Safety encoders: SIL2 PLd rating for automated vehicles

The sensor redundancy required to ensure safe operation is already integrated in the safety encoder. This and the corresponding continuous self-monitoring of safe operation have been tested and certified by TÜV Rheinland. The sensor is also integrated into the SISTEMA library. This immensely reduces the effort required to implement and subsequently accept safety-related automation. The safety encoder also has both a CAN input and a CAN output. Hence, several encoders or other compatible sensors can be connected in series, making the installation of safety sensors efficient and simple.

The combination with the ifm controller also significantly reduces the programming effort in CODESYS because the seamless connection of the encoder to the controller and secure communication between the two products is guaranteed by default.

1. CANopen  safety encoder
2. Safety controller / Hardened PLC
3. O3M mobile camera
4. HMI display controller
5. RFID readers / tags

AGVs and AMRs

In automated vehicles such as AGVs and AMRs, safety encoders provide reliable position and movement detection to support precise navigation and control in dynamic environments such as warehouses, factories and logistics centers.

Use case: Comprehensive AGV ecosystem

Mobile forestry machines

In mobile forestry machines, safety encoders provide reliable rotation and position detection, allowing precise control when felling, cutting and transporting wooden materials.

Use case: Precise positioning in the forestry industry

Mobile machines

Safety encoders enable precise control and monitoring of moving elements such as axles or turntable ladders, increasing the safety and efficiency of mobile machines, including construction vehicles, refuse trucks and fire engines, in various industries.

Use case: Improved machine safety

Cranes and hoist machines

Safety encoders support cranes and hoist machines by precisely detecting rotation angles and height positions, enabling safe and efficient handling of heavy loads in various industrial applications.

Use case: Safe operation of elevating platforms and lift trucks

Comprehensive AGV ecosystem

ifm offers seamless integration solutions for the AGV/AMR market. RFID tags can be securely embedded into the end user’s floor, while RFID readers are installed on the moving AGVs to detect these tags and determine their position. Safety-rated encoders can be dynamically "preset on the fly", allowing AGVs to receive new parameters and navigate accurately once an RFID tag is detected. This ensures operators can track the AGV’s past and future movements precisely. Coupled with ifm’s mobile robotics perception platform and durable mobile controller, ifm delivers a full-fledged solution for the market.

According to an AGV manufacturer from Spain, "The fact that this device supports "preset on the fly" is a big advantage for us as an AGV manufacturer."

1. CANopen safety encoder
2. Safety controller / Hardened PLC
3. O3M mobile camera
4. RFID readers / tags

Precise positioning in the forestry industry

In the forestry industry, precise positioning is critical for both safety and efficiency. A leading manufacturer of forestry machinery has implemented the ifm safety encoder on the gear rim of a rotating crane arm. The encoder accurately detects the position of the crane arm, allowing operators to maneuver it with pinpoint accuracy.

By continuously monitoring the arm’s position, the safety encoder ensures that the machinery operates within safe parameters, reducing the risk of accidents. This precision also enhances operational efficiency, as the crane arm can be positioned quickly and accurately, minimizing downtime and maximizing productivity. The implementation of this technology represents a significant advancement in forestry machinery, combining safety with high performance to meet the demanding needs of the industry.

Improved machine safety

Many construction machine manufacturers that utilize ifm’s safety controllers are now incorporating safety encoders into their equipment. These encoders are being used, for example, to precisely detect the position of the rotating superstructure of excavators. This precise detection is required for machines that must operate within specific ranges to avoid hazardous areas.

By installing the safety encoder directly on the slewing gear of the superstructure, manufacturers can achieve accurate position detection. This enhancement significantly boosts both the safety and efficiency of mobile machines. The precise positioning ensures that the machinery operates within safe boundaries, reducing the risk of accidents and improving overall operational efficiency. This integration of safety encoders represents a significant technological advancement, providing construction machines with the ability to perform tasks with greater precision and reliability.

Safe operation of elevating platforms and lift trucks

For the customer, precise monitoring of the position and speed of lift trucks and elevating platforms is important to ensure the safety and efficiency of activities. The safety encoder reliably transmits these values for precise and efficient vehicle control.

To ensure safety on elevated platforms and lift trucks, their inclination angles and extended telescopic lengths must also be monitored. If angle and length do not match, tip-overs are likely. To minimize this risk, the customer uses the safety encoder on the telescopic joints to control the axis angle. Internal draw wires monitor the extended length of the telescopic arm. This ensures maximum safety and reliability of the lifting equipment.

According to a customer from the lifting technology sector, "This device looks very solid. Its architecture would be SIL3 Ple capable."

The “preset on the fly” feature of the safety encoder enables quick and effortless position synchronization without halting ongoing operations. This synchronization can occur automatically, utilizing data from RFID tags embedded in the floor. Consequently, the position of the AGV can be dynamically adjusted, eliminating inaccuracies caused by factors such as slip.

ifm's safety encoders use the same magnetic technology as our other multi-turn absolute encoders.

Magnetic encoders use Hall-effect sensors to detect rotary movements. The sensors detect the orientation of a permanent magnet attached to the shaft. A microprocessor then calculates the angle of rotation of the shaft from the sensor signals.

• High resolution and accuracy but smaller package and lower price point
• Fewer components for more robust solution
• Programmable resolution and output
• Variants available with IO-Link for process transparency

1. Magnet
2. Hall sensor
3. Wiegand wire

Multi-turn encoders provide a unique coded value consisting of the location on the disc (resolution) and the location of the gear train (revolutions).