With the new Sendix F5868 and F5888 encoders, Kübler complements its F multiturn family products range with robust high-resolution CANopen encoders with a through hollow shaft up to 15 mm for a compact size of only 58 mm. This through hollow shaft leaves, for example on drives, many possibilities for other motor options located behind the encoder. These gearless optical encoders are based on the innovative and patented Intelligent-Scan-Technology™. Besides many other CANopen functionalities, this encoder also features a Universal Scaling Function (USF).

The new encoders of the F58 series are used for example for measuring the rotation angle of booms or upper structures mounted on vehicles. Typical applications may be found for example in the Mobile Automation sector, but these new encoders can be used also in other applications with CANopen communication.

The USF function prevents the occurrence of an error at the end of the physical resolution of an encoder when a scale factor is active. In such a case, it mat happen that the division of the physical limit by the programmable total resolution results in a figure that is not an integer. The USF function corrects automatically this error in the encoder when the end of the measuring range is reached. This way, no measuring error can occur in case of endless boom rotation in both directions.

The complete integration of the singleturn and multiturn functionality on an OptoASIC makes this encoder 100 % insensitive to magnetic fields. With its multiturn and singleturn resoltion of 16 bits each, this encoder reaches a high total resolution of up to 32 bits, ensuring its compatibility with the CANopen profile. The Kübler Sendix F5868 and F5888 encoders support the latest CANopen communication profile in compliance with DS 301 V4.2.

At the Hanover Fair 2013 Kübler will be exhibiting the latest generation of Sendix absolute EtherCAT encoders that boast the shortest bus cycle time for EtherCAT currently available. With a position update within 62.5 μs these new EtherCAT encoders from Kübler are faster than other devices on the market, which – though also able to send data with the same speed – are merely repeating the old position.

The shorter cycle time with the new Sendix absolute EtherCAT encoders allow customers to implement highly dynamic systems with EtherCAT Fieldbus technology. A wide temperature range of – 40 °C up to + 85 °C, as well as a high level of shock resistance of up to 2,500 m/s² and high vibration resistance up to 100 m/s² qualify the devices for use also in extremely harsh environments. Integrated functionalities such as speed calculation and Work Area States make the implementation of these values in the controller unnecessary. The customers thereby receive more precise results and do not have to write lines of code to implement these values in the controller.

The latest Slave-EtherCAT stack from Beckhoff, Version 5.01, has been integrated into the new Sendix absolute EtherCAT encoders and in addition the latest CANopen profile 3.2.10 from 18th February 2011 has also been implemented. Moreover the devices offer dynamic mapping.

Along with the scaled position the raw data position can also be mapped as a process value, also the sensor temperature in °C and the speed calculation with sign are mappable values. Four units can be selected for the speed calculation: Steps/sec, Steps/100ms, Steps/10ms as well as RPM. By means of Gating Time the time interval can also be set, via which the speed value can be interpolated. Two Work Area State Registers permit the calculation of Work Area States and thus very close-to-process results. A further benefit arises when downloading the parameters to the encoder, during which a comprehensive plausibility test is carried out.

With the new EtherCAT encoders from Kübler the customers can count on modern devices with fully developed technology that can reliably withstand the tough demands placed on such sensors during operation – a decisive point for manufacturers of EtherCAT based systems, for whom high safety and availability of the plant are indispensable.

Optical fibres always show their advantages when very long distances have to be bridged, or when energy cables or other electromagnetic sources are located in the immediate vicinity. The optical fibres are characterised by their total insensitivity to interfering electromagnetic radiation. In addition, they allow high bandwidths and can cross very long distances, which quickly become very expansive when using copper lines.

The Sendix Heavy Duty H120 encoder with the special HD-Safety-Lock™ structure has proven itself in applications under extreme conditions, on large motors or for the accurate rotary speed measurement on generators. This encoder has accurate and particularly reliable optic sensors, which means that it is 100 percent insensitive to magnetic influences. Even seawater cannot harm its shock and vibration-resistant housing. Resistant materials, a wide temperature range from -40°C to +100°C and the high protection levels IP66 or IP67 master the harshest environmental conditions.

It was thus logical to complement this robust Heavy Duty package further with the optical fibre, which guarantees the same high safety level also for signal transmission. Thanks to their noise immunity, the optical fibres can be routed without any problem in the immediate vicinity of energy cables or other electromagnetic sources. Cable routing could not be easier; and, thanks to the innovative connection technology, it is particularly quick to install.

Suitably complemented, the Sendix H120 encoder with optical fibre connection becomes an optical fibre system in which everything fits perfectly: the encoder is compatible both with the Kübler optical fibre incremental receiver module and with the Kübler optical fibre cable/connector system.

Functional Safety has been at the top of the agenda for the Kübler Group for many years and it has, especially since the arrival of the revised version of the EU Machinery Directive 2006/42/EC, also been main area of focus amongst the company’s customers. With the new SIL2 incremental encoders and SIL2 absolute encoders from its Sendix SIL family, the sensor expert is now rounding off the lower end of its range of SIL encoders. The new products will have their first showing to the technical trade visitors at the Hanover Fair 2013.

Since 2009 Kübler has already been able to offer certified encoders from its Sendix-SIL family for applications up to SIL3 or PLe and in 2012 it expanded the top end of its range with ATEX encoders for hazardous areas. Now with the new devices Kübler boasts a integrated portfolio of certified encoders from its Sendix SIL family with SIL2 and SIL3, which can also be used in applications up to PLd or PLe according to the EN ISO 13849-1 standard.

Based on the high demand for SIL2 certified encoders for Functional Safety in the automation sector, Kübler sees excellent prospects for its new products. When monitoring position and motion with encoders from the Sendix SIL family, traditional sensors such as proximity switches and/or limit switches can be dispensed with, which can considerably reduce installation costs.

Because of their exceptional ruggedness, the Sendix SIL encoders offer additional protection beyond that of Functional Safety. With their extra sturdy bearings in the Safety-Lock™ Design these encoders demonstrate a particularly high level of resistance to vibration and installation errors.

The safety control family Safety-M that was especially designed for drive monitoring has been expanded with new variants. Thanks to the additional safe inputs and outputs, even more complex tasks can now be addressed in the area of Functional Safety.

The compact, modular Safety-M safety control system can monitor up to two independent axes simultaneously and/or in conjunction with each other. The devices are freely programmable for the safe processing of drive-related safety functions as well as of EMERGENCY STOP switches, two-hand operator controls, light barriers, operating mode selectors, etc. Complex motion monitoring tasks are also possible when both axes are combined.

Up to two safe encoder connections can be implemented. 14 safe inputs, two safe analogue inputs and three safe shut-off channels are available.

For safe speed and/or position detection 1-encoder solutions (for example, with Sendix SIL encoders) and, to a limited extent, 2-encoder solutions (a combination of any encoder technologies) are supported. The devices have a complete range of speed and position-related safety functions for drive monitoring acc. to DIN EN 61800 integrated in the firmware (e.g. SS1, SS2, SOS, SLS, SDI, SLA, SSM, SCA, SBC, EDM, SLT, SMT).

The function-chart oriented Software SafePLC offers a comprehensive library for pre-configured safety sensors and command devices.
The basic unit comes with 14 safe input lines and 3 cut off channels, comprising 1 safe relay output and 2 signal outputs. Moreover, the 4 analogue inputs allow for integration into complex environments. A notable feature is the cross-shorting monitoring. Contact multiplication or contact amplification by means of external contactors in conjunction with integrated monitoring is also possible.

The encoder interface supports TTL, HTL, SinCos, SSI, resolvers und proximity switches.
Simple operation is possible by means of a coded status display via the 7-segment display on the front and status LEDs as well as by the Quit, Start and Reset buttons also on the front.

The modules can be expanded up to a max. 65 safe I/Os by means of the integrated backplane bus (connector can be snapped on to top-hat rail). Expansion modules with up to 8 relay outputs allow, for example, for safe electronic cam switches. Optional field bus interfaces (bus modules for PROFIBUS, PROFINET, CANopen, EtherCAT and DeviceNet) permit integration into existing networks.

The patented Intelligent-Scan-Technologie™ of the F-Multiturn encoder family from Kübler, which has received several awards, has now been used in an encoder of the 58 mm standard type, thus allowing its use in additional applications with higher bearing loads. The variants with hollow through shafts of up to 15 mm will make it possible to use them for larger drives without causing any problems. The new Multiturn encoder series distinguishes itself by its high reliability and a particularly good resolution. The Singleturn resolution reaches up to 17 bit, the Multiturn resolution up to 24 bit, so that the encoder achieves a total resolution of 41 bit.

An extremely stable zinc die cast housing and the robust Safety-Lock™ bearing design will ensure the highest reliability not only on the mechanical side, but also on the electronic side, since both the Singleturn and Multiturn functionalities are completely integrated into one OptoASIC. This makes the encoder 100% magnetically insensitive, even more so, since the Singleturn and Multiturn scanning works contactless and is free from wear.

With its clock frequency of up to 2 MHz SSI and 10 MHz BISS, a data update within less than 1 µs as well as additional incremental outputs, the encoder will facilitate highly precise position sensing with a high-resolution feedback in real time. The SET button and status-LED, a wide range of assembly/installation accessories as well as cable and plug-in solutions will ensure the encoder's simple, fast and correct installation and commissioning.

The bearing-free encoder system with the Limes reading head and magnetic rings, as well as the linear measuring system with Limes reading head and magnetic bands, are non-contact systems, which have been specially developed for exacting environmental conditions and for installation conditions where space is tight.

In addition to the standard IP67 measuring head the Limes family now offers a new sensor head specially designed for use outdoors. This has a very sturdy aluminium housing with a stainless-steel cover and protection levels of IP69k, IP68 and IP67. The special encapsulation technology provides excellent resistance to humidity. Special tests such as tested resistance to cyclic humidity according to EN60068-3-38 and to damp heat according to EN60068-3-78 substantiate this. Together with its wide temperature range and UV-resistant cable, the system offers the highest levels of reliability for all applications outdoors.

The very compact system can be accommodated in the smallest installation spaces. Setup of the system is particularly easy due to the large tolerances of up to 1 mm (this applies both to the distance between the band and the reading head as well as for lateral misalignment).

A built-in red diagnostic LED indicates the index pulse or gives a warning if the tolerances are exceeded, in order to satisfy each application in the best way possible.
The index pulse available on the magnetic band allows for fast re-determining of the position after a breakdown or maintenance.
Rings and bands can be customized within a wide spectrum of different geometries to ensure perfect implementation into the application. On request reference signals can be incorporated or ready to be installed magnetic bands with installation kits can be supplied.

Kübler is offering a special service to its customers for the inclinometers in its IS60 series, a service unique in the market. The inclinometers can be ordered ready parameterized to a customer's specific requirements. This allows the user to install the inclinometer in his application without first having to set it up and configure it. This saves time and installation costs, as well as avoiding errors during installation. All the customer-specific parameters are stored in the internal non-volatile memory.

The inclinometer IS60 for CANopen field bus networks measures 2-dimensional inclinations. Depending on the version, measurement ranges of ±10°, ± 45° or ± 60° are possible. The IS60 has an extraordinarily compact and robust plastic housing. This is also substantiated 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 include the excellent resistance to shock and vibration as well as a high sampling rate and bandwidth. Two M12 plug connectors ensure a secure connection.

This is the ideal inclinometer for use in harsh industrial environments and impresses with its high resolution and accuracy, as well as its parameterizable vibration suppression. The calibration accuracy (at 25° C) is ± 0.1°.

The Kübler Group is one of the leading suppliers of position and motion sensors. Eight group members and 50 distributors support this international alignment. The company has given great attention to the subject of safety for years now. No wonder, therefore, that Kübler is nowadays considered the pioneer in the field of functional safety. Impressive testimony thereto: The sensor technology specialist marketed its first certified SIL encoder two years ago.

Undoubtedly a milestone, but in view of the European Machinery Directives it becomes more and more obvious that the maximum level of safety cannot be achieved with certified components alone. The matter is much more complex. The user therefore requires more and more system solutions – with systems from one source only. Kübler has responded to this demand and offers an effective top-class package for functional safety in a combination of encoders and safety modules that has never been on the market before.

Encoder SIL 5873

When selecting the right encoder for functional safety purposes, "togetherness" is crucial, because safety will be achieved by the intelligent interaction of encoder, control and actuator.

Being SIL3 / PLe certified, the Sendix SSI/BiSS absolute encoders are now available with an additional sine/cosine incremental output and the Sendix incremental encoders in Sin/Cos design. This puts them in a top position among the components of a safe plant.

Safe absolute encoder

The encoder types of the 58x3SIL range will provide an absolute and an incremental signal. The absolute position will be transmitted in the form of a digital SSI or BiSS data word. In the case of the singleturn variants 5853SIL and 5873SIL, the resolution ranges between 10 bit and 17 bit, depending on the variant. Compared with the singleturn variants 5853SIL / 5873SIL, the multiturn variants 5863SIL / 5883SIL are equipped with an additional drive to record absolute positions larger than 360°. It requires 12 bit to capture the number of revolutions. The incremental position will be provided by way of an analogue sine/cosine signal, with the resolution amounting to 2 048 sine/cosine periods per revolution.

Sendix SIL absolute encoders will gain safe information about the absolute position from the control that counts the incremental pulses and compares the result thus achieved with the absolute position that has also been provided by the encoder. In the case of the incremental Sendix SIL, however, the control will monitor the validity of the analogue sine/cosine signals – that are offset to each other by 90° – with the help of the function sin² + cos² = 1.

During plant operations:
The reported position will be verified by comparing the digital position data with the sine/cosine signals which the control continuously counts and compares.

When switching on and off the plant:
Before the plant is switched off, the control will store the absolute position value. When re-starting the plant, the control will compare the stored value with the absolute value that has been newly measured after the re-start. If both values are identical, the position will be safe. If the position values are not identical, the position will not be safe and need to be verified anew.

Safe incremental encoder

The encoder types of the 58x4SIL range will provide an incremental signal. The incremental position will be provided in the form of an analogue sine/cosine signal, with the resolution amounting to 1 024 or 2 048 sine/cosine periods per revolution.

Safety afforded from the mechanical construction

Mechanical faults, such as a breakage of the rigid torque stop with its torque pin or the encoder dropping off the motor shaft, will be excluded by mechanically overdimensioning the components of our safety encoder. Apart from providing functional safety, Kübler Sendix SIL encoders offer additional protection thanks to their special robustness. They feature a well-proven and reliable interface and distinguish themselves by their ability to withstand high mechanical and electronic loads: with extra stable bearings in the Safety Lock™ design, a particular accuracy and a long service life. With their maximum degree of protection IP67 and magnetic insensitivity thanks to optical scanning, Sendix SIL encoders will ensure "perfect safety". Both the incremental and the absolute encoders for functional safety will only be safe in combination with a safe control which can monitor the functions mentioned above. Both encoders have been certified for applications up to SIL3 or PLe by the ifa (Institut for Arbeitssicherheit [Institute of Work Safety], formerly BGIA).

Perfect interplay of the Safety-M module with Sendix SIL encoders

Safety Module MSP1.

A wide range of safety functions can be implemented with these encoders in combination with the Safety-M modules from Kübler. Again, these modules distinguish themselves by their high safety standards and integration potential. They are therefore suitable for applications up to PLe pursuant to EN 13849 or SIL3 pursuant to EN 61508, and, being equipped with a safe and type-approved logic control, they conform to the Machinery Directive 2006/42/EC. Besides, the Safety-M modules feature all the integrated safety functions required for monitoring the drive pursuant to EN 61800-5-2.

Thanks to their modular design and the interface for all conventional fieldbus systems, they can be universally used and are fully in line with the respective requirements. In order to ensure the highest possible diagnostic coverage (DC), the Safety-M modules monitor the sine/cosine signals on the basis of the function sin² + cos² = 1, as mentioned above. The safety module will compare the internal position gained from the incremental signals with the encoder's absolute value, so that safe information about the position can be ascertained, also after the plant had been reenergised.

Sendix SIL encoders and the safety module MSP1 will create an effective system for functional safety.

Machines are equipped with a large number of speed-controlled or position-controlled drives. There is a considerable danger potential inherent in some of these movements, from which the user needs to be protected. Major protective measures in this connection are light barriers or safety enclosures, but also a restriction of movements by limit switches that will deactivate the drive. A motionless, reenergised drive will mean that the conditions are safe. However, it may well be necessary that a person must stay inside a machine's danger zone during on-going operations, in order to, say, clear a fault. This will, of course, require an extension of the safety function to the movement of the machine by way of a safely reduced speed, a safe working area or a limitation of the torque. This, in turn, will considerably increase the benefit from the plant. Limit switches may become superfluous in connection with safe positioning and the scope of the original safety control can be reduced.

Apart from gaining extra functions this may also lead to cost savings, although the encoder will also have to satisfy additional requirements. This will often necessitate the use of a further encoder, which is redundant to the motor encoder. A rather cost-intensive solution. It is therefore desirable to have the motor encoder designed as a safe encoder that can be used up to PLe. A further separate encoder will become superfluous and the space required will remain the same. This again turns out to be a considerable cost and installation benefit for the user.

Safe drive monitoring

Safety functions for the sensor/actuator processing will considerably simplify the programming. As an example, the entire programming efforts for the logical/time-based comparison of multiple inputs from the safety sensors will become superfluous. Instead, the necessary processing will be speedily and safely selected via the peripheral configuration menu. Each input and output element will appear in the program editor as a function block only. They have already been reduced to a single logic signal.

Conventional safety controls will be restricted to logic processing or the reduced word processing of data. It will be difficult in this way to implement the safe drive monitoring, as required by the European Machinery Directive. The Kübler Group, on the other hand, has taken great care that its Safety-M modules will also ensure safety in the future. New requirements can now be satisfied speedily and efficiently with the safety functions for drive monitoring that are integrated in the firmware. Irrespective of the drive technology, they offer all functions for drive monitoring pursuant to EN 61800-5-2 and, in addition to that, practice-oriented functional upgrades. This applies to single and multiple axis operations alike, to simple inverters or high-quality servo-drives as well as electric, hydraulic or pneumatic drives. The safety functions that are integrated into the firmware can be easily used in every industrial sector.

Safety is – not least since the EU Machinery Directive 2006/42/EC – an "integral part of the construction of drives". The Kübler company has been well-known as a trailblazer in this sector for many years. Firstly because of components such as the certified Sendix SSI absolute encoders with additional SinCos incremental output as well as SinCos versions of its incremental encoders. And secondly because of its system solutions, since safe individual components alone do not lead to a safe total application.

Only an optimal combination of safety sensors and safety monitoring modules can offer reliable solutions. Such a combination is available in the form of the Kübler Safety-M modules and the Sendix SIL encoders, which together allow for the simple implementation of a safe drive monitoring system. With this Kübler is able to offer an overall package for Functional Safety from a single source.

Sendix Heavy Duty H120 encoders with the HD-Safety-Lock™ construction were specially designed for use with large motors and for the precise determination of the speed on the generator in wind turbines.

Resistant materials, incl. seawater resistant housing, wide temperature ranges from -40°C to +100°C and a high protection level (IP 66 + IP 67) as well as a high shock (2000 m/s2, 6 ms) and vibration resistance (150 m/s2, 10 ...2000 Hz) ensure they remain unaffected by the harshest environmental conditions. The innovative connection technology enables simple quick installation.

Simple and quick installation HD-Safety-Lock™ Hollow-shaft

Heavy Duty hollow shaft design of the latest generation is extremely robust and has an integrated shaft isolation.

• Extremely robust flange mounting due to screw-on housing
• Extremely robust bearing construction due to
  • mechanically interlocked bearings
  • use of very large highly robust bearings
  • large bearing span
• Maximum level of protection against dust and humidity due to
  • shielding cover disk on the shaft
  • high quality radial shaft seal
• Bearing design incorporates integrated isolation (isolating inserts not required), tested up to 2.5 kV for high running accuracy
• Metal to metal connection for slip free mounting

The encoders of the Sendix H120 family – a wide variety of versions for every installation situation.

There are three shaft attachment solutions:

1. Tapered hollow shaft 1:10 with central fixing – for highly accurate direct connection to the application shaft.
2. Cylindrical blind hollow shaft Ø 12 mm or 16 mm with central fixing – the standard mounting solution for generators.
3. Through hollow shaft from Ø 16 mm to 28 mm (unique on the market) – the flexible mounting solution for all cases.

Also three connection options

1. Connector or cable connection for fast error-free connection of the encoder.
2. Terminal box connection with plug-in spring terminal connectors, which guarantee an easy cable connection and a high safety level. And also a connection cover rotatable through 180° for the highest level of flexibility when installing the encoder.
3. Optical fibre connection for the highest degree of security during signal transmission, even over very long distances.

Time is money. This applies especially to cost-intensive industrial plants. Every even short downtime has a negative impact. And the always repeated start-up times add up and become cost-intensive interruptions. No wonder then that people looked for a technical solution to reduce these times. And they found it.

TThe Fast Start Up (FSU) allows now to start up a system in much less than a second. The Profinet encoders from Kübler make this quick start possible.

What a difference with respect to the equipment used until now. Without FSU, starting up a Profinet system with all the field devices participating in the communication requires about ten seconds. Too long and too expansive. In the case of applications such as highly complex industrial robots, it must be possible to carry out for example a tool change much faster, since these changes have direct influence on the processing cycles. Flexibility in production is essential within the timed cycle of an assembly line. In short: it must be possible to manufacture quickly and flexibly various vehicle types. The Sendix Profinet encoders from Kübler make this possible. They support FSU by storing remanently the parameters that have been determined during the first Auto-Negotiation/Auto-Crossover. They also store remanently the IP address. Moreover, the internal start-up after a reset also guarantees speed thanks to the use of a performant Embedded operating system.

Time is saved also during control, since Ezturn ensures a very easy testing of the defined parameters and setting of the preset values.

But, in spits of the increased speed, the functionality of the sensor has not been reduced. Kübler's Sendix Absolute family implements the whole encoder profile according to "Profile Encoder Version 4.1" and "Identification & Maintenance Functionality in Version 1.16" (IM 0, 1, 2, 3 and 4).

Another plus: Kübler offers the customers Profinet encoder-specific components for the STEP7 environment.

These encoders support the Isochronous-Real-Time-Mode, also called IRT Mode, and are therefore ideal for real-time applications. Implementation is easy, thanks to the simple "Plug-and Play" installation with the help of the "Ezturn for Profinet" software supplied with the encoder, which also allows a quick and simple update of the software of the encoder. This firmware update allows expanding the features of the encoder without having to disassemble it. Result: also in this case, the production cycle does not need to be interrupted.

To ensure a quick and error-free start-up, all parameters can be programmed via the bus. The bus terminal cover is equipped with 3 x M12 connectors for a quick, simple and error-free connection. The standard Ethernet interface ensures a direct link, for example from the laptop to the encoder.

Thanks to the "Safety-LockTM" bearing structure, the Sendix Profinet singleturn and multiturn encoders guarantee highest safety. The large interlocked, widely spaced bearings ensure stability in case of vibrations and confer a robustness that even accepts incorrect installation, avoiding machine stoppages and repair work. This also reduces considerably the downtimes. The sturdy die-cast housing, with its protection up to IP67 and the wide temperature range of –40°C to +85°C, also allow using these encoders for outdoor applications.

Visual warning and alarm signals advise of sensor faults, undervoltage or over-temperature. Fault diagnosis is therefore much simpler, allowing the measures necessary to correct the problem to be taken without delay, avoiding long machine downtimes.

The Sendix Technology ensure, through robust housing technology, wide temperature range and sturdy mechanical Safety-Lock™ design, a high reliability and a long service life.

The strong die-cast housing of the Sendix encoders has extra thick walls. It is fastened to the encoder flange by multiple crimping. The die-cast housing has a very strong base, onto which the connector flange is fastened with four screws. The high protection (up to IP69k) and the wide temperature range from -40°C to +90°C allow outdoor use without any problem.
The Sensor-Protect™ design of the magnetic Sendix encoders allows, thanks to fully encapsulated electronics, the highest protection IP69k. Thanks to the separate mechanical components with mechanically protected shaft and labyrinth seals, no additional protection is required in case of steam or high-pressure cleaning.

Although it has already proved itself in harsh environments, the Sendix encoders family has been tested and certified according to the IEC 68-2-11 standards about resistance to the effects of salt-spray water over a period of up to 672 hours – the highest test level.

The high certification level for the Sendix encoders gives further reliability for a high level of resistance against corrosion.
The Sendix encoders offer higher reliability and longer service life, as well as a very sturdy, rugged bearing construction, as a result of the Kübler Safety-Lock™ technology. Encoders with Safety-Lock™ tolerate installation errors and high loads on the shaft, such as occur with wide temperature fluctuation or vibration. Interlocked, positive-fitting bearings, large bearing spans and a special assembly technique make a contribution here.
The Sendix encoder family comprises optical and magnetic encoders. The product portfolio offers incremental, absolute singleturn, absolute multiturn and fieldbus encoders.

The Limes measuring system with bands or rings is a non-contact system designed especially for outdoor use and for very high reliability in the field.

The though solid aluminium housing with a stainless steel cover, the protection levels up to IP69k, the special potting process, the withstands to cyclic humidity according to moisture test as per EN60068-3-38 and to damp heat test as per EN60068-3-78 ensure outstanding resistance to condensation. Additionally the wide temperature range, plus UV-resistant cables give to the system highest reliability in Solar plants such as CSP – parabolic trough applications.

The very compact system can be accommodated in the smallest installation spaces. Setup of the system is particularly easy as the tolerance for distance and misalignment between band and measuring head is up to 1 mm. A built-in diagnostic LED indicates the index pulse or gives a warning if the tolerances are exceeded. The index pulse available on the magnetic band allows for fast position recovery after downtime or maintenance.

Rings and bands can be customized within a wide spectrum of different geometries to have an optimal fit for the application. Also application specific index pulse references can be realised upon request as well as ready to be installed magnetic bands with installation kits.

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°.

Also 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.

Kübler a étendu sa gamme de produits. Les nouveaux modules de sécurité pour la surveillance d'entraînements constituent un élément de plus dans le domaine de la sécurité fonctionnelle. Qu'il s'agisse de la construction de machines ou d'installations, de la technique des procédés, de la production ou du stockage et du transport, les modules Safety de Kübler garantissent le plus haut niveau de sécurité. Grâce à leur structure modulaire, chaque utilisateur peut choisir la solution correspondant exactement à ses besoins en termes de sécurité de déplacement, en position et/ou en vitesse (selon DIN EN 61800). Les modules peuvent être étendus, depuis un simple relais de survitesse jusqu'à la commande de sécurité complète. Ces appareils sont librement programmables pour le retraitement sûr de barrières lumineuses, de surveillances de portes, de boutons d'arrêt d'urgence, de commandes bimanuelles, ainsi que de fonctions de sécurité spécifiques aux entraînements.

Les modules Safety sont disponibles dans les versions suivantes :
Safety MS1: vitesse, 1 axe
Safety MSP1: vitesse et position, 1 axe
Safety MS2: vitesse, 2 axes
Safety MSP2: vitesse et position 2 axes
En outre, divers modules bus sont disponibles, comme CANopen ou Profibus.

Ces modules sont les seuls modules de commande ayant intégré la fonctionnalité d'un variateur d'entraînement sûr complet et qui disposent en outre, en combinaison avec des codeurs, d'un examen CE de type. La programmation graphique à l'aide de symboles est très simple, tout comme le paramétrage. Celui-ci peut être réalisé lors du montage ou sur le terrain, sans exiger d'adaptation du logiciel. La validation du logiciel fait également partie d'une commande sûre. Les modules Safety-M permettent à cet effet l'impression d'un compte-rendu de validation qui doit être vérifié, pointé et signé. Le fournisseur du logiciel, ayant ainsi répondu à son devoir de précaution, est déchargé de sa responsabilité.

Les caractéristiques techniques d'un coup d'œil :

• Vaste bibliothèque pour des capteurs et des contrôleurs de sécurité préconfigurés
• Interface codeur paramétrable pour 4 x Inc-TTL/SIN-COS/SSI/Resolver en face avant et 2 x HTL via bornier
• Appareil de base avec 14 entrées sûres et 3 sorties sûres, dont 1 sortie par relais sûre et 2 sorties de signalisation
• Possibilité de multiplication des contacts ou de renforcement des contacts à l'aide de contacteurs externes avec surveillance intégrée
• Nombreuses fonctions de diagnostic intégrées dans le firmware
• Indication d'état codée à l'aide d'un affichage frontal à 7 segments et de LED d'état
• Touche Quit-/Start-/Reset utilisable en face avant
• Extensible à max. 65 E/S sûres grâce à un bus de paroi arrière (connecteur enclipsable sur profilé chapeau)
• Interface pour bus de terrain en option (module d'extension pour ProfiBus/ProfiNet, Devicenet)

Le Groupe Kübler appartient aux leaders dans le domaine des capteurs de position et de déplacement. Les huit entreprises membres du Groupe et ses 50 partenaires commerciaux sont la preuve de son orientation internationale. Depuis des années déjà, l'entreprise accorde une attention toute particulière à la sécurité. Il n'y a donc rien d'étonnant à ce que Kübler soit considéré aujourd'hui comme un pionnier justement dans le domaine de la sécurité fonctionnelle. Un exemple impressionnant : il y a deux ans, l'entreprise a commercialisé le premier codeur certifié SIL.

Sans aucun doute une étape importante, mais, au vu des directives européennes sur les machines, il devient de plus en plus évident qu'il n'est pas possible d'atteindre la maximum de la sécurité simplement en faisant appel à des composants certifiés. Ce domaine est beaucoup trop complexe pour cela. Et c'est pourquoi l'utilisateur demande de plus en plus souvent des systèmes – des systèmes d'une seule main. Kübler a réagi à ces demandes et présente, avec sa combinaison de codeurs et de modules de sécurité, une offre globale performante et unique en son genre pour la sécurité fonctionnelle.

Module Safety-M SP1

Il n'y a pas de limites aux possibilités d'utilisation : surveillance sûre d'un déplacement sur un ou plusieurs axes, retraitement sûr d'informations fournies par des barrières lumineuses, surveillance de portes et de verrouillages, arrêt d'urgence, commande bimanuelle – le système de Kübler permet une mise en œuvre simple, rapide et économique de toutes les tâches techniques de sécurité.

Ces modules se distinguent par leur haut niveau de sécurité et leurs grandes capacités d'intégration. Ils conviennent à des applications jusqu'à PLe selon EN 13849 ou SIL3 selon EN 61508. Ces commandes logiques ont fait l'objet d'un examen CE de type et répondent aux exigences de la directive sur les machines 2006/42/CE. En outre, les modules Safety-M disposent de toutes les fonctions de sécurité intégrées requises pour la surveillance d'entraînements selon EN 61800-5-2. Grâce à leur structure modulaire et à leur interface pour tous les systèmes de bus de terrain usuels, ils peuvent s'utiliser de manière universelle et s'adapter à tous les besoins.

La combinaison parfaite, les modules Safety-M et les codeurs Sendix SIL

Les modules Safety-M assurent un fonctionnement idéal lorsqu'ils sont mis en œuvre avec les codeurs pour la sécurité fonctionnelle SENDIX SIL de la société Kübler. Ces codeurs sont disponibles en trois variantes principales : d'une part SENDIX SIL incrémental avec des signaux purement sin/cos et, d'autre part, SENDIX SIL absolu monotour/multitours avec information absolue SSI supplémentaire. Ces codeurs sont certifiés pour une utilisation jusqu'à SIL3 ou PLe. Afin d'offrir une couverture de diagnostic (Diagnostic Coverage DC) maximale, les modules Safety-M surveillent les signaux sinus/cosinus à l'aide de la fonction sin2 + cos2 = 1. De même, afin de garantir une information de position sûre, même après une coupure de courant, le module de sécurité compare la position interne obtenue à partir des signaux incrémentaux avec la valeur absolue fournie par le codeur.

Une utilisation simple et polyvalente

Le codeur Sendix SIL et le module Safety-M SP1 forment un système efficace pour assurer la sécurité fonctionnelle.

Grâce aux fonctions intégrées pour le retraitement de signaux numériques émis par des capteurs, des dispositifs de commande et des canaux d'arrêt, la réalisation de tâches de sécurité typiques est très confortable. Mais les modules Safety-M offrent encore bien plus : la surveillance sûre de déplacements répondant aux exigences les plus sévères ne pose aucun problème. Et les fonctions de surveillance intégrées, avec de nombreuses extensions développées pour des applications pratiques, assurent une résolution simple et transparente des tâches à réaliser.
Grâce à leurs fonctions technologiques intégrées, les modules Safety-M garantissent une réalisation rapide et sans problèmes des tâches techniques de sécurité requises. Ils disposent d'une vaste bibliothèque de fonctions pour le prétraitement de capteurs (entrées) ou d'actionneurs (sorties). Cette bibliothèque peut également s'utiliser justement pour une surveillance sûre d'entraînements. Une combinaison simple des fonctions d'entrée, de surveillance et de sortie au moyen de blocs logiques permet de créer de manière très rapide et transparente des fonctions de sécurité même étendues. Toutes les fonctions sont ouvertes quant aux capteurs, entraînements et actionneurs utilisés. Quelle que soit la technologie d'entraînement mise en œuvre, moteur électrique avec variateur vectoriel ou de fréquence, actionnement pneumatique ou hydraulique, les modules Safety-M constituent la solution orientée pratique pour la gestion de la sécurité dans la construction de machines et d'installations.

Une surveillance sûre des entraînements.

Les fonctions de sécurité pour le retraitement de capteurs/d'actionneurs offrent une simplification sensible de la programmation. Ainsi, par exemple, le travail de programmation pour la comparaison logique/temporelle d'entrées multiples des capteurs de sécurité disparaît. En lieu et place, les opérations de retraitement nécessaires sont sélectionnées de manière rapide et sûre à l'aide du menu de configuration de la périphérie. L'éditeur de programme n'affiche chaque élément d'entrée et de sortie que sous la forme d'un bloc de fonction. Ces éléments sont déjà réduits à un seul signal logique.

Les commandes de sécurité conventionnelles se limitent à un retraitement logique ou à un retraitement réduit de mots de données. Elles ne permettent que difficilement la réalisation d'une surveillance sûre des entrainements, comme l'exige la directive européenne sur les machines de par la loi. Par ailleurs, la société Kübler a mis l'accent, avec ses modules Safety-M, sur le respect des obligations de sécurité futures. Les fonctions de sécurité intégrées dans le firmware pour la surveillance des entraînements permettent l'implémentation rapide et efficace de nouvelles tâches. Indépendamment de la technologie d'entraînement, ils offrent toutes les fonctions selon EN 61800-5-2 pour la surveillance des entraînements et, en plus, des extensions de fonctions nécessaires dans la pratique, et ce pour un fonctionnement mono ou multiaxes, avec les variateurs les plus simples ou les servomoteurs de haute qualité, ainsi que pour les commandes hydrauliques ou pneumatiques. Quel que soit le domaine, les fonctions de sécurité intégrées dans le firmware sont faciles à utiliser.

Programmation, paramétrage et validation aisés

La programmation graphique à l'aide de symboles a une structure très simple et n'exige pas de connaissances de programmation particulières. Il est possible, après la programmation, de paramétrer les modules. Cette possibilité est très pratique, notamment si un module doit être utilisé lors du montage pour différents types de machine. Les paramètres spécifiques à la machine peuvent se modifier lors du montage ou sur le terrain, sans aucune adaptation du logiciel. La validation du logiciel fait également partie d'une commande sûre. Les modules Safety-M permettent à cet effet l'impression d'un compte-rendu de validation qui doit être vérifié, pointé et signé. Le fournisseur du logiciel, ayant ainsi répondu à son devoir de précaution, est déchargé de sa responsabilité.

L'une des nombreuses possibilités surveillance sûre de déplacements sur 2 axes.

Possibilités de raccordement des modules Safety-M.

La sécurité joue un rôle-clé dans le domaine de l'automatisation. Kübler prend cette réalité en compte et fait constamment évoluer ses produits dans cette direction. Ses efforts ont de toute évidence été couronnés de succès, car l'entreprise peut maintenant présenter une combinaison inédite jusqu'ici. Pour la première fois, la sécurité fonctionnelle et l'homologation ATEX sont réunies dans un codeur. Davantage de sécurité serait impossible !

Dans les atmosphères explosibles, comme dans l'industrie chimique ou pétrolière, les codeurs doivent répondre à des exigences spéciales en termes de protection, car déjà la plus petite étincelle peut avoir des conséquences dramatiques. Kübler propose désormais, spécialement pour ce genre d'applications, de nouveaux codeurs Sendix absolus et multitours avec homologation ATEX. Ces codeurs ATEX monotour et multitours équipés d'« enveloppes antidéflagrantes » sont homologués pour les zones 1, 2, 21 et 22. Ils peuvent également s'utiliser dans des applications maritimes : leur boîtier et leur bride sont réalisés en aluminium résistant à l'eau de mer.

Ces codeurs ATEX sont résistants aux chocs et aux vibrations ; ils travaillent de manière flexible avec une résolution atteignant 17 bits (monotour) et 29 bits (multitours). Grâce à leur indice de protection de IP67 et leur large plage de températures de -40 à +60° C, ces codeurs ATEX restent étanches même dans des environnements sévères et garantissent une excellente sécurité contre les pannes sur le terrain. Leur construction compacte, avec une profondeur de montage de 145 mm seulement, un diamètre de 70 mm et un départ de câble à gain de place complète leur large palette de possibilités d'utilisation dans des atmosphères explosibles.

La certification SIL3 / PLe est disponible pour les codeurs Sendix absolus SSI/BiSS avec sortie incrémentale Sin/Cos supplémentaire et pour les codeurs Sendix incrémentaux en exécution Sin/Cos. Les codeurs Sendix SIL absolus garantissent la sûreté des informations de position absolue en permettant à la commande de compter les impulsions incrémentales et de comparer le résultat avec la position absolue –également fournie par le codeur. Pour les codeurs Sendix SIL incrémentaux, la commande surveille la validité des signaux Sinus/Cosinus analogiques - décalés de 90° entre eux - à l'aide de la fonction sin²+cos² = 1.

Mais la sécurité n'est pas obtenue seulement au moyen de signaux sûrs; il faut également assurer une liaison mécanique sûre. Les codeurs SIL garantissent celle-ci par un surdimensionnement des éléments de montage qui permet d'exclure toute défaillance.

Au-delà de la sécurité fonctionnelle, les codeurs Sendix SIL de Kübler garantissent une protection supplémentaire grâce à leur robustesse hors du commun, à des paliers Safety Lock™ e xtrêmement résistants et à une précision et une durée de vie exceptionnelles. Avec leur indice de protection IP67 et leur insensibilité magnétique grâce à une lecture optique, les codeurs Sendix SIL garantissent une "sécurité intégrale".

En outre, Kübler fournit désormais - conformément à la directive sur les machines 2006/42/CE – les valeurs MTTFd pour les codeurs standards les plus importants. Les utilisateurs peuvent ainsi effectuer leurs propres calculs selon DIN EN 61800-5-2 et DIN EN ISO 13849.

Kübler a franchi une nouvelle étape dans le transfert de données avec l'implémentation de l'interface BISS-C pour les codeurs absolus Sendix. L'interface libre BISS-C (Bidirectionnelle/Série/Synchrone) est basée sur un protocole destiné à la réalisation d'une interface en temps réel pour une communication purement numérique, série et sécurisée entre un contrôleur et des capteurs ou des actionneurs. Le protocole BiSS a été conçu pour des applications industrielles exigeant de hautes vitesses de transmission, la sécurité (CRC), la souplesse d'utilisation et un minimum de travail pour sa réalisation.

Les avantages sont extrêmement importants et concernent tous les domaines, comme la technologie, la qualité, les coûts ou la logistique. L'interface BISS-C est une solution en temps réel pour la position et la vitesse, qui est de manière typique 100 fois plus rapide que les systèmes de bus de terrain standards. Il est en outre possible de prédéfinir une valeur de prépositionnement pour le codeur à l'aide du logiciel (API) ou d'une touche de positionnement. Cette Interface est entièrement numérique; son câblage nécessite moins de fils et son blindage est plus simple. Cette interface bidirectionnelle permet une mise en service automatique.
Comme il s'agit d'une interface libre, tout le monde peut bénéficier sans restriction aucune des avantages techniques de BiSS-C. Pour ce qui est des coûts : BiSS-C peut être implémenté dans les commandes standards usuelles sans modification du matériel.

En plus de ces nombreux avantages, un autre point revêt une importance déterminante : le service. Kübler est à votre disposition à cet égard aussi : ses propres experts vous assisteront de leur savoir-faire lors de la mise en œuvre de votre projet.

Kübler a développé une solution innovante pour la fixation des codeurs absolus monotour sur des entraînements sans réducteurs (entraînements directs). Son grand avantage par rapport aux techniques de montage utilisées jusqu'ici réside dans sa mise en place rapide et sans difficultés grâce à un dispositif anti-rotation novateur. Unr touche Set pour une mise en service rapide et l'interface absolue libre BiSS-C – ainsi qu'une piste incrémentale SinCos – constituent d'autres points forts de ces codeurs.

Cette solution offre aux constructeurs d'ascenseurs sans réducteurs de nouvelles possibilités de réduction sensible du travail de montage, et ce aussi bien en production qu'en utilisation. Cette simplicité d'installation est permise par l'arbre conique qui équipe le codeur, qui garantit un accouplement direct et de haute précision avec l'entraînement direct. Cet arbre conique est serré sur l'arbre moteur à l'aide d'une vis centrale.
Autres spécificités techniques :

• Résolution monotour jusqu'à max. 17 bits avec interface BiSS-C ou SSI
• Touche de mise à zéro en option, pour une mise en service aisée
• Piste incrémentale SinCos avec 2048 imp./tour
• Mise en place rapide grâce au dispositif anti-rotation novateur
• Départ de câble tangentiel pour un raccordement optimal

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.

Les codeurs Sendix avec interface CANopen Lift sont disponibles en version monotour et multitours, avec boîtier réseau pour une intégration optimale dans des réseaux CAN complexes ou avec raccordement fixe - et directement par contacteur SUB-D - pour un raccordement simple au système de commande.

L'interface CANopen Lift (Profil DS 417 V1.1) permet une implémentation particulièrement simple de la commande de l'ascenseur, avec les fonctions spéciales correspondantes telles que :

• Car Position Unit
• 2 appareils virtuels : pour la position en pas de mesure absolus (steps) et pour la position sous la forme d'une information absolue de la course en mm
• Numéro d'ascenseur programmable
• Réglage indépendant de l'adresse de nœud en liaison avec les identifiants CAN
• Facteur pour le calcul de la vitesse (p. ex. circonférence de la roue de mesure)
• Temps d'intégration de 1 ... 32 pour la valeur de la vitesse
• 2 plages de travail avec 2 limites supérieures et inférieures et les états correspondants des sorties
• Gestion étendue des erreurs pour la lecture de la position avec contrôle de température intégré
• Mapping PDO variable dans la mémoire. Position, vitesse, accélération, zone de travail - c'est l'utilisateur qui décide de quelles informations il a besoin en temps réel.

En outre, les LED et la touche SET permettent une mise en service et des diagnostics aisés. L'adresse de nœud et la vitesse de transmission sont réglables à l'aide de commutateurs rotatifs/DIP ou par logiciel.

Deux appareils en un :
Les codeurs pour bus de terrain Sendix absolus CANopen sont également disponibles avec une piste incrémentale TTL supplémentaire. Il est ainsi possible de réaliser en même temps, avec un seul codeur, un positionnement via le réseau CAN et un retour direct de la vitesse de rotation via la piste incrémentale, ce qui permet d'économiser le coût et l'espace requis pour un second codeur. Le codeur fournit, en parallèle avec la sortie CANopen, un autre signal compatible TTL avec 2048 impulsions par tour. Il existe, en plus de la sortie CANopen, une interface RS422 avec les signaux A, /A, B, /B.

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".

La complémentarité est essentielle lors de la sélection du codeur pour la sécurité fonctionnelle, car c'est la combinaison intelligente du codeur, de la commande et de l'actionneur qui garantit la sécurité. Les codeurs absolus Sendix SSI/BiSS équipés d'une sortie Sin/Cos supplémentaire et les codeurs incrémentaux Sendix en version Sin/Cos sont désormais disponibles avec l'homologation SIL3 / PLe, ce qui leur permet de jouer un rôle de tout premier rang parmi les composants de sécurité d'une installation.

Les codeurs absolus Sendix SIL permettent d'obtenir une information de position absolue sûre : le contrôleur compte les impulsions incrémentales et compare le résultat à la position absolue fournie par le même codeur. Par ailleurs, dans le cas des codeurs incrémentaux Sendix SIL, le contrôleur vérifie la validité des signaux sinus/cosinus analogiques décalés de 90° à l'aide de la fonction sin²+cos² = 1.
En outre, les codeurs incrémentaux et absolus Sendix homologués SIL assurent une liaison mécanique parfaitement sûre dans l'application. Des éléments de fixation robustes, largement dimensionnés, garantissent une fiabilité à 100%.

Cependant, pour les codeurs Sendix SIL de Kübler, la sécurité va bien plus loin. Ils sont munis d'une interface robuste et fiable et sont en mesure de résister à des charges mécaniques comme électriques élevées, grâce à des paliers particulièrement résistants conçus selon le design Safety Lock™. Le résultat : un niveau de précision extrême et une longue durée de vie. Grâce à leur indice de protection élevé, IP67, et à leur insensibilité aux champs magnétiques – permise par la lecture optique – les codeurs Sendix SIL assurent une sécurité "tous azimuts".

Conformément aux exigences de la Directive 2006/42/CE sur les machines, Kübler fournit également les valeurs MTTFd pour ses codeurs standard les plus importants. Ces valeurs permettent à l'utilisateur d'effectuer lui-même ses calculs conformément aux normes DIN EN 61800-5-2 et 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.

Le H100 est le plus grand codeur de Kübler ; grâce à lui, l’entreprise s’attaque à de nouveaux domaines d’utilisation. Le codeur Heavy-Duty Sendix H100 est un codeur incrémental extrêmement robuste. Il peut être équipé en option d’un commutateur de vitesse mécanique garantissant la protection contre les vitesses excessives. La structure spéciale HD-Safety-Lock™ des roulements garantit leur résistance à des charges très élevées, jusqu'à 300 N en axial et 400 N en radial.

Les surcharges temporaires typiques des codeurs, dues par exemple à un effort axial important lors de l’installation ou à de fortes vibrations, sont largement tolérées, ce qui évite des détériorations prématurées, voire la défaillance du codeur sur le terrain. Ce codeur convient ainsi parfaitement à des applications dans l’industrie lourde comme les aciéries et le secteur des grues. Même les conditions d’utilisation les plus sévères n’affectent pas ce codeur résistant, car il a été conçu justement pour résister à ces conditions. Ainsi, la grande distance entre les roulements du palier, comme les roulements eux-mêmes, extrêmement grands et robustes, augmentent sa charge admissible et sa durée de vie.

Le roulement libre placé du côté de la bride évite les déformations internes. L’unité de lecture mobile assure une qualité de signal constante même en cas de dilatation thermique importante, l’unité capteur étant découplée mécaniquement du boîtier.

La très large plage de températures, de -40°C à +100°C, l’indice de protection IP66, la matière protégée contre l’eau de mer, un joint double sur l’arbre (un joint frottant contre l’humidité et un joint labyrinthe supplémentaire contre la pénétration de poussière, assurant la protection du joint frottant contre les jets d’eau) garantissent une résistance élevée contre les influences extérieures négatives. Et, enfin, la rainure de clavette de l'arbre garantit une liaison mécanique positive parfaite avec l'application. Mais ce n’est pas que du point de vue de sa résistance que le codeur Heavy-Duty Sendix H100 répond aux exigences les plus élevées : ses fonctionnalités aussi répondront aux besoins les plus divers. Les bornes à ressort débrochables innovantes dans la boîte à bornes assurent un raccordement aisé et rapide des câbles. Ces bornes permettent un montage du codeur séparé du câblage électrique. L’installation sur le terrain est ainsi facilitée, et le remplacement du codeur en cas d’intervention est grandement simplifié. Aucun outil n’est nécessaire pour raccorder le câble aux bornes à ressort. La boîte à bornes peut pivoter de 180°; offrant différentes possibilités de raccordement, ce qui constitue un grand avantage lorsque l’espace disponible est limité, en évitant de plier un câble. Le H100 se distingue en outre par un grand nombre de résolutions et de vitesses de commutation.

Les nouveaux codeurs monotour et multitours Profinet de la robuste gamme Sendix complètent la grande famille de codeurs absolus Sendix de Kübler. Ces appareils intègrent l’ensemble du profil codeurs selon le « Profil Codeur Version 4.1 » et la « Fonctionnalité d’Identification & de Maintenance Version 1.16 » (IM 0, 1, 2, 3 et 4).

Ces codeurs supportent le mode isochrone en temps réel, appelé aussi mode IRT, et conviennent ainsi de manière idéale aux applications en temps réel. Grâce au découplage de la communication en temps réel de la communication standard (TCP/IP), le mode IRT offre une solution en temps réel pour toutes les applications à hautes performances, comme par exemple les applications synchronisées. Le temps de cycle court, <= 1ms, permet une utilisation flexible dans de nombreuses applications.

Il faut également noter la possibilité d’étendre facilement les caractéristiques du codeur par de simples remises à jour de son programme, sans démontage du codeur. Les facteurs d’échelle, les présélections et de nombreux autres paramètres sont programmables via le bus Profinet.

Il est possible d’émettre des valeurs de position, de vitesse, de température ainsi que d’autres informations sur l’état du codeur.

Tous les paramètres sont programmables via le bus, pour une mise en route rapide et sans erreurs. Le boîtier réseau est équipé de 3 connecteurs M12 pour un raccordement rapide, simple et sans erreurs. La résolution est de 16 bits pour les codeurs monotour, la résolution totale atteint 28 bits pour les codeurs multitours.

Grâce à leur structure « Safety-Lock™ » des paliers, les codeurs monotour et multitours Profinet Sendix garantissent une sécurité maximale. Le grand palier bloqué, avec ses deux roulements largement espacés, assure la stabilité en cas de vibrations et confère aux codeurs une robustesse qui pardonne même des erreurs de montage, évitant ainsi des immobilisations pour la réparation des machines. Grâce à la technologie Opto-ASIC à haute intégration de Kübler, l’électronique et les capteurs optiques sont réduits à un petit nombre de composants, ce qui augmente la fiabilité des appareils. Le boîtier résistant, moulé sous pression, avec un indice de protection atteignant IP67, et la large plage de températures de -40°C à +80°C permettent l’utilisation de ces codeurs également à l’air libre.

Des signaux visuels d’alarme et d’avertissement informent en cas de défaut du capteur, de tension trop basse ou de température trop élevée. Le diagnostic des défauts est ainsi sensiblement facilité, les mesures correctives nécessaires peuvent être prises sans délai, évitant de longues périodes d’immobilisation.

Leurs nombreuses possibilités d’utilisation différentes ont assuré le grand succès des inclinomètres de la gamme IS dans de nombreuses branches d’activité. Ceux-ci sont ainsi mis en œuvre notamment dans la technique des véhicules, des grues et du levage, ainsi que pour les installations solaires et les véhicules utilitaires.
Cette flexibilité repose sur une technique soigneusement élaborée, qui distingue également le dernier-né des produits de cette gamme : l’inclinomètre IS60. Ce capteur destiné aux réseaux de bus de terrain CANopen mesure des inclinaisons dans deux dimensions. Selon la version, sa plage de mesure est de ±10°, ± 45° ou ± 60°.
Le capteur est équipé d’une interface standardisée CANopen qui permet une configuration et une mise en route aisées. En outre, l’ensemble des paramètres est sauvegardé dans la mémoire des paramètres interne.

L’IS60 est muni d’un boîtier en matière plastique extraordinairement compact et robuste, qui assure un indice de protection IP68. Des températures glaciales, une chaleur insupportable ou d’autres conditions environnementales sévères ne sont pas un problème pour cet appareil. La plage de températures va de -40°C à +80°C, avec une résistance élevée aux chocs et aux vibrations, une haute vitesse d’échantillonnage et une grande largeur de bande. Deux connecteurs M12 garantissent la sécurité des raccordements. Ce dispositif de mesure angulaire idéal pour un environnement industriel rude séduit en outre par sa haute résolution et sa grande précision, ainsi que par son amortissement des vibrations programmable. La précision de calibrage est de ± 0,1° à 25°C.

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 7720 3903-27

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.

La complémentarité est essentielle lors de la sélection du codeur pour la sécurité fonctionnelle, car c'est la combinaison intelligente du codeur, de la commande et de l'actionneur qui garantit la sécurité. Les codeurs absolus Sendix SSI/BiSS équipés d'une sortie Sin/Cos supplémentaire et les codeurs incrémentaux Sendix en version Sin/Cos sont désormais disponibles avec l'homologation SIL3 / PLe, ce qui leur permet de jouer un rôle de tout premier rang parmi les composants de sécurité d'une installation.

Les codeurs absolus Sendix SIL permettent d'obtenir une information de position absolue sûre : le contrôleur compte les impulsions incrémentales et compare le résultat à la position absolue fournie par le même codeur. Par ailleurs, dans le cas des codeurs incrémentaux Sendix SIL, le contrôleur vérifie la validité des signaux sinus/cosinus analogiques décalés de 90° à l'aide de la fonction sin²+cos² = 1.
En outre, les codeurs incrémentaux et absolus Sendix homologués SIL assurent une liaison mécanique parfaitement sûre dans l'application. Des éléments de fixation robustes, largement dimensionnés, garantissent une fiabilité à 100%.

Cependant, pour les codeurs Sendix SIL de Kübler, la sécurité va bien plus loin. Ils sont munis d'une interface robuste et fiable et sont en mesure de résister à des charges mécaniques comme électriques élevées, grâce à des paliers particulièrement résistants conçus selon le design Safety Lock™. Le résultat : un niveau de précision extrême et une longue durée de vie. Grâce à leur indice de protection élevé, IP67, et à leur insensibilité aux champs magnétiques – permise par la lecture optique – les codeurs Sendix SIL assurent une sécurité "tous azimuts".

Conformément aux exigences de la Directive 2006/42/CE sur les machines, Kübler fournit également les valeurs MTTFd pour ses codeurs standard les plus importants. Ces valeurs permettent à l'utilisateur d'effectuer lui-même ses calculs conformément aux normes DIN EN 61800-5-2 et 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 Septembre 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 Octobre 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 Octobre 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.