The universal encoder system U-ONE®-SAFETY-Compact consists of a basic unit and directly attached switch or bus modules. All functions are integrated in a robust housing designed to meet the specific demands of heavy industry. Safety switching signals are provided according to position and speed based on a 13 / 15 bit resolution (max. 32768 rotations). It is possible to combine diverse bus interfaces as well as a 4 – 20 mA analog output or an incremental output according to application requirements. As a consequence, it is possible to replace several individual devices with a single compact device. The system-wide two channel architecture facilitates the implementation of safety functions up to Category 3 and Performance Level (PL) d as well as SIL 2.
Excavator/Hoist: U-ONE-SAFETY-Compact implements safety functions in open cast mining even without a safety PLC
Pilger mill in tube rolling mills - hot and cold pipe detection
- Replaces several individual devices with a single, compact system incl. additional functions
- Safe position and end position monitoring
- Easy to configure, no need to modify with the control software
- Certified safety ensures uncomplicated acceptance test
Before: Mechanical spindle limit switches were driven by gearwheel and used for monitoring and switching of end positions.
Challenges
Absolute encoders and mechanical limit switches (levers and / or spindle limit switches) characterize state-of-the-art solutions for position detection and limiting the end position of moving system components in relation to one another on large machinery in open-cast mining applications. To ensure the safety of personnel and safeguard machinery it is essential that limit switches are reliably actuated when end positions are reached. Consequently, highly reliable monitoring technology is necessary to comply with the corresponding safety requirements – in particular when implementing modernization or automation measures. To meet the required performance level, two-channel architectures or diverse redundant systems are needed.
After: The direct driven universal encoder system U-ONE-SAFETY-Compact allows high precise and safety certified monitoring and switching of end positions.
Solution
- The universal encoder system U-ONE®-SAFETY-Compact consists of a basic unit and directly attached switch or bus modules. All functions are integrated in a robust housing designed to meet the specific demands of heavy industry. Safety switching signals are provided according to position and speed based on a 13 / 15 bit resolution (max. 32768 rotations). It is possible to combine diverse bus interfaces as well as a 4 – 20 mA analog output or an incremental output according to application requirements. As a consequence, it is possible to replace several individual devices with a single compact device. The system-wide two channel architecture facilitates the implementation of safety functions up to Category 3 and Performance Level (PL) d as well as SIL 2.
Products and Accessories
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
Case Studies
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