Clever, intelligent…but more commonly recognised as ‘smart’. A simple definition of an essential component increasingly used in today’s food and beverage manufacturing applications and acknowledged as a bridge to the digital future from analog to IO-Link.
So what is the technical definition of a smart sensor?
It’s a device that takes input from the physical environment and utilises built-in computer resources to perform predefined functions with detection of specific input and then processes data before passing it on to operators for analysis and action. Or, put it another way, ‘Smart’ sensors allow for ultimate machine performance using powerful measurement technology, innovative design principles and reliable repeatability.
What are the key Features and Benefits?
Today, smart sensors are being increasingly used in food manufacturing industries as they reduce resource consumption in some applications by 30% or even up to 50%. CIP (Cleaning-in-place) is one area where smart sensors are helping operators to save time and energy, whilst also reducing water and detergent consumption, without jeopardising food and process safety.
Also, for faster and more accurate measuring of heat exchangers, helping to optimise energy consumption and cleaning regimes, along with improved inventory management. The result is more accurate production planning based on real-time values helping to optimise safe batch separation, improving production quality whilst minimising material wastage by optimising the emptying of storage tanks and silos.
Inventory Management is another area where smart sensors enable more accurate production planning based on real-time values, ensuring complete material consumption in emptying storage tanks and silos. Also, safer, more efficient batch separation which ultimately improves production quality.
Providing a Bridge to the Digital Future
The connected Smart Sensors offered by Baumer are characterised by industry leading precision, miniaturised design and trend-setting functions. Flexible Dual Channel interfaces help operators to switch from analogue to digital output in parallel which means all the IO-Link benefits are accessible. However, sensors can be controlled via 4-20mA analogue output, especially in filling and packaging applications in food and beverage production. The sensors are designed to supply both fast real-time data for machine control as well as acyclic data for status analysis and process optimisation, paving the way to digital 4.0 communication.
So what is the potential for Smart Sensors?
Most people associate the term ‘smart sensor’ with IO-Link and secondary data for machine monitoring. However, for Baumer important features like these are just the beginning because with smart sensors integrating freely accessible additional digital services ensures maximum ease of operation. A good example of this is their OXM200, a smart profile sensor and one of the most compact and lightweight in its class. The important questions posed by system designers would typically be; how does the sensor integrate into a machine? How do ‘blind’ areas in the receiver and detection range behave? In most cases users continue to follow the complex, conventional procedures of collecting dimensions and coverage from data sheets for design-in via CAD, but this is time-consuming and prone to errors.
The Baumer solution is smarter as it provides a full 3D CAD sensor model with detection area and other relevant information as a digital twin which means designers can easily transfer the supplied data to their models and compare it with the machine design. This means users can see the sensors dimensions, detection range, blind and receiver range and so ensures they can identify the ideal position and parameterisation already on screen.
Sensor specialists BAUMER have proven expertise in developing high-precision, smart sensor solutions for factory and process automation helping to pave the way to the smart factory. The Baumer Group is one of the World’s leading experts in high-performance sensors and sensor technology for industrial automation. Find out more at: https://www.baumer.com/gb/en/product-overview/smart-vision/c/296
