APPLICATIONREPORTS2024
Automation solutions from ifm

A PPLICATION REPO RTS 2024

A passion
for automation
ifm is synonymous for automation and digitalisation witha passion. It makes us happy and proud to see this passion
spread from us to our customers and witness how it advancesthem.
In this ninth edition of “Application Reports”, you will once
more learn first-hand exactly what this means. Because again,
our customers have allowed us a look behind the scenes andshared with us how they have overcome challenges and taken
innovative approaches successfully with the help of our automation and digitalisation solutions.
So you can look forward to yet more exciting reports, this timeon topics such as sensor-based quality assurance in battery cellmanufacturing or in the assembly of scissors, smart valve monitoring in the brewery or digitalisation in cigar storage.

Present your know-how to a large audience!
We are constantly looking for exciting and clever solutions you
have implemented with our products. Why? Because nothingis more inspiring than successful practical experience. Are you
interested in sharing the benefits you are gaining from ifm
products with others? If so, please let us know. We will also bepleased to report on your success story in the next issue.
It’s that simple:
Send us a short description of your application. We will contact
you, visit you on site, take professional photographs and do aninterview with you. Based on this, we will create an Application
Report. It will not only be published in the next issue, but alsoin specialist magazines or, on request, as a special print for you
and your customers.

Enjoy reading!
Your ifm Application Report teamInterested? We look forward to your message toapplication.reports@ifm.com

ifm.com/gb/application-reports

EDI TO RI AL / CO NTENTS 03

04

Berchtesgadener Land
Reliable temperature monitoring

38

Köster Systemtechnik
Training on a smart factory model

08

EREMA
Digitalised recycling systems

44

New Logic Research Efficient construction
and operation of filtration systems

12

Fraunhofer Research Institution
Sensor-based quality assurance

48

Refresco
Digitised bottling plant with IO-Link and AS-i

16

Gardena
Quality control during assembly52

Steffen Hartmann Recyclingtechnologien
Vacuum evaporator

20

Gerber Humidors
Digitalising cigar storage

58

Veltins
Smart valve monitoring
for the secondary circuit

26

GeTechSensor-based check gauges

30

Grégoire Autonomousline guidance for grape harvesters

34

Koedood Hydrogen propulsion
for inland waterway vessels

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Editorial staff:
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ifm electronic gmbh

Photography: Andreas Biniasch
Type setting and layout:
Andrea Tönnes
Production: Paula Pötschick

Friedrichstraße 145128 Essen
Germany
Telephone +49 / 201 / 24 22-0
Telefax+49 / 201 / 24 22-1200
E-mail info@ifm.com

Berchtesgadener Land
Reliable temperaturemonitoring

The Berchtesgadener Land dairy 05

Trust is good, control is better
Reliable temperature monitoring in dairy processing

Milk is a high-quality natural product whose processing
requires precise temperature settings. The Berchtesgadener Land dairy uses innovative temperature sensors
from ifm in key process areas. These special sensors continuously monitor themselves, thus ensuring compliancewith the highest safety standards and optimising thequality of the dairy products.
The Berchtesgadener Land dairy, a cooperative organisation
situated between the Watzmann and the Zugspitze mountains
in the picturesque foothills of the Alps, processes around 300
million kilograms of milk from its farmers every year.

Every year in the idyllic Berchtesgadener Land
district, the dairy processes 300 million kilogramsof milk produced by its cooperative farmers
between the Watzmann and Zugspitze mountains.

At the production site in Piding, in the BL district, the milk isused to make premium products with the utmost care. Berchtesgadener Land’s portfolio includes numerous products suchas traditionally produced fresh bottled milk, whipping cream,butter, quark, natural yoghurt, kefir and buttermilk.
Lorenz Engljähringer, plant manager at the BerchtesgadenerLand dairy, explains the orientation of the business: “Quality is
our top priority. We process the raw milk as carefully as possible and try to produce high-quality products in as few process
steps as possible.”

Temperature monitoring
The quality of all milk products depends on maintaining precise
temperatures throughout the entire dairy process. High-precision sensors guarantee defined temperatures along the entire
process chain, from the inbound delivery of the milk in thetankers to processing and intermediate storage to outbounddelivery of the processed final products. The continuous temperature monitoring also extends to secondary processes suchas cleaning and sterilisation, to ensure compliance with statutory regulations and hygiene standards.

100% reliable measurement values:
self-monitoring temperature sensors
from the TCC series with on-board
diagnostics in dairy processing.

The temperature sensors
from ifm can be used toensure high product quality.

Reliable measured values
Sensor-manufacturer ifm has developed the TCC temperature sensor for monitoring temperatures at particularly criticalpoints. What makes it special is its integrated permanent
self-monitoring function.
Christian Doll, Technical Sales Engineer at ifm, explains: “TheTCC temperature sensor uses two thermally coupled sensor
elements, a sensing element and a reference element to conduct precise measurements in the sensor tip. The measured
temperature value is generated by the sensing element andprovided via the analogue output or IO-Link. The reference element is used for comparison purposes and to verify the process
value. Possible effects of ageing cause inaccuracies in temperature measurement and can be identified by a drift between thesensing element and reference element. A warning is triggered
if the temperature difference exceeds the predefined calibration check limit. In this case, the LED display on the sensor
switches from green to blue and the diagnostic output sends
a warning signal to the controller. This unique permanent selfmonitoring across the whole measuring range creates trust in
the accuracy of the measured value.”
Another advantage of this integrated diagnostic function isthat there is no need for a second monitoring sensor to beinstalled at critical points. This significantly reduces the costsof hardware, installation and calibration. The TCC temperature
sensor also revolutionises the conventional cyclical replacement of sensors at sensitive measuring points. Instead of being
replaced regularly and preventatively, the TCC can be replaced

The Berchtesgadener Land dairy 07

Automated processes ensure maximum
efficiency.

cost-efficiently as needed. The special feature: the sensor automatically detects when its accuracy tolerance is reached andalerts the user. Only then is replacement necessary – avoiding
unnecessary preventative replacement.
The calibrated process values of the TCC sensor can be considered reliable until the accuracy tolerance is reached. This way,
the sensor guarantees maximum measurement value reliability
and contributes to maintaining consistently high product quality.
Every TCC is delivered ex works with a ISO 3-point calibration
certificate which also contributes to quality assurance. For
maximum reliability, the device serial number can be monitored
via IO-Link, representing a new dimension for quality assurance
and documentation of the process values.
Digital data transmission and diagnostics with
the IO-Link
In addition to the conventional integration of the sensor via
analogue output (4–20 mA) and the diagnostic switching
output, the TCC can also be connected via IO-Link. This digitalcommunication offers advanced diagnostic options such as
being able to separately read the temperature values of thetwo measuring elements. This allows the user to recognise
trends in drift behaviour early, regardless of the set limit. Thisfunction enables early identification of calibration requirements
and timely planning of device replacement. In addition, the
IO-Link is used to conveniently set the parameters for the sensors, for example to determine the drift limit.
Won over by TCC
The dairy has been won over by the advantages offered by the
TCC.
“The temperature sensors from ifm can be used to ensurehigh product quality. We use the TCC sensors for in-process
measurement of product temperature, cleaning temperatureand sterilisation temperature. Because the sensor contains twotemperature probes, the process remains stable even if one of
the measurement probes is defective, because the sensor continues to send the measurement signal of the other measurement element to the controller. These sensors were chosen
not only based on their attractive price, but also on their foodsafe resistance to alkalis, acids and disinfectants,” explains
Andreas Holleis, Head of Process Engineering & Automation
at the Berchtesgadener Land dairy.

Partnership with ifm
In addition to the temperature sensors, the dairy also uses
numerous other ifm sensors including pressure sensors in pipes
and tanks and inductive sensors on valve manifolds. This is no
coincidence, as plant manager Lorenz Engljähringer explains:“We’ve been working in close partnership with ifm for decades. For us, this is an important building block in achieving
our goal of manufacturing high-quality products and being
able to make the process safe and efficient.”

Conclusion
Having trust in measured values is important, but only continuous self-monitoring guarantees a 100% reliable measured
value. This is essential in sensitive processes such as milk production that demand the highest quality. The TCC from ifm
makes a key contribution to this.

EREMA
Digitalised recycling
systems

EREMA 09

Digitalised recycling
EREMA, manufacturer of recycling systems,
relies on hardware and vibration expertise from ifm

Drinking bottles, food packaging, bags, toys: many thingsin everyday life are made of plastic - but we only needsome of them for more than a few hours or days. Around
400 million tonnes of plastic are produced worldwide
every year. Only a small share of this is recycled and thus
reused. Among the players that keep the plastics cycle
going and successfully complete it, are the Austrian
EREMA Group and PET-Verpackungen GmbH from Germany.
The EREMA Group is committed to giving plastics a new life.
To this end, EREMA develops and produces plastics recycling
systems and the associated solutions and services. The approximately 7,500 active plants worldwide have the capacity to
produce more than 20 million tonnes of recycled granulate.
“To produce the granulate, the plastic is delivered to theoperators of our systems in the form of flakes, which are
already shredded, clean and sorted,” says Florian Schieder,
R&D Management &IPR at EREMA Engineering Maschinen
und Anlagen GmbH.

The recycling material is delivered
to the plant operator in the formof flakes.

The sensor data from the recycling plant is collected
decentrally via an IO-Link master and forwarded tothe control system in bundled form.

“The flakes are then dehumidified, compacted, melted,
filtered and then granulated in our plants. The granulate
produced is the basis for reusing the recycled material
to manufacture new plastic products.”
If food-grade granulate is to be produced, as is the caseat PET-Verpackungen GmbH, for example, the flakes are
shredded at a higher temperature and under vacuum.
“On the one hand, this ensures that the material isdecontaminated, and on the other hand, this special
treatment enables us to achieve better colour properties
for both the granulate and the end product,”
Florian Schieder continues.

The evaluation electronics in thecontrol cabinet process the data fromthe vibration sensors and transmit theresults via Ethernet to the gateway,
the IIoT controller from ifm.

Up to 80 vibration sensors per system
EREMA relies on sensor technology and IO-Link masters
from ifm to control the manufacturing process.
“We have been using pressure sensors, photoelectric
distance sensors and flow sensors for a long time toensure that all relevant process values are adhered toand that the material flow takes place at the required
speed,” says Yvonne Kappacher-Winter,
Development Project Manager PredictOn at
EREMA Engineering Maschinen und Anlagen GmbH.

The IIoT controller transmits all sensor data to thehigher IT level, where it can be accessed by EREMA
customers at any time on a laptop or smartphone.

EREMA 11

At ifm, we receive everythingfrom a single source, fromthe sensor to the evaluationelectronics, IO-Link masterand gateway.

“We are now digitalising our systems even further by equipping
motors, gears, vacuum pumps and roots compressors witha total of up to 80 vibration sensors and other oil condition
sensors. This enables us to precisely record the system’s maintenance requirements. The customer can see information on
the health status of the system via our PredictOn predictive
maintenance system both directly on the system and via our
BluPort customer portal. This enables early damage prediction
and the planning of appropriate maintenance measures tominimise downtimes,” says Yvonne Kappacher-Winter.
Digitalisation: everything from a single source
Florian Schieder adds: “We have customers who operate
their systems around the clock and produce up to six tonnes of
granulate per hour. The long-term availability of our machines
is becoming increasingly important for us and our customers.
It was clear to us that we needed more sensor technology
and further digitalisation in order to be able to detect andavert impending failures at an early stage. We needed a strong
partner who could support us with the right products andexpertise in vibration analysis. At ifm, we receive everythingfrom a single source, from the sensor to the evaluation electronics, IO-Link master and gateway. This makes it easy for us
to offer the customer a seamless solution. They can see theprocessed data on their laptop and smartphone at any time
and take appropriate action, including ordering spare parts
from us.”

Up to 80 vibration sensors are installed in a current EREMA
system. For example, they monitor the motors and gears of
the system.

Containers made from 100 per cent recycled material
PET-Verpackungen GmbH also appreciates precisely these
possibilities of data-based maintenance planning. As partof the Wiegand Glas Group, the company primarily produces
PET preforms for the beverage industry, but also moulded PET
containers with a capacity of 10 millilitres up to 30 litres.
“The topic of recycling is becoming more and more importantfor us. Our customers are increasingly asking for products
made from recycled materials. In some cases, the proportionis 100 per cent,” says Matthias Raab, Operations Manager
at PET Packaging.
“That is why we decided to commission our own recycling
plant three years ago and chose EREMA as our technology
partner.” PET-Verpackungen produces up to 50 tonnes of
granulate every day for further processing.
“In order to maintain the production process, it is importantthat all systems and processes function reliably. The digitalisation solution from EREMA supports us enormously here, as thecondition monitoring and planning of maintenance is considerably simplified by the data provided,” says Raab.

Conclusion
With integrated solutions for digitalised, comprehensive
system monitoring, ifm helps EREMA to offer its customers
added value in the plastics recycling process. Thanks to
condition-based maintenance, system availability is
increased and the recycling potential is maximised.

Fraunhofer
Research Institution
Sensor-based
quality assuranceFraunhofer Research Institution 13

Research into more efficient battery
cell production
The Dualis 2D vision sensor from ifm keeps a close eye on electrode manufacture

Electromobility is still racing along the fast lane worldwide. Between 2020 and 2023 alone, the proportion ofregistered e-vehicles increased from below five per cent toan estimated 18 per cent – and the trend is clearly rising.
However: if the intended mobility transition is to be
fully accomplished, one thing in particular is required:increased capacity in the production of powerful batteries –and very soon, too.
As the link between science, research and industry,
the Fraunhofer Research Institution for Battery Cell
Production FFB intends to contribute to ensuring thatthe development of new, powerful cell formats is accelerated.
The target for Europe has been set: the EU aims to play a more
important role in the battery cell production market in the
future, and has set itself the target of considerably improving
production efficiency by as early as 2030.

This is to include reducing rejects to below five percent – anambitious undertaking, as Fabian Kux, Research Associate(Quality Assurance) at the Fraunhofer FFB clarifies: “Reject
rates are still noticeably high along the entire battery production process chain worldwide.”
Well-adjusted plants produce around 10 per cent scrap; thispercentage may be even higher during the ramp-up phase.
“Therefore, our aim is to accelerate the manufacture of innovative and, above all, efficient battery cells,” says Kux.
Quality assurance using 2D vision sensors
The FFB already ascribes an important role to automation technology. “An important element of our research is working out
how sensor technology can help to enhance the quality of the
products and the efficiency of the individual process steps.”
Within the framework of a joint project with ifm, Kux and his
team are testing the possibilities for using the Dualis 2D vision
sensor, for example.

At the beginning of the production process,the Dualis vision sensor (O2D5) monitors
the application of the slurry. Double-sided
monitoring is also being tested at the
Fraunhofer Research Institution.

The Dualis checks contours and surfaces and compares theactual state with the target specification. This enables reliable
detection of the smallest differences in details, such as missing
retaining clamps or malformed threads.
In addition, surface dimensions can be analysed, such as – inthis specific use case – those of the slurry, a paste of active
materials, conductive additives, solvents and binding agents,that has been applied. The vision sensor reliably recognises a
defective application and emits an error message. The process
can then be readjusted to avoid further rejects and to maintaina high level of product quality in the manufacturing process.
Integrating the vision sensor is extremely simple: the 2D vision
sensor can be parameterised for most use cases by means of
the teach function of the free ifm
Vision Assistant software and its parameterising assistants anda few mouse clicks.
Three applications for the Dualis“In consultation with automation specialist ifm, we identified
three applications for which the Dualis can be used,” explains
Kux. “The first application involves detecting defects in the
freshly applied electrode slurry on the surface of the film substrate. You see, contamination or missed areas will have a negative effect on the safety and performance of the cell and must
therefore be identified as scrap,” says Kux. “The dimensionsof the coating are checked at the same time. In a continuous
application process, the width of the film is measured; in anintermittent application process, the length is also measured.”Fraunhofer Research Institution 15

Gaps in the slurry coating result in rejection and it is imperative that theybe identified. ifm’s Dualis vision sensor indicates this defect, thus helping
to keep the reject rate to a minimum.

Always precisely wound
If both sides of a film are being coated, a second Dualis is used
to inspect the underside.
“In this case, we have to ensure that the slurry is applied toboth sides in equal measure in order to guarantee the required
quality.”In the third scenario, the Dualis inspects the edge of the film
and coating.
“Wet slurry is applied to the film and then goes through adrying process. The coated, dried electrode film is then wound
up. Otherwise the irregular load can damage the film andcoating.”
From the digital twin to the battery passport
The vision sensor data can be used not only to reduce thereject rate at an early stage and ensure quality. From 2026 itwill be mandatory for all newly produced batteries to have abattery passport. This will contain information not only about
the supply chain and the new or recycled raw materials used,
but also about the performance and health of the battery.
“All the data that the sensors record along the entire production process can be transferred to the digital twin. This canthen be used to easily create the battery passport.”

The Dualis also reliably identifies irregularities or pockets inthe applied slurry, assuring quality and high productivity.

A good example of a successful partnership
The Fraunhofer FFB is still in the start-up phase. In the future,
the Münster location will provide the capacity for high-volume,industrial-scale production.
“This is intended to enable us to produce batteries at highthroughput in order to jointly test new technologies withpartners in industry in research projects in real conditions. The
collaboration with ifm is thus a good example of how we cantest, optimise and upscale the battery cell manufacturing technologies of the future with our partners.”

Conclusion
In partnership with the Fraunhofer Research Institution forBattery Cell Production FFB, ifm can test its Dualis 2D vision
sensor in real conditions. In the future, the resulting insights
will help everyone: the Fraunhofer FFB, ifm, battery cell manufacturers and electromobility as a whole.

In consultation with
automation specialist ifm, we
identified three applications
for which Dualis can be used.

Gardena
Quality control
during assemblyGardena 17

Monitoring with precision
2D vision sensor monitors small parts during assembly

In manufacturing, delicate components often need to
be checked before the next processing step. Gardena,a recognized manufacturer of gardening tools, relies
on powerful vision sensors from ifm.
Gardena is the leading German brand for irrigation products,
mechanical cutting tools and classical gardening tools. Basedin Ulm, Germany, the subsidiary of the Swedish Husqvarna
Group successfully manufactures and distributes its products
worldwide.
At its plant in Niederstotzingen near Ulm, Gardena produces
manual shears, loppers and grass shears. Production Manager
Jens Starke states: “Our very high vertical range of manufacturing starts with the processing of supplied stainless steel
coils, including punching and laser cutting of the blades, followed by hardening and, above all, grinding, which is the corecompetence of our plant and decisive for shear quality. Then,the blades are coated and assembled.”

The ifm vision sensor checks that the parts
are correctly assembled.

Semi-automated production
Significant portions of the production process are automated.
For example, robots are used to feed the metal sheets to thepunching or laser cutting systems. During grinding, robots
precisely guide the blades along the grind stone. This ensuresconsistently high product quality.
However, some tasks are still carried out manually, such as
the final assembly step of Gardena’s all-purpose scissors“SchnippSchnapp”. Here, a small disc spring is manuallyinserted into a recess in one of the scissor halves. This will
later allow the scissors to open and close smoothly. To ensure
flawless product quality, the system automatically checks
whether the disc spring has been inserted correctly before
screwing the parts together.

The components are assembled manually. This allows assemblyof different types of shears on the same production line.

At the Gardena plant in Niederstotzingennear Ulm, the all-purpose scissors“SchnippSchnapp” are produced.

Sven Cermak, tool setter at Gardena, explains: “Position
detection is very special here, because the very small and flatdisc spring sits in a recess. Inductive or photoelectric fork sensors would not be useful here. This is why we use ifm’s camera
system. It can even detect whether the spring has been inserted the right way round.”The vision sensor checks whether the disc spring is in the joint and whether it is the right way round(on the left) or the wrong way round (on the right). Rejects due to assembly errors are reliably prevented.

The 2D vision sensor O2D
As inductive or photoelectric fork sensors are not suited for thisspecific position detection task, the O2D5 vision sensor from
ifm is used. This camera-based sensor was specially developed
for optical 2D object inspection. It uses blob analysis to compare sets of contiguous pixels, comparing the size, shape andother properties of the disc spring with a programmed target
surface.
The ifm parameter setting software Vision Assistant allows easyand quick set-up of the sensor. The user simply defines image
zones in which the objects to be detected are located. Using
the teach method, a reference image is recorded and then tolerance limits are defined. As soon as these limits are exceeded,
the sensor generates an error signal.
The O2D5 device is equipped with an ifm memory stick onwhich all parameters and settings are stored. If the device
needs to be replaced, the stick can be used to easily transfer
the data to the new sensor.

Gardena 19

We have been working
closely with ifm for many
years and have developed
outstanding solutions together
With the help of the “Vision Assistant”
software, the sensor can be easily adjusted
to the desired application using the teachfunction. Fine-tuning is possible thanks tooptional parameters.

Extraneous light as a challenge
A particular challenge for camera-based inspection systems arechanging light conditions, such as sunlight entering throughwindows depending on the position of the sun and hitting theobjects to be inspected. In such cases, the ifm system proves tobe particularly reliable. The trick: During measurement, the system takes five shots at different exposures and automaticallyuses the image with the optimum exposure for comparison.

Sven Cermak: “We have been working closely with ifm formany years and have developed outstanding solutions together,including the introduction of the camera. Initially, we did notknow which systems are available on the market or what is
technically feasible. The product experts from ifm advised us
expertly, ensuring short and direct lines of communication. We
were able to test different camera versions and the collaboration was extremely successful.”

Sven Cermak is very pleased with the solution: “On this system, extraneous light does not play a significant role, but we
use the same camera on another production line where wehave to inspect extremely small parts in the millimetre range.
There are large windows there, which means that we have todeal with more pronounced changes in light conditions. Evenin this environment, ifm’s camera provides excellent results.”
The integrated polarisation filter in front of the camera lensmaximizes detection efficiency, allowing highly reflective
objects to be detected without any problems.

There are many production lines at different sites, where
production processes are monitored and quality checks are
performed. Here too, the vision sensor from ifm proves to bea highly valuable solution.

ifm as a reliable partner
Introducing new technology to an organisation requires
comprehensive consultation, as the best solution will only be
successful if it fits within the context within which it is being
implemented. The partnership of several decades between therenowned garden tool manufacturer Gardena and the specialist for automation solutions ifm emphasises this cooperation.

Jens Starke is confident about the future: “One big project isstill to come, where certain factory standards have to be met.
It all centers around sensors, camera technology, scanning andsimilar topics, so it would be great to work on this project withifm.”

“We always check whether we can use the camera in otherareas as well. We now have three or four cameras in our
department. Of course, the cameras are also used extensively
by other departments and sites, even more than here,” says
Sven Cermak.

Conclusion
The vision sensors from ifm prove to be a highly effective solution for production control and quality assurance, in particularfor small parts monitoring, where conventional position sensors reach their limits. With its slogan ‘close to you’, ifm not
only demonstrates its commitment to hardware, but also its
active support and expertise.
Production Manager Jens Starke sums it up this way:
“The ifm slogan ‘close to you’ definitely reaches the shop
floor.”

Gerber humidors
Digitalising cigar storage

Gerber humidors 21

A feel-good oasis for cigars
Industrial automation technology for a perfect climate in Gerber humidors

Storing valuable cigars is almost a science. True aficionados spare no expense in storing the rolled tobacco leaves
in sophisticated humidors. What you cannot see:Behind the façade, sophisticated technology maintains a
constant humidity to keep the aromas and consistency ofthe cigar in optimum condition.
Founded in Duisburg 140 years ago, Gerber is a joiner’s businessthat is steeped in tradition.
Karl-Heinz Gerber is the fifth generation of his family to leadthe company and explains: “We are still traditional joiners,
but we also cover a broad spectrum of services including store
fitting, interior fittings and exhibition stand construction. A
few years ago, we also launched ‘Gerber Humidor’. This brandrepresents our passion for creating the perfect, unique pieceof furniture with equally perfect humidity for cigar aficionados.
Our mission is to build the world’s most beautiful humidors.
To do this, we use the best and most expensive woods on themarket.”So it is no wonder that Gerber’s customers include Hollywood
greats and famous football stars.

Comprehensive expertise required
From a purely technological point of view, a humidor ensuresthat cigars are stored in optimal conditions and therefore
maintain their value and quality. Our customers have highstandards, as Karl-Heinz Gerber knows: “You need to havea very high level of technical expertise to ensure the optimum
humidity in these humidors. The humidity level can be set by
the cigar aficionado depending on their taste and preference.
What makes it complicated is that the external climate conditions have an impact on the humidors.”
This is why Gerber humidors offer an automatic humidity
regulator developed and implemented in cooperation withthe automation specialist ifm.
“We measure and control humidification and dehumidification.
In doing this, we take into consideration the ambient humidity,
which can be very different in different countries around theworld. At the same time, we also have to control the ventilation. So, all in all, it’s a very unique and complex situation. The
art here is in ensuring the perfect humidity on all levels of thehumidor. It requires experience and, of course, the right technical equipment,” says Gerber.

Humidors provide optimum humidity
to ensure that expensive cigars are
stored perfectly.

The consistent use of connectors hereon the IO-Link module prevents cabling
errors and makes it possible for components to be easily replaced in theevent of a fault.

Gerber humidors 23

The edgeController is ifm’s
first product to feature an
automation server. So, if
any problems arise, you caneasily access it via remote
maintenance.

Wanted: a partner with international experience
When Gerber decided to forge ahead with the automation of
its humidors a few years ago, they had to find a partner withan industrial background, active in the German and international markets. The head of the company explains why thiswas necessary: “We deliver our humidors worldwide, so wewant to offer maintenance-free solutions because international
support is time-consuming and expensive. Our customers store
very expensive cigars in our humidors – we’re talking five or six
figures here. That’s why we needed a partner that could supply
us with reliable technology. We did our research and foundthat partner in ifm.”
Requirement: Simple cabling and remote maintenanceIn the joiner’s workshop in Duisburg, the humidors, which areoften the size of cupboards, are assembled with the highest
standards of craftsmanship using fine woods and veneers andequipped with electronic components for humidity regulation.
However, after extensive testing, the humidors must be dismantled and packaged for delivery. “We need to ensure that
our humidors can be operated effortlessly and function flawlessly at all times anywhere in the world. That’s why we opted
for an easy-to-use, i.e. plug-and-play, system for connecting
the electronic components. Another of our requirements was

All components are connected using standardised
M-12 connectors.

remote maintenance, namely the capability to make adjustments, for example in response to changes in habits or climate,for instance with the help of intelligent AI systems,” explains
Karl-Heinz Gerber.
For this reason, all sensors are IO-Link compatible and connected via an IO-Link master module.This module collects the data
and transmits it to the controller via EtherNet/IP interface. The
advantage of this IO-Link communication is that it not only
makes it possible to use the controller to set parameters forthe sensors, but also provides an insight into the sensor. For
example, it makes it possible to read the sensor’s minimum andmaximum values. The diagnostics parameters saved in the sensor can also be called up using the controller, which allows forquick, precise analysis in the event of a fault.
Devices installed in the humidors, such as ventilators or lighting, are also controlled via the IO-Link master. The advantage
here is the standardised M12 connectors. Neither the assembly

nor the replacement of components requires an electrician –all you need to do is screw connectors into the module, whichmakes wiring errors impossible.
Everything from a single source
Dirk Scheffler, Senior Field Technical Sales Engineer at ifm,
played a significant role in the implementation of the control
technology and the development of the software: “All of theautomation components needed to come from a single source.
That’s why we chose the ifm edgeController as the central control unit. This unit meets all of Gerber’s key requirements: simple wiring, deep diagnostics both during commissioning andfor the end customer, attractive visualisation and the option of
remote maintenance.”Top-class craftsmanship for
sophisticated, unique pieces.

Past measurement readings
can be displayed clearly on thewidescreen display.

A truly multitalented centrepiece: the edgeController
ifm’s edgeController is much more than just a conventional
PLC. The eye is immediately drawn to the impressive 12.3-inch
graphics display on the top of the device, which has a resolution of 1280 x 480 pixels to enable sophisticated visualisations.
In its humidors, Gerber has chosen a photorealistic display inwhich the key measurement, humidity, is stylishly visualised ona virtual analogue hygrometer. Users can also choose between
different views, for example to look at past measurement
readings or change the settings.
The actual program processing is handled by a powerful 1.3 GHz
quad-core processor which operates at full performance atambient temperatures of up to 60 °C. CODESYS V3.5 is used
for programming.
One of the edgeController’s outstanding features is its extensive connectivity. Either as an IT gateway or as a link to thecloud: The edgeController can transmit the recorded andprepared data to the most common cloud platforms such as
AWS, Microsoft Azure, Google Cloud and AnyViz.

Gerber humidors 25
The edgeController’s touch display,which is used for viewing and changing
settings, fits seamlessly into its elegant
surroundings. Large humidors are
divided into several climate zones.

In addition, the edgeController speaks the leading standard
digitalisation languages such as OPC UA and MQTT. Industrial
Ethernet protocols such as EtherCAT, EtherNet/IP or Modbus
TCP can be used to collect and process data in real time.
Dirk Scheffler explains another feature that is important toGerber: “The edgeController is ifm’s first product to feature
an automation server. So, if any problems arise, you can easily
access it via remote maintenance. All you need is for theedgeController to be connected to a router via an Ethernet
cable, for example to a router.”This way, the IO-Link infrastructure makes it possible to takea look into every individual sensor, which enables detailed
and accurate (remote) diagnostics. If major adjustments are
required, Gerber can also carry these out via remote maintenance. “Another advantage of the integrated automation
server is that it makes it easy to install updates,” adds
Scheffler.

Reliable power supply
One important aspect is voltage fluctuation. In some partsof the world, the power grid is not as constantly stable as inGermany. In this regard, ifm power supplies offer a crucial
advantage by providing a sufficient buffer in the form of abroad input voltage range of 110 to 300 V AC, which largely
compensates for voltage fluctuations and thus ensures that
humidors can operate continuously. Moreover, the power supplies are intelligent, using IO-Link to communicate diagnostic
values such as output voltage, load currents, power supply
quality or the cause of automatic shutdowns in the event ofa fault.
Integrated electronic fuses provide additional protection against
overloading and short-circuiting. The fuses can be reset via
IO-Link.
Other separate electronic fuses in the secondary circuit provide
additional protection by allowing individual components to be
switched off selectively in the event of a fault. These fuses arealso IO-Link compatible, which enables comprehensive diagnostics using the edgeController in the event of a fault.

A resounding successThis project represented a premier for both Gerber and ifm,
because it was the first time the edgeController had ever been
used.
Karl-Heinz Gerber sums up positively: “Together, we’ve done
a lot of development work. The software needed to be developed from scratch, often even outside regular working hours.
It’s fantastic when you’re passionate about a project. ifm also
provides fist-class service. We can rely on their support teamresponding immediately. We have done a lot of development
work in the last few years and all I can say is: sensational. I
hope that this success continues.”

Conclusion
This project impressively demonstrates the symbiosis of topclass workmanship and high-end technology. It shows thatindustrial automation technology also proves itself an exclusive
environment and this synergy is what makes these humidors
the perfect feel-good product for cigars.

GeTechSensor-based checkgaugesGeTech 27

Perfectly bent?
Sensor-based check gauges for pipes

Pipelines are the lifelines of systems that provide planes
or cars with oil, fuel, coolant or other fluids. They often
have to be bent into complex three-dimensional shapes
in order to fit into confined spaces and efficiently connect units and containers.
Effective quality control is essential to ensure thateverything can be assembled cleanly and all connections
fit perfectly. Prior to installation, special fixtures are used
to check that the bends and lengths conform to the specifications. Only then can a smooth integration into theoverall system and the durable efficient functioning ofthese complex pipes be guaranteed.

The three-dimensionally bent air conditioning tube is placed into the checkfixture for quality inspection.

GeTech, a Dutch company based in Westerbork, specialises
in the development, production and distribution of checkfixtures, which are used to check such pipes for geometry.
GeTech Managing Director Alco Poppinga explains:“We manufacture check gauges for the automotive andaerospace industries. The tube to be checked is placed in our
fixtures and mounted in the same way it will later be installed
in a car, for example. “It’s a quick and reliable way to check
whether a product is within the tolerance limits.”
GeTech develops the check gauges in their own CAD laboratory. The robot-assisted production process using modern
machine tools is also handled internally, as is the precise checkon their in-house measuring system.

Each check fixture is customised to the pipe to be checked. For
For this purpose, aluminium blocks are lined up and stacked on
an aluminium base plate. The resulting “stilts” serve as support
points for the product. Their height and orientation are calculated with accuracy to a fraction of a millimetre. The top of theblocks has a milled groove into which the pipes or tubes to bechecked should fit perfectly without tension.

Alco Poppinga: “We produce our gauges according to ourcustomers’ high expectations. Currently, we are in the process
of automating our production with robots. This ensures a highoutput of our products.”

Optionally, the gauges can be integrated into the GeTech
Product Inspection System (GPI) as a modular component. Thissystem consists of sensors, a screen-based dialogue system anda control unit.

One of multiple optical sensors detects thatthe tube has been placed in the fixture. The
lock is released once all steps of the quality
check have been passed.

ifm’s contour sensor inspects thecountry-specific fill valve of the air
conditioning tube.

Alco Poppinga describes the GPI inspection process: “Whenthe user has checked into the system via RFID chip, the righttest sequence is automatically loaded and indicated on the display. The user is guided through every step of the process andis given instructions, for example, on how to insert the pipe
into the check fixture and close the clamps.”
Sensors monitor the process
The inspection process is monitored with the help of several
products from the sensor specialist ifm. For example, theirinductive sensors are installed on the toggle clamps to ensurethat all required levers are closed correctly. Only then will thisoperating step be released. The inductive IY type sensors havean even smaller design. For example, they are embedded in theflaps which report the correctly seated position of the productto the controller. Thanks to their compact M5 design, they areparticularly space-saving.
To detect the presence of certain parts, such as the O-rings at
the tube ends, photoelectric sensors are used. In this application, the miniature diffuse reflection sensors of the O8H series
score with their compact size and a precise light spot even atlong distances.

GeTech 29

The user is guided through every step of
the process. This ensures an efficient anderror-free test sequence and eliminates theneed for lengthy preparation in case ofchanging check fixtures.

Another important sensor system is the O2D contour sensor,
which detects the actual contour and compares it with thetarget contour defined in the test program. Values outside thetolerance limits are recognised as faults.
Alco Poppinga: “We use the contour sensor from ifm tocheck the fill valves on air conditioning lines. These filler necks
can differ from country to country. By checking their contour,
the camera-based sensor verifies whether the correct country
version has been installed.”
To confirm a successful product test, a label with a barcode
is printed and affixed to a specific part of the test tube. A
camera-based code reader from ifm checks whether the rightlabel has been applied in the right place. The product is thenapproved and released for removal.
Modular concept
The sensor setup of the measurement system depends on thetest requirements of the specific product.
Alco Poppinga: “The GPI is a work station which allows users
to easily exchange the check gauges via a plug-in connection.
Most sensors are permanently installed on the levers andclamps. The contour sensor or the QR code reader remain at
the work station because we can quickly adjust them to theapplication using the free and convenient software ‘ifm Vision
Assistant’. This also helps reduce the production costs of thegauges, which benefits our customers.”
Partnership with ifm
GeTech relies on products from ifm, both in terms of sensors
and dialogue displays.
Alco Poppinga explains why GeTech now also uses the industrial sensors for quality control: “In 2016, one of our customers
approached us because they had received complaints about
the tubes missing certain parts. Together with this customer,
we analysed the problem and had the idea to use sensors
for support. In the same year, we met ifm at an exhibition.
We brought up our customer’s problem and quickly realisedthat we would be a good match. ifm provided us with some
sensors and a programmable display to test our ideas. The
products convinced us, which is how the GPI was born –a work station for easy connection and exchange of checkgauges.”Bottom line
Sensors from ifm help secure the manufacturing qualityof complex pipes. They reliably detect defects that may beoverlooked in a purely manual inspection process. An easyto-use dialogue system ensures efficient inspections andhighest product quality.

Grégoire
Autonomous line guidancefor grape harvesters

Grégoire 31

Automatic grape harvestingwith ifm
Autonomous line guidance without GPS for mobile agricultural machines

With EasyPilot, the manufacturer of multi-equipment
carriers and harvesters, Grégoire , has created a sensorassisted automatic line guidance system that boasts a
precision of 3 cm without needing a GPS position signal.
No other beverage holds so many secrets and divides so many
opinions as wine. Wine: The Italians claim it as their national
beverage, and the cup of the everlasting covenant of the Christianfaith is filled with it – for in wine is truth: “in vino veritas”. One
truth about wine is that it is necessary to harvest grapes to
produce it. And in our days, which are marked by technologicalprogress, the most important question is: man or machine?
The romanticised image of the grape harvest, which we often
see in movies and which will surely have inspired one or theother Hollywood star to buy their own vineyard, actually looks
quite different in reality. Considering that in Germany alone
the average citizen drinks about 20 litres of wine per year, it
becomes quite obvious how much work has to be done in a

Grape harvester with the EasyPilot automaticline guidance system.

short space of time by about 80,000 German winemakers who
cultivate and harvest wine on an area of about 102,000 hectares.
Given these figures, how is it possible to be successful?
Success through technology: Many winemakers use state-ofthe-art harvesting machines like grape harvesters instead ofmanual labourers.
Grape harvesters offer various advantages. One hectare, forexample, can be harvested in 3 to 5 hours. Achieving the same
result with manual labour requires 40 to 60 workers.
How does an automatic grape harvester function?
The French company Grégoire is a manufacturer of grape harvesters. Their grape harvesters can additionally be equippedwith an automatic line guidance system: the “EasyPilot”. Thissystem boasts a precision of 3 cm without depending on satellite signals.

The 3D camera precisely detects the grape
row in front of the vehicle.

The automatic line guidance systemsteers the vehicle precisely along thegrape row.

The grape row is detected by a 3D camera sensor (type O3M)
from ifm which measures the distance to the nearest surface
for each pixel using time-of-flight technology, thus detecting
the general properties of the vines. Inaccuracies caused by vinebranches from the side or high grass can be excluded.
While the grape harvester moves over the vines, it creates atunnel beneath the driver’s cab. In this tunnel, shaking rods
made of food-grade plastic fix and shake the trellises. These
vibrations shake the vines, so that the grapes fall off. They
tumble on a conveyor belt that transports them to stainlesssteel containers. Suckers remove unwanted elements such asleaves and twigs.
Another 3D sensor is mounted on top of the grape harvester’s
driver cab. This sensor is aimed at the ground and determines
the height and thickness of the trellis. Once the sensor signal
has been processed, a virtual guiding track is generated thatvisualises the grape row as a model. This model is used as abasis to calculate the ideal route for the harvester to take.

Grégoire 33

The driver only controls the operating
speed, EasyPilot does the steering.

When the machine is in the grape row, the driver starts the
EasyPilot via the screen in the cab. Once the system has been
started, all the driver needs to do is have an eye on the operating speed and the tools – everything else is taken care of automatically by the system. At the end of the grape row, a visualand acoustic signal informs the driver that the harvester needs
to be turned around to move along the next grape row.
There were times when the time for the grape harvest was
ordained by the government. Today, winemakers can decide
for themselves, and with the grape harvesters from Grégoire,grapes can be harvested at any time – even at night.
It remains to be said that innovation pays off: Grégoire have
won the innovation award for their new automatic line guidancesystem EasyPilot, which is based on the O3M sensor from ifm.

Numerous advantages
Besides the absence of a GPS connection, Grégoire’s system
offers many other advantages: precise line guidance even inlots with uneven ground, increased quality of the grape harvest(improved ingress resistance, reduced loss, preservation of thevines), increased steadiness of processes beyond the grape harvest (crop spraying, pruning...), protection of the mechanics,
convenience and productivity, application possibilities at day
and night, operating speeds of up to 12 km/h.
EasyPilot is available as an option for the current GM7,
GL7, GL8, GX8 and GX9 models. Most predecessor models
equipped with a direction sensor can be retrofitted with thesystem.

Use of inclination sensors
The inclination sensors installed on the harvester play an
indispensable role in ensuring that the machine is constantlyaligned vertically, no matter how steep the slope. Only the perfect levelling of the grape harvester, regardless of the terrain,
makes it possible to achieve maximum throughput and ensure
the safety of the user. Besides, the machine can drive faster,saving valuable working time. The 1-axis inclination sensors(type EC2045) used have a CANopen interface which ensureseasy integration into the machine controller.

Conclusion
Grégoire shows that traditional viticulture and modern harvesting machines complement each other perfectly. The EasyPilot,
with its 3D camera, guarantees optimum, smooth line guidance. This ensures that no grape is lost during wine production.

Koedood
Hydrogen propulsion forinland waterway vessels

Koedood 35

Emission-free inland shipping
Koedood equips the first inland vessel with hydrogen propulsion

The European goods transport chain could not be
imagined without inland navigation. On the contrary:
Aiming to become the world’s first climate-neutral economy by 2050, the EU wants to promote inland shipping
more actively as one of the most CO2-efficient transportmodes. In order to significantly reduce the still quite highemissions on the over 40,000 km of navigable inland
waterways, the EU focuses on clean fuel through effective after-treatment of exhaust gases and new forms ofpropulsion.

In both areas, Koedood acts as a competent partner. The company, which is based in Hendrik-Ido-Ambacht near Rotterdam
in the Netherlands, retrofits existing ships with diesel enginesthat comply with the strict EU Stage V emission regulations.
“By developing a proprietary after-treatment system we call
Koedood Engine & Emission System, or KEES, we have beenable to significantly reduce nitrogen oxide emissions,” says
Sander Roosjen, Research and Development Manager at
Koedood.
First fully hydrogen-powered inland vessel
Koedood also partners with the shipbuilding company
Kooiman to develop a completely new, clean propulsion
technology: “After the first hybrid models, we are now equipping an inland vessel with a fully hydrogen-powered and thus
emission-free system for the first time,” says Roosjen.
”The energy required by the ship is supplied by three modular
fuel cell systems developed in-house, each with a maximum
output of 300 kW,” Roosjen explains.

The K2 hydrogen generator developed
by Koedood and Kooiman is tested before
installation.

The complex process is closely monitored with various sensors
in order to achieve maximum efficiency.

Modular system in 20 ft format
The K2 – a reference to the two companies Koedood and Kooiman
and the chemical hydrogen formula H2 – is dimensioned to fit
into a standard 20 ft container. It consists of 32 low-temperature
PEM fuel cells, an air supply and a cooling water circuit. The
required hydrogen is transported onboard the ship under low
pressure.
The 32 low-temperature PEM fuel cells produce the energy
for propulsion of the vessel.

Sensors ensure optimum efficiency
For monitoring and optimum operation of this system, Koedooduses various sensors from ifm, including the LMC100 point levelsensor, the TA2405 temperature sensor, the PT5503 pressure
sensor and the LR9020 level sensor.
“Because it is a completely new propulsion system, we doof course want to collect as much data as possible to ensuresmooth operation of the system,” says Roosjen.
60 sensors monitor the fuel cell propulsion and transmit thedata to the IT level for evaluation.

Koedood 37

Precise continuous monitoring of pressure, level andtemperature values is necessary to ensure efficient operationof the hydrogen propulsion system.

Process values at a glance: The sensor data is not only
evaluated in the controller, but also at the IT level. Especiallyin the course of new developments, deviations and potential
areas for optimisation can be quickly identified.

“To achieve optimum efficiency, all relevant process values
must be precisely adhered to. So, it is important for us thatthe sensors are always reliable and accurate. Fresh air with aconstant level of humidity must continuously be transported
to the fuel cells. In addition, the operating temperature of thefuel cells must be kept at a constant level to ensure the best
possible energy yield.”

Koedood relies on ifm’s innovative strength
Koedood’s development of a zero-emission propulsion system
for inland vessels can truly be called pioneering work.

In addition to the required energy for the ship’s engines andon-board electronics, pure water is produced as a by-productof the conversion.
“We use some of it as cooling water in the process cycle andneed to ensure its availability on a permanent basis. The excesswater can simply be pumped out of the cycle.”“As an innovative company, we have recognised the potential of inland navigation to become an even greener mode oftransport, and we want to do our part with clean propulsion
solutions,” says Sander Roosjen.
“This is why we like working with ifm as a company that
continuously drives the innovative development of its sensor
technology forward. ifm really understands our needs andwhat we want to achieve, and provides us with the necessary
automation solutions. Joining forces and combining strengths
and competences gets you further. And that is exactly what
ifm and Koedood are doing in the case of maritime fuel cell
propulsion.”

Conclusion
With innovative developments, Koedood is driving the change
towards clean propulsion solutions for inland navigation. The
company relies on ifm’s technical expertise and process sensor
technology to achieve maximum efficiency in their hydrogen
propulsion systems.

ifm really understands ourneeds and what we wantto achieve, and provides us
with the necessary
automation solutions.

Köster Systemtechnik
Training on a smart
factory modelKöster Systemtechnik 39

Learning 4.0.
Training on a smart factory model

Industry 4.0 is becoming increasingly important in theoccupational field of mechatronics and automation technology. Modern training models help to teach trainees,
students and teachers about the relevant technologies.
With components such as those, actually used in industrial
production, automation solutions of varying complexity
can be developed and tested.

Nothing will remind you of the dusty training models you
may have encountered during the physics lessons at school
anymore. The Iserlohn-based company Köster Systemtechnik
offers didactic models that use standard industrial PLCs, fullgraphic touch panels for display and operation, RFID technology
and modern sensor technology with IO-Link data transmission.
Their 3-axis gantry can be used to represent a wide variety oftransport or machining situations, i.e. scenarios the trainees
will also be confronted with later in their careers – albeit in adifferent dimension and complexity. The automation principle,
however, is the same.

The compact smart factory model is used
for training in the development andsimulation of industrial processes according to the principles of Industry 4.0.

Peter Konegen, managing partner at Köster Systemtechnik,
explains: “We build model systems for didactic purposes. The
scope ranges from small compact models to large training systems on which real products can be manufactured. The model
shown here is called SFM, which stands for ”smart factorymodel”. The training focus here is on Industry 4.0. This refers,
for example, to technologies that allow efficient production
with a “batch size of one”, enable a straightforward scaling ofproduction and offer new ways in plant maintenance.

With our SFM models,data mining, connection to
an ERP system or to the cloud
can be simulated.

Technologies such as data mining, connection to an ERP
system or to the cloud can also be simulated with our SFM
models. Ultimately, the curriculum of the respective educational institution determines how deeply these technologicalstrategies are addressed. In any case, our SFM models are wellequipped for these purposes.”As it recognises the position of
workpieces placed on it, the touch
panel serves as an interactive storage
surface.

What the hardware does
The centrepiece of the system is a Siemens PLC, on which
trainees can load and test the application programme. Without
actuators and sensors, however, a controller is pointless. The“executing component” in this model is a 3-axis gantry that isused to move a head in the X/Y/Z directions. A magnet on thehead then allows to “grab” objects.
The icing on the cake is the arrangement of a touch panel.
Integrated flush into the work surface, it not only serves forvisualisation and operation, but also as an interactive storage
surface. The position of objects placed on the touch-sensitive
display can be detected and processed by the controller programme. This offers trainees creative scope, for example in thesimulation of logistical processes.

Köster Systemtechnik 41

The laser distance sensor transmits
distance values, which are accurate to
the nearest millimetre, to the PLC via
IO-Link.

Intelligent sensors with IO-Link
The smart factory model’s sensor equipment comes from theautomation specialist ifm. It includes modern components thatgo far beyond the mere output of switching signals but offertransparency right into the sensor by means of IO-Link communication.
The O5D100 photoelectric distance sensor uses laser-based
time-of-flight technology to provide distance values which
are accurate to the nearest millimetre. It not only detects thepresence of an object and reports it via a switching signal, it
can also detect the height of an object. The measured value istransmitted digitally via the IO-Link communication protocol,
which has established itself as a manufacturer-independent
standard in the sensor world in recent years. And IO-Link offers

even more: the parameters of sensors can be set remotelyusing IO-Link. Switching values can be set from the PC, butalso directly via the PLC’s controller programme. They can also
be changed during operation, if required. Speaking of “batch
size one”, individual adjustments in the production process canbe implemented easily.
IO-Link also transmits diagnostic data. The photoelectric sensor
e.g. detects the presence of dirt on its lens and automaticallyissues a warning message if, as a result, reliable detection is
no longer guaranteed. This self-monitoring function makes it
possible to implement effective maintenance concepts such as
real-time maintenance.

Generally, the sensors communicate via an AL1100 IO-Link
master from ifm. While providing a connection for sensors
and actuators via an M12 screw connection, this field module
handles all communication with the PLC via Profinet protocol.
In real plants, these decentralised modules offer the benefit ofgreatly simplified wiring. And due to the addressing of individual IO-Link sensors, wiring faults or mix-ups are ruled out whenconnecting or replacing devices.

The IO-Link master serves as a gateway
between the sensors and the PLC, whichis connected via Profinet in this case.

Köster Systemtechnik 43

The RFID read/write head operates
with the tags on the bottom side of
the workpieces. The data is transmitted
to the PLC via IO-Link.

Identification by means of RFID
Identification solutions have become indispensable in real
production processes, as they play a decisive role in producttracking or product processing. For this reason, the smart factory model is also equipped with an RFID read/write head. The
DTI515 has a flat design and is mounted below the working
surface. The workpieces of the model have an ID tag on theirbottom side. Data can be written to it and read when theworkpieces are above the RFID read/write head. Like the othersensors, the latter communicates with the master module via
IO-Link.
Cooperation with educational institutes
Despite its apparently rather small dimensions, the technological depth of the smart factory model is enormous. Trainees
can develop and simulate countless processes on the model ina very small space. The federal state of Lower Saxony, too, hasdiscovered this potential and equipped 23 schools with up to
twelve smart factory models each.
Knowledge transfer is also of particular importance in thiscontext. Because all models are identically equipped, learning
content and projects can be exchanged via networks. This hascreated a real community around the “SFM”.
At some schools, several models have actually been placed
right next to each other. Workpieces are moved from one
platform to the next where they are then further “processed”,

as is common practice in industrial production. Groups oftrainees programme different processing steps for each station.
This kind of co-working prepares the trainees perfectly for thedemands of later working life.
Peter Konegen also perceives another advantage of the SFM:
“Thanks to the connectivity, trainees were able to access thesmart factory model at school remotely from their home PCs
at the time of online teaching during the pandemic, allowing
them to test and present their application to others. This way,practice lessons could also take place online.”

Conclusion
The latest automation technology cleverly combined in thesmallest space – this is how educational institutes succeed
in introducing and training their trainees, students andteachers with varying degrees of technological depth tomodern production development according to the principles
of Industry 4.0. The automation components that the prospective technicians and engineers will find later in their jobs arealso included. For both sides, this is a worthwhile investmentin the future.

New Logic Research
Efficient construction andoperation of filtration systems

New Logi c Research 45

Filtering water permanently
and more efficiently
New Logic Research relies on vibration and ifm for its VSEP technology

Heart of the overall system: The
filtration system together with the
20 hp motor that generates thevibratory action at the membrane.

Filtration is the simplest way to separate solids from aliquid. Basically, all you need is a filter – usually a membrane in the industrial sector – and pressure to press
the mixture onto the membrane surface. The size of thepores in the membrane determines which solids in theliquid are retained by the membrane.
The problem: Over time, these solids foul and plug the
pores, thus preventing any liquid from passing. It is thenhigh time to replace the membrane.
Vibration prevents membrane fouling
The founders of New Logic Research also realised that this issometimes quite an expensive undertaking. With Vibratory
Shear Enhanced Processing (VSEP), they offer a filtration technique that, according to the company, significantly increases
the service life of the membrane and also allows up to tentimes higher filtration rates. Chip Johnson, COO of New Logic

Research, explains: “As the name suggests, we use vibration,
which is specifically applied to the membrane, during thefiltration process. This helps to keep the membrane surface
cleaner and ensures the cycles between cleaning or replacing amembrane are significantly longer than those of competing filtration techniques. At the same time, we achieve an extremely
high level of throughput with less power consumption.”
All relevant values of the system at a glance
To ensure the filtration process runs as efficiently as possible,
New Logic Research today relies on numerous ifm sensors topermanently monitor the parameters vibration, flow rate, pressure, temperature and the conductivity of the water as indicators of the filtration quality. “In the beginning, we supplied
filtration systems without comprehensive sensor technology to
our customers, who were then responsible for their operation.
However, we soon realised that our system can only achieve

Instead of routing the cables of all sensors of the filtration
system to a central controller, IO-Link masters receive thedata in a decentralised manner and forward it as a bundled
package. This reduces cable routes, saves time and eliminates sources of error.

The IO-Link masters receive the datafrom the sensors in a decentralisedmanner and forward it as a bundled
package. This reduces cable routes, saves
time and eliminates sources of error.

the desired and expected efficiency and longevity if it is handled correctly, and that correct handling is intrinsically linked
to specific know-how that we cannot always expect customers
to have. That’s why we decided to offer filtration as a service,”says Chip Johnson.
Automation creates maximum efficiency
Since changing the corporate approach, relevant values are
now monitored by sensors – which provides a range of benefits
for both customers and New Logic Research: “Thanks to fullscale automation and continuous monitoring of the filtration
system, we’re always able to get a clear picture of a system’s
condition for ourselves and our customers. This is how we
prevent the expensive membranes from being excessively
stressed. In most cases, we can perform the regular system
checks remotely – saving us and our customers a lot of timeand money, as our experts only have to be on site in case ofan emergency,” says Johnson.
Reliable sensor makes a lasting impression
The fact that New Logic Research relies primarily on ifm formonitoring and controlling its filtration systems has to dowith Johnson’s initial experience with a pressure sensor fromthe automation specialist: “I don’t remember exactly when I
first came into contact with ifm,” says Johnson. “What I do
remember very clearly though is that the first pressure sensor

New Logi c Research 47

Because ifm offers a wide range ofsensors that we can actually use, thecompany is our first choice in thesecases.

More clarity in the control cabinet: Thanks to IO-Link, thenumber of incoming cables is reduced considerably. And thestandard M12 connection ensures error-free wiring.

I bought from ifm was simply indestructible. It ran and ran
and ran – I wouldn’t be surprised if it’s still busy at work insome system somewhere. This level of reliability, this excellent
price-performance ratio, quickly convinced all of us at New
Logic Research. And because ifm offers a wide range ofsensors that we can actually use, the company is our first
choice in these cases.”
IO-Link infrastructure speeds up cabling
In addition to the sensor technology, New Logic Researchalso relies on ifm’s IO-Link portfolio.
Engineering Manager Matt Ayers describes the advantagesof the system: “Thanks to the IO-Link masters and standard
M12 cabling, we’ve been able to speed up the wiring of ourfiltration systems considerably. Instead of having to label hundreds of metres of cables, pulling them through the system tothe central controller and making sure they’re all connected
correctly, we can now connect the sensors to the masters in adecentralised manner. And thanks to the standard M12 connection, this is achieved without errors and without having
to constantly think about what you’re doing. What took us a
few weeks in the past, can now be implemented in just a few
days. This provides a considerable time buffer, especially in thehigh-pressure phase shortly before delivery to our customers.”

Separating the precious from the valuable
Customers who rely on New Logic Research’s filtration systems
include, for example, mine operators and manufacturers ofcatalytic converters for the automotive market.
“The reasons why our customers turn to our systems are thesame, no matter what industry they’re from. They want toseparate water from valuable solids as efficiently as possible inorder to use them either for the first time or again. Other customers use our systems to treat their industrial process water
before returning it to the regular cycle. The more efficiently ourcustomers achieve their goals, the more attractive our filtration
method becomes. And the more water of sufficient quality isreturned to the global cycle. So, in many cases we separate
the precious from the valuable. As water is set to become thenew oil; and the only thing that can be done today and in the
future is to conserve as much of this increasingly rare resource
as possible. And we want to contribute to this with our solutions.”

Conclusion
With the help of ifm’s reliable sensors, New Logic Research canoffer its customers a holistic service consisting of efficient filtration and condition monitoring. And IO-Link takes efficiency tothe next level by enabling automation. Thanks to fast, guaranteed error-free cabling.

Refresco
Digitised bottling plantwith IO-Link and AS-i

Refresco 49

Modern, efficient, transparent:
bottling plant 4.0
ifm has supported Refresco and Tetra Pak in a “greenfield” digitisation project

Refresco Group is the leading soft drinks bottler inEurope. As co-packer, the company fills non-alcoholic
beverages from numerous well-known brand manufacturers in bottles and carton packs. In France alone, thecompany operates four bottling plants, including one
at the Le Quesnoy site. In order to meet the growing
demand for both types of containers even more efficiently,
Refresco decided to build a new factory here in the northof France with a capacity to fill up to 30,000 PET bottles
and 8,000 cartons per hour.

For us, AS-i offers theadvantage of simple,
well-prepared planningand an equally trouble-free
implementation.

Digitisation project accompanied from the outset“It was clear to us from the very beginning that we wanted a
new building that was state of the art and, above all, that we
also wanted to benefit from the advantages of digitisation,”says Joseph Kerdo, project manager at Refresco France andresponsible for planning the new plant.
To realise the networked factory, the company worked closelywith ifm as their digitisation partner, and also with Tetra Pak,
who were responsible for constructing the filling lines.
“ifm supported us in the project from the very beginning,proposing the right solutions and answering all our questions,”
explains Grégory Croizier, Automation Team Leader at Tetra Pak.

Using insulation displacement
technology, the individual valves canbe reliably and accurately connected to
the AS-i infrastructure via the hygienic
AS-i flat cable insulation displacement
connectors made of stainless steel.

ifm supported us in
the project from the very
beginning, proposing theright solutions and answering
all our questions.

AS-i and IO-Link for digital data transmission
An infrastructure of IO-Link and AS-Interface was designed
for reliable digital data exchange. The advantage of IO-Link
over analogue wiring is the decentralised bundling of sensor
information via IO-Link masters installed in the field, to which
the sensors are connected via unscreened, standardised 5-polecables. This simplifies wiring and reduces the error potential in
the sensor connection. Since data transmission is digital only,
measurement data is not distorted by conversion processes.
EMC effects, too, cannot affect the information.
“IO-Link and AS-i greatly simplify data architecture,” confirms
Grégory Croizier. “The data is consistently available and thecustomer benefits from easy, reliable maintenance because
the diagnostic options are much better than before. Anotheradvantage is that components can be easily replaced without
having to be reprogrammed.”

Field-compatible IO-Link masters andAS-i modules enable a decentralised
connection of the sensors and thus
considerably reduce the wiring complexity.

Simple, flexible, versatile
AS-i is used to connect the valves and for the process level.
Grégory Croizier explains the reasons: “For us, AS-i offers theadvantage of simple, well-prepared planning and an equally
trouble-free implementation.”AS-i shows its advantages especially when widely distributed
data points are connected. Only a two-wire flat cable is requiredfor data transmission and power supply to the connected sensors.

The cable length can be up to 1,000 metres when using standard cables and repeaters. Longer distances of up to 3,000 metres
can also be bridged using fibre optic cables. Sensors and masters
can be connected to the AS-i cable flexibly and precisely at any
point using the insulation displacement technology.
Another advantage: AS-i can be combined with IO-Link – ashas been the case in the Refresco project. The decentralised
sensors on the individual plant components are bundled via
AS-i-compatible IO-Link masters and then transmitted to the
PLC and the IT level via the AS-i infrastructure. Even safetyrelated applications, such as the monitoring of manholes, canbe implemented using AS-i thanks to the safety portfolio.

Conclusion
Given the flexible possibilities and easy handling of IO-Link
and AS-Interface, Tetra Pak was able to plan and implement
the bottling plant digitisation for the Refresco Bluebird project
quickly and easily. Refresco itself also enjoys various benefits:
more accurate sensor information, better diagnostic options
and easy maintenance.

Refresco 51

RFID-coded safety sensors monitor
the condition of the manholes, thus
ensuring a safe operation of thesystem.

Steffen Hartmann
Recyclingtechnologien
Vacuum evaporator

Steffen Hartmann Recyclingtechnologien 53

Cleanly evaporated
Efficient industrial water treatment using IO-Link

Vacuum evaporation is a suitable method for treating
industrial wastewater such as coolants. Vacuum evaporators separate water from contaminants and treat itfor reuse. Intelligent sensors ensure low-maintenance,
cost-effective operation.

In vacuum conditions
The operating principle of the vacuum evaporator consists of“boiling” the polluted medium in a boiling chamber. Similar
to a kitchen stove, heat is supplied to the lower part of thecontainer, resulting in clean water vapour, which is condensed
in the boiling chamber and discharged. The contaminatedconcentrate remains at the bottom. But why is the process
conducted under vacuum?

In many industrial processes, liquids are treated to be reused,ensuring a low carbon footprint and reducing disposal costs.
A common example is the treatment of coolant emulsions usedin machine tools. In addition to mechanical cleaning, the waste
oil must also be separated from the water.
The company Steffen Hartmann Recyclingtechnologien GmbH
from Thale in the German Harz region specialises in the development and manufacture of wastewater treatment plants,
including vacuum evaporators.

In the boiling chamber, the polluted
medium evaporates at around 40 °C
under vacuum, and is thus separated
into clean distillate and concentrate.
LMT sensors monitor the level in thechamber at different heights.

Managing Director Sascha Holthusen explains: “Our vacuum
evaporator has been specifically developed for treating thiskind of industrial wastewater. The consumed coolant emulsion
is fed in, and out comes a small amount of concentrate as well
as a clean distillate, the pure water, which can be used forother processes or discharged to the sewer system, eliminatingcost-intensive disposal.”

Sascha Holthusen explains: “In vacuum conditions, waterboils at lower temperatures, in this case already at 40 °C. At
this temperature, we can even evaporate more aggressive
media such as acids or alkalis without damaging the stainlesssteel walls, as would happen at higher temperatures. Also,
certain substances remain in the concentrate at this relatively
low temperature and do not separate. Another advantage ofvacuum evaporation is that we need less energy for heating.
For this purpose, we use an efficient refrigerant compressor.
The way it works is similar to a heat pump, and it is moreenergy-efficient than direct electric heating, for example. The
same refrigerant allows the water vapour to be condensed.
Alternatively, we can also use the existing process heat of ourcustomers, which we then feed to our vacuum evaporator via
a heat exchanger.”The LDL101 conductivity sensor
monitors the purity of the distillate.

Process parameters at a glance
As part of process monitoring, key parameters such as pressure and temperature are monitored. ifm sensors continuously
monitor these parameters to optimally manage the evaporation process. They control both the heat supply and the vacuum pump.
Another decisive factor is the level in the boiling chamber,which is precisely monitored by LMT level sensors installedin the tank wall at different heights. The medium supply is
stopped as soon as the upper level sensor reacts, and resumed
when the level drops to the lower sensor.
Further LMT sensors are installed in the coolant supply tank of
the vacuum pump for level monitoring at three different positions. Yet another LMT sensor is installed in the distillate collection tank. As soon as its maximum capacity is reached, thesensor provides a switching signal, which causes the distillate
to be pumped out.
LMT level sensors are distinguished by their hygienic design.
Their high-quality housing materials such as PEEK and stainlesssteel (316L / 1.4404) are highly resistant to aggressive media.

Steffen Hartmann Recyclingtechnologien 55

Specially designed for aggressive
ultra-pure water, the SU flow sensor
measures the amount of distillate.

Foam and other potential deposits are automatically suppressed and cannot affect the sensor performance, ensuring continuous and reliable level detection.
Water quality measurement
Continuous water quality monitoring is essential, especiallywhen it comes to ensuring the purity of the distillate. For
this task, an LDL101 conductivity sensor is used. Its measured value secures the quality of the entire evaporation
process and of the pure water obtained from it.
The ultrasonic flow meter “SU Puresonic” has been optimised specifically for applications in pure and ultra-purewater. This sensor can precisely determine the amount ofdistillate. Its component-free measuring pipe is made ofhigh-grade stainless steel, providing excellent resistance toaggressive media. It is important to note that “pure” ordistilled water, while it may sound harmless, can be aggressive toward metal materials and requires special stainlesssteel alloys. Interestingly, this sensor is often used in plastic
pipes, as they are not affected by pure water.

Pump monitoring prevents damage
A central unit of the system is the vacuum pump. If it is notadequately cooled or if the vacuum becomes too strong,
unwanted cavitation can occur on the impellers, which canlead to material wear. Cavitation produces extraordinary vibrations. A vibration sensor installed in the housing of the vacuum
pump detects any unusual vibration patterns and transmits
them to the controller. As a result, an unloading valve will open
automatically and secondary air will be supplied to bring thepump operation back to its normal state. This effectively prevents expensive pump damage.
Digitisation with IO-Link
All of the sensors used are IO-Link compatible, offering a real
added value that goes far beyond the simple transmission of
measured values or switching signals: IO-Link enables users toaccess the sensors remotely, read data and diagnostic values
and configure the devices in various ways.
Sascha Holthusen explains the use of IO-Link as follows: “If acustomer has a problem with their system, we can connect toit remotely via a VPN connection. In the past, without IO-Link,

All sensors are connected via IO-Link.
This reduces set-up times, facilitatesparameter setting and enables remotediagnosis right down to the sensor
level.

Steffen Hartmann Recyclingtechnologien 57

With IO-Link, we can
now see the status of
the system right down toeach sensor.

we only got as far as the PLC, but not down to the sensor
level. With IO-Link, we can now see the status of the systemright down to each sensor. We can see whether a sensor delivers measured values or whether a specific error occurred in
the IO card of the PLC or in the cabling. We can also read thesensor’s diagnostic values and adjust its parameters remotely ifnecessary. If the customer has replaced a sensor, we can configure it remotely. Thus, IO-Link offers us and our customers
a considerable advantage in terms of remote maintenance.
Another important benefit is the scalability of the measured
sensor values, which we can configure via IO-Link. We usepressure sensors with a measuring range from -1 to 10 bar.
We can scale them in such a way that the measuring range
covers -1 to 1 bar at full resolution. It’s impossible to achieve
this with conventional sensors with analogue current output.
What’s more, IO-Link sensors can transmit multiple measured
values. For example, the flow meter and the pressure sensor
also provide temperature values via IO-Link. This reduces thenumber of required sensors and mounting locations.”

Cost savings through IO-Link
The IO-Link sensors are connected to decentralised IO-Link
master modules, which communicate with the PLC via a fieldbus such as PROFINET. This type of cabling has many benefits
during installation, as Sascha Holthusen explains:“Especially with large systems that are dismantled for delivery,
this cabling proves to be extremely beneficial. The mechanic
who reassembles the system at the customer’s site only needs
to connect the plugs. We don’t need an electrician to reconnect wires or route them to the control cabinet. In times
where skilled workers are scarce, reducing the time spent onsite offers considerable cost saving potential. Another benefit is that the I/O check during system set-up can be donemuch faster, as no wiring errors or terminal problems occur.
While the initial cost of IO-Link may be higher than that ofconventional wiring, the time saved during installation andthe extended diagnostic and remote maintenance capabilities
mentioned earlier ultimately lead to substantial cost savings.”

Conclusion
Cost-efficient water treatment is achieved through two key
factors: energy-efficient vacuum evaporation and implementation of a digitalised control concept down to the sensor level.
This concept considerably minimises installation and maintenance costs and keeps the boiling point at a low level, which isbeneficial both economically as well as ecologically.

Veltins
Smart valve monitoring forthe secondary circuit

C. & A. Veltins brewery 59

Making valve monitoring enjoyable
The C. & A. Veltins brewery relies on MVQ valve sensors supplied by ifm

Transitioning tradition into the modern age – that is
one way to describe the history and development of theGerman C. & A. Veltins brewery, headquartered in
Grevenstein, over nearly two-hundred years. What started
as a country brewery has become one of Europe’s largest
and most modern private breweries, producing over
3.36 million hectolitres annually at the last count.

heated or cooled during the process, we do that by means ofwater. Brought to the right temperature, the water is available
via the secondary circuit. Inflow and outflow are controlled
by valves. To ensure uniformly high product quality and keep
wastage to a minimum, we need to control the flow of water
exactly and reliably all the time. This, in turn, means that it isvery important that the valves function without a hitch.”

Whether it concerns electricity, innovative brewing and bottlingtechnology or its own waste disposal plant:
Time and again, C. & A. Veltins has trodden new paths, setsector standards and devoted itself to sustainable use of natural
resources – especially the spring water that emerges right next
to the brewery.

Easy to use, solid quality, precise data
Previously, the valve flaps were monitored with the aid of two
proximity switches per valve that determined the flap position.
These sent a switching signal to the controller, either ‘valve
open’ or ‘valve closed’.

Exactly controlling the temperature
C. & A. Veltins’ CEO, Peter Peschmann, explains that thisspring water is not only used for brewing, but also as a meansof heating and cooling. “Whenever our products need to be

Technology CEO Peter Peschmann explains: “Quite apart fromthe need for dual cabling, this method was especially prone to
failure in the hot water pipes, because the inductive sensors
supplied previously by another company could not cope withthe temperatures over long periods of time.”

The MVQ valve sensor is a reliable and also easy-to-use alternative, and it is successively being implemented by ifm’s automation specialists.
It is mounted on the axis of rotation of the swivel valve. From
there, it registers the position of the valve flap – continuously
and with an accuracy to the nearest degree – and transmits the

For C. & A. Veltins, the MVQ
represents real progress on our
way towards reducing water
losses as much as possible.”The hot water needed during the production process is kept in a separate pipe
system. Inflow and outflow are controlled
via valves. The green LED on the MVQs
shows: The valves are open.

Hops, malt, water: The ingredients fora classic Pilsner beer. To ensure that theresult really tastes good, the temperature has to be exactly controlled during
the brewing process.

The position of each individual valve is visible from afar thanks
to the MVQ’s informative LEDs. In the Veltins brewery, permanent
red means: valve closed. Altogether, the MVQ provides sevencolours for coding status.

data via analogue signal to the controller. It can also transmit
the data via the digital IO-Link communication protocol, witheven more detailed diagnostic information. For instance, slower-than-expected flap movements or failure to reach the exact
end position on account of wear or deposits are registeredby the sensor, and the results are sent to the PLC for further
processing as well as being displayed locally via LED. Switching
points can be set freely so as to allow for simple integration
into the control program.
Fewer losses – genuine benefits“Thanks to the exact registration of the angle and the movement times via IO-Link, we are able to detect deposits at an
early stage and plan the flap maintenance in the best possibleway,” explains Peter Peschmann.
A case has already arisen in which the capacity to detect evenvery small flap openings was a great help to the company.

C. & A. Veltins brewery 61

Veltins already has around 40 MVQs in its heating andcooling systems. Data is transmitted either via digital IO-Link
communication, or analogue.

“We were losing water in the circuit, and we couldn’t localize
the cause because there are no inspection visors installed in
our large pipes. The MVQ then enabled us to find out that oneof the valves was not closing completely. The valve was thenrendered serviceable again at short notice, putting an end to
the water losses. This demonstrates the potential and options
that precise valve monitoring open up. For C. & A. Veltins, theMVQ represents real progress on our way towards reducing
water losses as much as possible.”
The status: clear as daylight
The MVQ’s display showing the current valve status by meansof easily visible, multi-colour status LEDs was another decisive
factor influencing Veltins’ decision to install the sensor successively on all swivel valves in the cooling and heating circuits ofthe brewing and bottling processes.

“The main plus-points in favour of the sensor are the clear
status display, the closed housing, the ease of installation that
only requires a standard unshielded M12 cable, as well as
the capability to gather all the data supplied by the sensors
at the central IT level,” says Veltins’ technology CEO Peter
Peschmann.
Over ten years of cooperation in mutual confidence
To date, around 40 ifm valve sensors are now in operation in
the C. & A. Veltins brewery, of which some operate in analogue mode, and some have an IO-Link connection.
“We are convinced that the IO-Link brings added value regarding plant availability,” says Peter Peschmann. Initial projects
involving vibration monitoring were also successfully implemented prior to the use of the MVQ.
“Altogether, we have already been working with ifm for overten years. Starting with the quality and usability of the prod-

ucts all the way to the competent, collegial support and advice
with regard to further development of our automation solutions, we are very convinced of the value of this cooperation.”

Conclusion
With high-quality products and expert support from ifm, theC. & A. Veltins brewery can ensure reliable functioning of theheating and cooling circuits, and set up the automation solutions in a forward-looking and resource-saving way.

ifm article no. 78005036 · We reserve the right to make technical alterations without prior notice · ifm electronic gmbh · Friedrichstr. 1 · 45128 Essen · Germany · 04/2024