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Safety is paramount for the railway industry, and one of the most important aspects of this is maintaining all railway tracks in a safe condition. While today’s longer welded rails have made the ride much smoother than the shorter rails of old, they do make it more difficult to assess the condition of the lines.

The standard test of the condition of any line is to exert an upwards force on a rail and measure the displacement from the sleeper that results from the force. If the displacement is too high for any given force, then maintenance is required. 

Clearly such testing cannot be carried out while the track is in use, and so maintenance crews perform the tests at night. However, time is still important, particularly on the busiest of main lines, and the testing has to be performed in between services while assuring the safety of the maintenance crew and of the test rigs themselves. 

One rail operator approached Sensor-Technik to help improve the design of such a test rig to reduce the time taken to perform the all-important rail safety testing. This involved supplying a tension loadcell and a displacement sensor that could be interfaced with an existing handheld computer. 

Like any heavy maintenance equipment, the hydraulic test rig and all its components needed to be very robust. And while the sensors specified by Sensor-Technik were inherently robust, the design included a rugged housing to provide extra protection, stainless-steel conduit to protect all the cables and special protective boots for all the joints and connections. 

The electrical design – ie getting the sensors to communicate with the handheld computer – was relatively simple. The majority of the development effort went into ensuring that the test rig was robust enough to withstand harsh environmental conditions and capable of handling the inevitable abuse from operators.

The test rig has been a great success: the sensors work well and the failure rate is low. However, occasionally sensors have been left in the wrong place and have been crushed by trains, and sensor cables have been known to become caught in the hydraulics and pulled out. As Morten Moller, MD of Sensor-Technik UK, points out: “We can can go to great lengths to create ruggedised equipment that will survive day-to-day use with ease, but we can’t account for every possible misuse!”.

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Available now from Sensor-Technik UK, the ENIX 50 is a universal encoder that uses all of Micronor’s latest technologies to save space and cost and increase reliability in all manner of industrial rotary measurement applications on shafts from 6 to 15mm. 

With its 50mm-diameter housing and depth of just 37.5mm, the ENIX 50 is compatible with all standard 58mm size encoders, providing immediate space and cost savings. Its hollow shaft design features Micronor’s “Safety lock” bearing construction, which not only resists damage caused by inadvertent loading during installation but also increases the overall life of the encoder, further reducing the total cost of ownership by cutting out maintenance and replacement. 

The rugged encoder features a solid die-cast housing, sealed to IP65 or IP67, and has a wide operating temperature range from -40 to +85C. The level of shaft sealing does, however, have an impact on the maximum speed rating of the encoder: IP67 sealing reduces the maximum permissible speed from 12,000 to 6000rev/min. 

The ENIX 50 is amply protected against shock and vibration, and meets all CE marking requirements for electrical safety and electromagnetic compatibility. It is UL approved, and can be supplied as an explosion-proof assembly for use in Zones 2 and 22. 

The ENIX 50 series is available with a choice of standard resolutions from 1 to 3600 pulses per revolution, covering a wide range of applications. There are also many connection options, including cables and M12 connectors, and outputs can be specified as RS422 or push-pull. All outputs are protected against short circuits. 

Application flexibility is further enhanced by a wide operating voltage range. All encoders in the family operate from 5-30V DC supplies, removing the need to specify different models for each individual application.

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Download datasheet

The Wachendorff OPUS A4 HMI available from Sensor-Technik UK is an ideal dashboard display for critical vehicle-mounted CANbus systems. Combining a high-brightness 16:9 format TFT display with the ability to superimpose live video inputs from vehicle-mounted cameras, the OPUS A4 ensures that the operator is always aware of the status of his or her onboard systems, and can monitor the outside environment at the same time.

Perfect for use in any off-highway application, including agricultural machinery and other commercial vehicles, the OPUS A4 HMI is designed with modern smooth lines that complement the décor of today’s vehicles, while featuring the rugged construction and reliability essential for the working environment.

Despite its compact size of just 250 x 140 x 74mm, the multi-talented HMI features a large 6.5-inch wide-screen display of 400 x 234 pixels and simple controls in the form of one hard-wired key with six softkeys for full control functionality. The display brightness is controlled from a single large-format potentiometer. Further feedback is provided by a single multicolour LED and a loud 80dB piezo alarm buzzer. All controls can easily be operated while wearing gloves – an important consideration in the off-highway machinery market.

At its heart, the A4 HMI features a powerful 16bit microcontroller with 1Mbyte of SDRAM, 8Mbyte of Flash memory for mass storage and 32Kbyte of serial EEPROM. The memory can be expanded via an optional SD card slot. Two CANbus interfaces are provided as standard, and an optional CCITT video input enables the overlay of video streams.

The unit runs from a wide 10 to 50V power supply, and so can be used with any commonly used automotive battery system. All standard connections are via a 12-pin Deutsch connector with protection against short circuits and reverse polarity. And although designed for the relative safety of the dashboard, the CE-marked HMI features a wide -25 to +65C operating temperature range and protection against shock (up to 30g) and vibration (5g up to 300Hz).

Systems integration is made easy with a choice of programming methodologies. The A4 can be programmed in C, or visually using Wachendorff’s own Projektor software package. Alternatively, Sensor-Technik can supply the attractive and versatile HMI ready programmed for the application or as part of a fully specified CANbus system.

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Available now from Sensor-Technik UK, the C2U-Mini is a compact unit that records data from CANbus systems for later analysis on a standard PC or notebook computer. Designed for easy integration with vehicle-mounted systems, the datalogger features both CANbus and USB interfaces to bridge the gap between the automotive and desktop worlds and enable CANbus systems analysis in a familiar desktop environment.

Housed in a rugged die-cast enclosure, the C2U-Mini is an all-solid-state device equipped with 128Mbyte of NAND Flash memory for data recording with a powerful 16bit microcontroller and 512Kbyte of RAM. There are two CAN 2.0B interfaces, each capable of communicating at up to 1Mbit/s with CANbus controllers such as Sensor-Technik’s own ESX family devices.

On the PC side, the logger has a full USB 2.0 interface, and comes with easy-to-use Windows-compatible software for downloading and analysis of the logged data. Alternatively, the C2U-Mini can be used “in reverse” for loading programs and data from a PC to a CANbus system. 

The unit is designed for easy installation and operation in automotive and off-road environments. A bespoke mounting bracket holds the logger securely in place, and all connections are by a single 8-pin M9 plug. Alternatively, Sensor-Technik can supply customised cable sets to suit individual applications. 

The logger operates from a wide 9-32V DC power supply, ensuring compatibility with all common automotive systems, and switches to 5V USB power when that interface is connected. All connections are short-circuit and reverse-polarity protected.

The C2U-Mini datalogger is available now from Sensor-Technik UK, both on its own and as an integral part of the company’s CANbus systems offering.

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The Richmond Industries 600 Series of folded shear-beam load cells offer compact and robust solutions to a wide range of industrial weighing applications. Their high-quality construction and high precision make these bidirectional devices ideal for use in vehicle and axle weigh platforms as well as in overhead crane weighing.

Available in standard ranges from 0-1 to 0-25kN, the 600 Series load cells are made from alloy and stainless steel, and the space-saving folded shear-beam design means that all devices share the same compact outline of 75 x 70 x 25mm. M12 threads are provided at the top and bottom for load connection, and all electrical signals are carried via an integral 2m-long screened cable. Longer cables can be supplied by special request, as can accessories such as load buttons, rod ends and eye rings to enable a full range of tension and compression measurement applications.

The 600 Series are highly accurate, with nonlinearity and hysteresis each quoted at better than 0.05% of full scale, and zero balance at 0.50% of full scale. They are also highly tolerant of rough treatment, accepting 150% overload with no loss of calibration and 200% overload without physical damage. All this is achieved over an operating temperature range of -20 to +70C, with full temperature compensation between +20 and +70C.

Engineers tasked with commissioning and checking of weighing equipment and systems based on the 600 Series will appreciate the provision of onboard calibration circuitry, which removes the need to carry physical weights to verify the accuracy of the load cells.

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Sensor-Technik UK is offering the latest in rotary measurement technology with the ENCAN 58 absolute encoder from Micronor. The highly reliable and versatile single-turn hollow-shaft 58mm encoder comes complete with a CANopen interface with the latest protocols embedded.

The ENCAN 58 is ruggedly constructed with a low internal component count to provide the highest levels of reliability. Its die cast housing is sealed up to IP67, and its OptoASIC design ensures that there are fewer points of weakness. These features combine to provide high levels of resistance to shock and vibration, contributing to long-term reliability in the field.

The encoder can be used reliably in high-speed applications. Versions are available for continuous duty up to 7000rev/min, and can tolerate maximum speeds up to 9000rev/min. All versions offer a generous -40 to +80C operating temperature range.

The ENCAN 58 supports the latest CANopen communication profile according to DS 301 V4.02, and device-specific profiles like the encoder profile DS 406 V3.1 are also included. The interface supports a choice of operating modes, including polled mode, cyclic mode, sync mode and a high resolution sync protocol. Scale factors, preset values, limit switch values and many other additional parameters can also be programmed via the CANbus, with all parameters saved in nonvolatile memory. Outputs can be chosen as position, speed or acceleration, as well as the status of the working area.

Electrically, the encoder runs from a wide 10-30V DC supply range, with a maximum current drain of just 60mA from a nominal 24V DC supply. A wide choice of connections is available, including a bus terminal cover with M12 connector or cable connection or fixed connection with M12, M23 or D-sub connector. Mechanically, the encoder can be mounted directly on large-diameter shafts up to 15mm.

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Download datasheet (PDF)

 The D02 is the new-generation differential pressure transmitter from Sensor-Technik UK. The device features a piezoresistive measuring element in a compact and robust stainless-steel housing to satisfy a wide range of differential pressure measurement tasks in applications ranging from mechanical engineering and industrial control to filter supervision and flow measurement. 

A wide choice of standard devices are stocked, covering differential pressure ranges from 0-0.1 to 0-20bar, and nonstandard ranges are available on request at no extra charge. All devices boast high measurement accuracy, with typical linearity of 0.25% of full scale and pressure hysteresis and repeatability at just 0.1% of full scale.

All sensors feature a wide operating temperature range from -10 to +85C, with temperature compensation provided from +10 to +40C.

The D02 differential pressure transmitter offers easy interfacing in a wide range of applications. The excitation voltage can be anything from 9 to 30V DC, and a choice of voltage (0-10V) and current (0-20 or 4-20mA) outputs further increases application flexibility. All electrical connections are via a standard M12 connector, which is protected against both short circuits and reverse-polarity connection. Other electrical connections are also available. 

With its all-stainless-steel construction, high accuracy and ease of application, the D02 is the ideal differential pressure transmitter for a wide range of applications.

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Download datasheet (PDF)

The OPUS A1 operator interface from Wachendorff has been specifically designed for use in inhospitable commercial vehicle applications. It combines a large bright landscape touchscreen display with a powerful 32bit processor in a ruggedised package to provide a flexible programmable platform for interfacing with all manner of vehicle-mounted systems from agricultural machinery to special-purpose vehicles such as snowploughs. 

The display of the OPUS A1 is an easy-to-read backlit colour TFT supporting VGA resolution with 256 colours. Importantly for use in all possible environments, the display backlight automatically adjusts to the ambient conditions, ensuring that the screen can be read at all times. It also features an analogue resistive touchscreen using PVC on glass technology to ensure easy operation and scratch resistance. 

Further control is provided in the form of a tactile silicon keypad with nine backlit programmable function keys plus a large digital potentiometer with push to operate functionality. 

The interface is not short of processing power. Its 200MHz Intel Xscale processor has access to 16Mbyte of Flash memory, 32Mbyte of SDRAM and 32Kbyte of EEPROM to enable complex applications to be programmed and run in real time. Ample interfacing is provided as standard, with two each of CANbus and serial interfaces, together with two memory card slots for system expansion and programming.

 The OPUS A1 survives the rigours of its environment with a diecast aluminium housing that is sealed to IP65K. Operating temperature range is a wide -25 to +65C, and the interface is also specified for automotive levels of vibration, shock, EMC and ESD. It runs from a wide range of power supplies from 8 to 36V DC, and so is compatible with both 12 and 24V vehicular power systems. 

Internally, the OPUS A1 runs an embedded Linux operating system, but it comes with easy-to use PC software that makes programming simple. The intuitive Prejektor package needs no specialist skills or even training to use. Simple drag-and-drop techniques allow even novice users to produce working systems on the PC that will look exactly the same when programmed into the interface. 

Alternatively, Sensor-Technik UK can supply the OPUS A1 interface ready programmed for any customer application.

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Download datasheet (PDF)

The STW M01 is a thin-film pressure transmitter engineered for the harsh conditions that are typical of mobile hydraulic applications. Sensors are available for pressure ranges from 0-25 to 0-800bar, all with a robust all-stainless-steel construction designed to withstand severe levels of shock, vibration and electromagnetic interference. Despite these attributes, the M01 is a low-cost device that is ideal for high-volume applications, and is also available as an OEM version. 

All sensors operate over a wide -40 to +125C temperature range, and full temperature compensation is provided from 0 to 80C, guaranteeing accuracy within 1.0% of full scale. Even beyond the compensated range the sensor’s output can still be relied on, with a maximum error of 2.5% of full scale over the full operating temperature range. This means that the M01 can be trusted to monitor hydraulic systems on vehicles that operate in true extremes of climate. All devices are amply protected against overpressure, with all but the largest devices withstanding twice their rated pressure.

Sensors are available with a choice of analogue outputs to cater for a variety of application scenarios. Current outputs of 0 and 4-20mA are available for two- and three-wire measurement techniques, and voltage outputs can be specified as 0-10, 0-5 or 0.5 to 4.5V. All types are short-circuit protected.

The M01 sensor’s connections are similarly flexible, with three different choices of electrical connector, plus cable output and three different choices of pressure connection, including G 1/4 and 1/4 NPT. Depending on these choices, the sensors exhibit ingress protection of either IP67 or IP69k.

The M01 pressure sensor is manufactured in accordance with ISO/TS16949 and complies with EN69000-6-2 and -3 for electromagnetic compatibility. Mechanical shock rating is 500g per IEC60068-2-27 and vibration rating is 20g per IEC60068-2-6 at resonant frequency.

The combination of low cost, rugged construction and reliable analogue output makes the M01 an ideal choice for high-volume applications both in off-highway vehicles and in general industrial applications.

Download datasheet (PDF)

Download datasheet (PDF)

The OPUS A3 series of rugged and stylish CANbus operator panels from Wachendorff Elektronik offers new levels of value, versatility and style to designers of vehicle-mounted systems. There are three devices in the series, each based on a powerful 32bit processor, a 4.3in wide-screen TFT display and each with two CANbus interfaces, one serial port and a USB interface. A second USB port is available as an option.

All OPUS A3 series operator interfaces are sealed to IP67 and IP65 with a wide -30 to + 70C operating temperature range, enabling their use in any outdoor application such as agricultural machinery and other off-road vehicles. And each panel can be specified in landscape or portrait orientation both as a stand-alone unit or for dashboard mounting.

The three different models – the economy A3e, the standard A3s and the extended A3x – come with a range of different controls and interfaces. The basic A3e model, for example, has no keypad or encoder, but can be supplied with a resistive touchscreen interface, which is also optional on the other two models. The A3s comes with a rotary encoder, three fixed keys and eight softkeys, whereas the A3x incorporates an encoder, a 15-key fixed keypad and eight softkeys. All keypads can be supplied with custom colours, legends and lighting.

Further options include composite video inputs to enable monitoring of reversing cameras, a rear-mounted Ethernet interface, increased memory capacity, analogue and digital I/O and Bluetooth.

As with other Wachendorff interface panels, the OPUS A3 offers a choice of programming methods to suit systems designers of all levels of expertise. These include: the company’s own Windows-based Projektor-Tool project development software; the popular CoDeSys IEC61131-3 compliant user interface programming language; and, because each A3 is based on an embedded Linux operating system, they can be programmed directly in C/C++.

Sensor-Technik UK offers full customisation, complete with programming and commissioning services for the OPUS A3 operator interface, and will use the units as part of complete CANbus systems.

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