler products benefit from 50 years experience in automation engineering. Over the years they have undergone ongoing development and been optimised for use in the heavy industry. Small details make a big difference. Our products feature many intelligent, high-quality extras, which offer our customers decisive advantages, whilst at the same time making a significant contribution to the high availability and safety of the machines.

Optical Multiturn Technology

100 percent resistant to magnetic fields - extremely compact design. Even strong magnetic fields, as occur in the vicinity of brakes or drive motors, pose no problems for the sensor technology of optical single- or multiturn devices. The technology dispenses with any components that may be susceptible to magnetic influences. As a result of the proven drive, the encoder has no need of a battery to store the number of revolutions.

Insensitive to interference: OptoASICs

The resistant Kübler OptoASIC technology offers a very high integration density of components. This means that, on the one hand, the reliability in the application can be increased significantly, and on the other hand the technology demonstrates quality EMC characteristics and shock resistance.

Well protected against dust and moisture

The sturdy, thick-walled die-cast housing of the Sendix encoders is press-fit stemmed several times on the encoder flange. The high protection level and the wide temperature range from -40°C to +90°C allow a safe outdoor operation. The die-cast housing is fitted with an extremely resistant base, on which the connector flange is screwed with four screws.

High temperatures

High heat resistance - combined with high rotational speeds - make the Sendix encoders the optimal solution for all applications in a high temperature environment. Also the used seals, cables and connectors withstand extreme temperatures.

Shock and vibration resistant

Kübler encoders avoid serious, expensive failures right from the start - even with increased levels of axial loading, shock and vibration. This can eliminate enormous service costs and expensive downtimes in applications worldwide.

Sea-water resistant versions

Although it has already proved itself in harsh environments, the Sendix family of devices has now been tested and certified to IEC 68-2-11 for resistance to the effects of salt-spray over a period of up to 672 hours - the highest test level. The high certification level for the Sendix encoders attests a high level of corrosion resistance.


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