Different load conditions, thermal expansion or manufacturing tolerances mean that high-bay warehouses are always on the move. Ensuring precise, undisturbed positioning of the racking control device in such an environment represents a technological challenge for sensors. What's more, in the wake of Industry 4.0 or IIoT, users' expectations of diagnostic and predictive maintenance options for sensors are growing. This requires the exchange of diagnostic and parameterization data with the sensor.
With the IPS 200i, Leuze electronic brings to market the smallest camera-based positioning sensor for precise pallet positioning on shelves in high-bay warehouses or small parts container warehouses. Leuze electronic thus offers an intelligent alternative to vertical and horizontal positioning with several direct-sensing retro-reflective photoelectric sensors. This eliminates the need for complex assembly, alignment and readjustment operations in continuous operation, saving the customer valuable time. Thanks to an innovative quality indicator, the IPS 200i informs the user of any changes to the sensor or compartment, enabling him to detect possible malfunctions in advance and carry out predictive maintenance: the quality indicator helps to identify anomalies, such as soiling or the presence of an overhanging plastic film. The endangered area can then be located in good time, thus avoiding plant downtime due to incorrect positioning. This approach saves time and money, and contributes significantly to a positive balance sheet in terms of total cost of ownership. An integrated web server provides global access to all relevant data worldwide, without the need for ordering.
Fast commissioning and high reading performance
The multilingual Web-based configuration tool with user-guided wizard minimizes commissioning time. The IPS 200i can also be configured using XML commands, or intuitively commissioned and operated using just two keys, without the need for a PC connection. Innovative LEDs provide direct feedback, making sensor alignment as easy as parking a car. The position of the marker in relation to the sensor is displayed by four LEDs on the sides. Each side LED corresponds to a unique quadrant. If the marker is in one of the quadrants, the corresponding LED glows or flashes. If the marker is in the center (coordinate origin), all four LEDs light up simultaneously. The sensor is then optimally positioned. In addition, in alignment mode, the distance from the marker to the origin is visually represented by the flashing frequency.
The new sensor, optimized for high depth of field, has a fixed focal length and, after coarse positioning, is used for precise optical positioning of the racking tester in the X/Y plane. It can then transmit the correction coordinates required for the exact approach of a compartment to a shelf controller. In concrete terms, the intelligent sensor detects holes or circular reflectors in a single-depth crossbar or column in a pallet warehouse, and determines the deviation of the position of pallets or containers in the X and Y directions from the target position. The positioning sensor generates one or more gray-scale images and looks for a well-defined round marking (hole/reflector). The X/Y deviation from the target position is expressed in millimeters, or signaled via the available switching outputs in quadrants.
Can be used in different temperature ranges
Compact (66 x 43 x 44 millimeters), the IPS 200i industrial version with IP 65 protection is suitable for use in the normal temperature range, as well as for low temperatures down to -30°C, with optional integrated heating. As standard, Leuze electronic offers the new device with a plastic housing cover, which can optionally be replaced by a glass cover. The sensor can be mounted on three sides, allowing flexible attachment to the rack tester. Powerful infrared LED illumination, unaffected by ambient light, provides a high degree of flexibility for use in conveyor and storage technology. The exposure time for moving objects is very short, and no additional external lighting is required. The high speed of object movement, combined with a large depth of field, further enhances the flexibility of Leuze electronic's new positioning sensor. Intelligent image processing algorithms guarantee reliable positioning and high throughput. The IPS 200i's FTP (File Transfer Protocol) image transmission enables uninterrupted (error) image recording.
Easy integration into existing network environment
An integrated Ethernet interface (TCP/IP and UDP) and a forthcoming Profinet interface make direct integration into the network environment and fast, location-independent diagnostics possible without difficulty, via intelligent remote control - a clear winner in the long term, not least from a cost point of view.
Learn more: www.leuze.fr