Increased efficiency, improved commissioning, machine monitoring and process optimisation

Everything in the sensor

Integrated connectivity means: All relevant industrial Ethernet interfaces are integrated into the sensor. It sounds simple but is not standard on the market. Instead, manufacturers often offer devices without an industrial Ethernet interface to save development effort. In such cases, the interface is available via a gateway.

The following examples show why this is not the optimal solution and why the system operator benefits in multiple ways with integrated connectivity from Leuze. The benefits range from commissioning (device management) to machine monitoring (condition monitoring) to process optimisation.

Streamlined system layout

Leuze offers devices with integrated interfaces for PROFINET, Ethernet/IP, and EtherCAT. The advantage that can already be gained during commissioning is demonstrated using design example with and without integrated connectivity. First a look at systems with barcode readers without integrated interfaces: here, each scanner must be connected to a separate gateway - this means an additional gateway with its own power supply for each barcode reader.

As a result, the installation effort and the number of cables are twice as much as needed. The parameterisation is also considerably more complex.

Don’t forget: Because of the required gateways, there are significantly more devices in the system that can cause a malfunction and must be checked. In comparison, the same system with integrated connectivity: The industrial Ethernet interface is already integrated into every bar code reader. This makes separate gateways superfluous.

Above all, the system layout is very clean and requires fewer cables. Last but not least, errors can be eliminated more quickly as fewer devices have to be checked.

Switch included

Leuze sensors with integrated connectivity also have an additional feature that contributes to efficient commissioning: the devices have one switch as standard, i.e. an Ethernet input port and output port each.

As a result, system operators do not need an external switch. In addition, several devices can be wired more easily, for example in a ring or linear topology. With linear wiring, the system operator connects one sensor to another through integrated switches.

Only the last sensor in the chian is connected to the controller. The advantage here is also a simpler system design and fewer cables. Devices without an integrated switch, on the other hand, require an external Ethernet switch. Users must also connect each individual sensor to the switch via a star topology and then connect this to the controller

The usual control environment

Integrated connectivity also means that you can work in your usual control environment. This is possible because the entire device parametrisation is integrated into the GSDML file ("Generic Station Description Markup Language") of PROFINET, for example.

In contrast, many other Ethernet-based devices on the market generally have to be parametrised via a web server. This is complicated because each manufacturer provides its own web server version with its own user interface.

Users have to familiarise themselves with new interfaces every time and find the corresponding functions. In addition: devices without Ethernet that are connected via a gateway often require productspecific manufacturer's software for parametrisation. This may result in compatibility issues with the hardware used.

For example, if the manufacturer does not update their software after a few years. Here too, integrated connectivity has multiple advantages:

• Users remain in their usual control environment
• No manufacturer software installation and related training required.
• No need to access a web server

Leuze devices with integrated connectivity are very easy to parametrise. Only the GSDML file has to be downloaded from the Leuze website via the control and copied once into your engineering software. The modules are then available in the hardware catalogue. The function of the device is explained in a clear and concise way. This makes parametrisation and sensor usage easy and the manual is not required in most cases.

Support from the sensor

A look at the sensor’s device profile with integrated connectivity further simplifies programming. As an example: for the AMS and BPS positioning sensors, Leuze not only provides positioning values but also a calculated speed value. Anyone who needs this value in their system saves time as it does not need to be calculated.

In addition, if you only want to filter for certain barcodes without integrated connectivity, you have to do this via the controller. Leuze BCL bar code readers can be done more efficiently because here you can prefilter according to specific criteria.

Only codes which correspond to the required pattern are transferred to the control. The option to duplicate PROFINET devices in the engineering tool saves time. Users only have to specify the parameters once and can then copy the settings as needed. Integrated connectivity even helps when a device is replaced: If a damaged sensor has to be replaced, the system automatically transfers all the parameters stored in the controller to the new device. The sensor is immediately ready for use.