Whether in road tankers or rail tank cars, chemicals must be transported with care, as over 40 percent of products are classified as hazardous. Despite the high percentage of high-risk cargo, the procedure for filling vehicles and rail cars with these substances is not always the same, as gases, liquids, and granules have different properties. Furthermore, there is often a risk of explosion. This means creative solutions are needed to ensure the required level of safety.
VOORTMANN GmbH & Co. KG Steuerungstechnik is a market leader in control, compression, loading, and spraying systems, based in Issum, Germany. Dirk Bubenzer, the company's loading technology specialist, is aware of the risks associated with loading chemicals: "Filling tank trucks and conventional tanks is usually not a fully automated process; some of the work is performed by workers on the platform. This means that one wrong decision can have catastrophic consequences for people and the environment. Since the vehicles can be up to four meters high, employees must move the loading platforms to the correct height, which creates another risk of damage."
Workers also wear heavy-duty protective clothing in these conditions, sometimes including breathing apparatus. Limited freedom of movement and a reduced field of vision increase the likelihood of error. This is where VOORTMANN specialists come in, offering solutions including a wide range of fall protection systems tailored to specific loading tasks. For several years, specialists have been installing light barriers and contact strips in these structures. However, exceptional potential has been discovered in laser sensors. This technology allows VOORTMANN to make loading safer and more efficient.
More automation, more security
The basic idea: the platform's safety cage not only moves at the press of a button, but also uses a 2-D LiDAR sensor mounted underneath the structure to detect obstacles. If the sensor detects, for example, a foreign object or part of a tank, the scanner emits a signal that activates an audible alarm or warning light and stops the lifting platform. This automatic shutdown function makes breakdowns and malfunctions a thing of the past. To implement these applications, VOORTMANN relies on the R2000 2-D LiDAR sensor from Pepperl+Fuchs, which is commonly used in the automotive, warehouse, and automated transport industries.
However, this award-winning sensor also impresses beyond factory floors and warehouses, reports Julian Crato, a specialist in complex systems at Pepperl+Fuchs: "Multiple evaluations of individual scans and an adjustable detection field allow us to reliably detect and filter out obstacles such as raindrops and snowflakes. The R2000 also has an IP67 rating, making it suitable for outdoor use."
The technical core of the R2000 is Pepperl+Fuchs' proprietary pulse range technology (PRT), which performs a huge number of individual measurements in a short period of time. With a frequency of up to 54,000 pulses per second and high angular resolution, the sensor delivers extremely accurate measurement results and detects obstacles with virtually no delay. "From a safety perspective, the fast and accurate PRT is the ideal choice for our applications. The 360° measurement angle also means we can manage everything with a single sensor, reducing costs for our end customers," says Bubenzer, highlighting other advantages of the R2000.
Industrial sensors comply with explosion protection requirements
And these end users continue to surprise with their increasingly demanding requirements. Recently, a customer approached VOORTMANN with a request to use an R2000-based fall protection system for tanks in ATEX Zone 1. This presented a real challenge, as the R2000 operating voltage, as well as optical and electromagnetic radiation, could potentially pose an ignition source in hazardous areas. Upon receiving the customer's request, Bubenzer and his colleagues came up with the idea of installing the sensor in an ATEX-certified housing. They didn't have to look far for a partner to implement this: "Since Pepperl+Fuchs has an excellent international reputation in industrial sensors and explosion protection, we were confident that together we could find a solution. The experience we gained during our collaboration on developing non-explosion-proof solutions also confirmed this."
Pepperl+Fuchs was delighted to accept VOORTMANN's request, as Henning Hansen, Process Automation Sales Engineer, explains: "Here we had to resolve a small paradox: How can I install a photoelectric device, which logically requires a clear line of sight to function properly, in an enclosure?" The answer to this crucial question was to mount the R2000 in a Pepperl+Fuchs GUB series enclosure, made of copper-free, corrosion-resistant aluminum. This enclosure features Ex d (flameproof) protection and an integrated viewing window, allowing the sensor to scan beneath the lifting platform. A flat disc and the R2000, tilted 15° to the disc, were used to avoid light refraction and possible scattering, which could distort the signal.
R2000 inside the GUB series case
The Pepperl+Fuchs GUB series Ex d enclosure contains a LiDAR sensor, making it suitable for use in Zone 1.
Multiple benefits in one solution
VOORTMANN is now benefiting greatly from this jointly developed solution. Working closely with Pepperl+Fuchs, the company has gained valuable new insights into the combination of laser sensors and explosion protection. At the same time, Pepperl+Fuchs will be able to offer its customers an integrated system for safe and hazardous areas, suitable for international use in Zones 1/2 and 21/22. This ensures highly efficient planning, installation, commissioning, storage, and subsequent maintenance.
The solution can be upgraded if necessary, for example, if environmental conditions require the integration of an internal heating system or a membrane connector for air circulation. "Thanks to the successful collaboration with Pepperl+ Fuchs, we were able to further expand our position as a technology pioneer. The jointly developed fall protection system with a 2D LiDAR sensor is the first of its kind to be used in hazardous areas," says Bubenzer. "For some time, we have been offering comparable customized solutions to customers, such as explosion-proof RFID read/write heads and distance sensors. Integrating the LiDAR sensor into an Ex d enclosure, now realized in collaboration with VOORTMANN, was an exciting challenge and allowed us to once again demonstrate our expertise in the interplay between industrial sensors and explosion protection," says Hansen, assessing the partnership from Pepperl+Fuchs' perspective.
In combination with special housings, other Pepperl+Fuchs general-purpose sensors can also be used in ATEX Zone 1/21. Various solutions are available to meet various application requirements.