In 2014, the Federal Cabinet presented Smart Factory/Industry 4.0 as a global challenge for innovation leaders in its "New High-Tech Strategy for Germany" and included it as a priority in its economic and science policy.

And indeed, the economy is on the cusp of the fourth industrial revolution. Driven by the internet, the real and virtual worlds continue to merge into the much-vaunted Internet of Things (IoT). Recent advances in the manufacturing industry have paved the way for the systematic use of cyber-physical systems (CPS), in which information from all related perspectives is closely monitored and synchronized between the physical factory floor and the computer room. The starting point for this is the use of sensors that convert the physical or electrochemical signal into an output signal. Which sensors are suitable for this purpose and which properties they must fulfill are described below.

Sensor systems in the network

More than 15 years ago, Panasonic responded to the tasks of collecting, collating and processing data for automation in production processes. Users expect a range of functions from modern sensors in terms of digital data processing: high reliability and minimal maintenance, flexible network functions and, above all, low energy consumption. These requirements can be met with intelligent sensors, so-called "smart sensors".

The potential benefits of sensor systems in production relate to the automatic identification and data acquisition of objects. The transmission and interpretation of sensor information, the derivation of production decisions and the control of production processes by tracking production orders are examples of applications.

In the future, these sensors will be an essential component of intelligent sensor systems that provide complete signal preparation and processing in addition to the actual measurement. In many cases, they communicate via high-performance industrial networks such as I/O Link, Profinet, EtherCAT, Ethernet/IP and other fieldbus technologies. This plays an important role, for example, in the distance measurement, pressure and flow measurement, fiber optic sensor technology and laser sensor technology segments. As a company, Panasonic was already focusing on smart sensors in 2006 and has played a key role in shaping them for the industrial sector. Four sensors and key application areas are presented here.

Smooth maintenance and parameterization

The compact SF4D safety light grid is designed with IP67 protection. © Panasonic Industry

Especially with mechanical and hydraulic presses, forming presses, punching, forming, riveting, eyeletting and other automechanical assembly systems, open moving parts are a danger zone for employees and personnel. The "point of operation", i.e. the part of the system responsible for carrying out the mechanical or hydraulic process, must be safeguarded as a source of danger. Safety light curtains are an indispensable protective measure for this and their perfect functioning and regular maintenance are essential. Both are a massive cost and time factor that is addressed by the SF4D series.

The SF4D series light curtains use specially developed software to check for incorrect wiring, disconnection, short circuits and the reliability of internal circuits. The ELCA function can also be used to prevent and calibrate unwanted machine downtimes caused by extraneous light. Details of all electrical problems are shown on the digital display, making maintenance more convenient. The M12 connector guarantees quick and uncomplicated installation.

Another advantage is the seamless structure and processing of the SF4D line, which guarantees high environmental resistance. The electronics are protected by a cylindrical inner housing, and seams on the unit and lens surfaces have been reduced to such an extent that particles such as oil mist and dust cannot penetrate. The aluminum profile does the rest, guaranteeing high stability while maintaining the same product size and being resistant to mechanical stress or torsion.

The HGC1000L analog sensor with IO-Link. © Panasonic Industry

The wide range of applications for laser distance sensors is reflected in their broad use in industry and research. They are suitable for quality control and process monitoring in packaging systems, medical manufacturing and electronics production. The HG-C series opens up many new possibilities for industrial automation. These include the positioning of robot arms, thickness and position measurement of strip material, presence detection of the smallest products or the detection of overlaps of the thinnest materials. These measurements can be carried out both statically and dynamically. Dynamic measurement makes it possible to implement control loops or determine the profiles and contours of various components.

The KG-C sensor is characterized by a measurement repeatability of up to 10 μm and a response time of 1.5 ms. With a size of just 20 x 44 x 25 mm (WD), it offers high-end performance in a compact package. Three measuring ranges (100 ±35 mm, 50 ±15 mm and 30 ±5 mm) are available with a measuring resolution of 10 to 70 μm, depending on the model. The integrated display supports setup and operation, and I/O options include a 0 to 5 V analog output alongside an NPN or PNP transistor output and an external input.

Miniature pressure gauge with M8 plug-in connection

Panasonic Industry's portfolio of miniature digital pressure gauges for air pressure measurement or monitoring focuses on smart and small devices. With the DP100 series, the company is launching microprocessor-controlled miniature pressure measuring devices on the market under the brand name Sunx. They are suitable for high-precision measurement and monitoring of air pressure and non-corrosive gases in a wide range of industrial applications, particularly in mechanical and plant engineering and in air/gas pressure monitoring in manufacturing processes in the microelectronics industry.