AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator

Electronic position switch ERC 40 enclosed in robust housing for use in extreme ambient conditions. The new solution offers customers the following benefits: Higher switching accuracy when approaching end position limits, Less downtimes, User-friendly calibration via preset input, Save and import parameter data sets, Time-saving safety check (switch test function), Additional real-time position data (4 – 20 mA output), Reduced type variety and costs for backup devices, Integrated status monitoring (temperature, speed, voltage, system limits and so on) with active signal output for time-saving identification in the event of a fault condition

Home Case Studies AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator

AMPN 41 provides safe position monitoring at slewing gear of a bucket wheel excavator

Home Case Studies Pilger mill in tube rolling mills – hot and cold pipe detection

Pilger mill in tube rolling mills - hot and cold pipe detection

Highly precise replacement solution for inaccurate mechanical cam limit switches
PROFIsafe via PROFINET for direct connection to the safety PLC
Certified safety ensures uncomplicated acceptance test
High levels of availability even in mining operations subject to extreme environmental conditions

Before: Frame construction for the slewing gear between the superstructure and substructure of the excavator with several mechanical cam limit switches for position monitoring.

Challenges

It is planned to equip a bucket wheel excavator with the latest automation and safety technologies as part of a complete modernisation project. To achieve the required safety categories identified by a risk assessment, safe position values are required for both slewing gear mechanisms between the superstructure and substructure of the excavator as well as between the discharging boom and the substructure of the excavator. By contrast standard position values are sufficient to determine the position of the crawler tracks.

After: The safety certified absolute encoder AMPN 41 provides safe position actual values to the safety plc.

The Hübner Giessen solution

Equipped with a safe PROFINET interface that uses the PROFIsafe protocol the AMPN 41 multiturn absolute encoders to be installed at the slewing gear mechanisms are certified for applications up to Safety Integrity Level (SIL) CL3 to EN 61508 and PL e to EN ISO13849. That saves the user having to provide separate verification of the functional safety of the position sensors. Absolute encoders AMP 40 equipped with a standard PROFIBUS interface will be installed at the crawler tracks. Robust, form-locked process coupling and the dedicated constructional design of the encoders for use in mining operations subject to extreme environmental conditions ensure position data is reliably made available at the safety level required for the respective application.

Case Study Number

TP3

Challenge

The increasing flexibility of production lines requires a high adaptability of sensors. Continually changing object geometries, different temperatures and very high radiation or surrounding temperatures are no rarity.
In a pilger mill those rough conditions can be found, among others in the production of seemless steel pipes. The raw steel blocks, each weighing a few tons are heated up first in a round oven at a temperature of 1300 °C.
After descaling of the surface, the steel block is prepunched in a hole press with a strength from a converted 2000 t. In the next sloping rolling mill the growing pipe rotates between two rollers that are positioned at an angle to each other. The punching is widened to the size of the mandrel diameter.

Previous solution / Competitor product

N/A

Solution

The sensor that was installed at this application is the HMD OKA 2038.38 G with tube OL 19.
The signal of the infrared sensors controls the movement of centering device and abutment. The point of view is restricted by the tube and prevents disturbances by steam in the cooling phase.
An optimum adaptation to the operating conditions is given due to the adjustable response temperature. The HMD with self-learning response temperature (Auto-Teach function) is suited to continually changing conditions.
The compact sensor with a stainless steel housing can withstand surrounding temperatures of up to 75° C. The use of a cooling jacket raises this up to 200° C.
Alternatively sensors with fibre optic cables are available which permit an application at ambient temperatures up to 600° C without cooling.

Customer Benefits

Maintenance-free
High temperature stability
Recognition of hot objects at big distances
Self adjustment with Auto-Teach or step switch for the response temperature

Product Part number

OKA 2038.38 G

Brand

Proxitron

Accessories

Piros swivel stand HM2
Tube OL 19
Pilot light unit (for alignment) DAK 308 + OL 26
Different cable lengths (e.g. 15 m)

Customer Testimonial

compared to previous solution or competition

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