Stationary optical reading devices

The stationary optical reading devices enable identification of products or product carrier systems, such as in the production line but also beyond. Recognition is based on an applied code, e.g. data matrix code, an applied plain text or on the shape of the object / object section.

The product range of stationary optical reading devices offers the following forms of optical identification:

• Code reading (two-dimensional (2D) codes and one-dimensional (1D) barcodes)
• Checking the marking quality of codes (verification)
• Optical character recognition (OCR) and object recognition using stored structures

The functionalities mentioned are generally available on the products to be combined as required. However, the functions have very different hardware requirements.

Below, the products are divided into families and the focus of the applications is described.

SIMATIC MV420

The SIMATIC MV420 family is particularly suitable for reading distances in the close-up to medium range (approx. 10 mm to 400 mm).

This optical reader was specifically designed for detecting and evaluating a variety of machine readable codes in the packaging industry (e.g. F&B, pharmaceuticals and tobacco) and industrial production (e.g. automotive, electronics and solar). The list of readable codes includes all standard matrix codes and barcodes which can be reliably detected - mostly independent of the printing technology applied and carrier medium used. One key feature of the unit is its ability to read data matrix codes (DMC). The SIMATIC MV420 device family is flexible, reliable and easy to use.

In addition, two different lenses are available for SIMATIC MV420 which can be adjusted to the required reading distances.

SIMATIC MV500

The three high-end SIMATIC MV540, MV550 and MV560 readers differ in terms of their hardware equipment, sensor resolution, varying sizes of installed memory and available interfaces. All three optical readers are characterized by very high computing power and the associated fast reading process as well as maximum reading reliability – even under difficult conditions. A comprehensive, high-performance, individually configurable portfolio of accessories is available for all devices in the SIMATIC MV500 family. For example, flexibly controllable ring lights that can automatically switch between different lighting variants.

The freely selectable lenses in various focal lengths cover the widest possible range of applications – for example from very small objects in the electronics industry with a short operating distance to very large objects in seaport cranes with several dozen meters operating distance. Optionally available E-focus lenses allow software-based focusing of the lenses. Manual intervention by the user is therefore not necessary. This enables self-adaptation of the system to changing production conditions or materials and significantly increases the range of possible applications.

The device configuration is uniformly performed via web-based management. Therefore, almost any HTML5-enabled device (see Technical Parameters) without separately installed software is suitable for operating the devices.

The devices support the Siemens TIA automation concept through integration into the TIA Portal and thus ensure convenient configuration. For the user, this means a maximum of safety and reliability in relation to investment security, plant security, standardized documentation and industrial security, to name just a few highlights.

With the one-button configuration, the devices of the SIMATIC MV500 series offer maximum user-friendliness. Pressing a button on the device is all it takes to assign parameters in the network configuration. Another button automatically configures the device to read codes and automatically stores the parameters determined in this way.

All devices of the new generation can be easily and safely integrated into almost all automation concepts. Connection to cloud applications is also possible via the SIMATIC S7-1500 controller and the CP1545-1 communications processor or via a communications module from the SIMATIC RF18xC/CI series and an Industrial IoT gateway such as SIMATIC CC716. The SIMATIC readers send process data to the cloud and enable optimization of the production process on this basis. The optimization can also affect cross-location supply chains. Efficiency and quality in production, logistics and asset management, for example, can thus be increased.

Main distinguishing features of the reader families

The following comparison of the device families illustrates the differences in terms of the software and hardware. This presentation should help in the selection of a suitable device type.

• Automotive industry
  • Needle markings on various automotive power train components
    (cylinder heads, cylinder blocks, manifolds etc.)
  • Laser markings on various automotive power train components
    (camshafts, crankshafts, pistons, connecting rods, transmission components, etc.)
  • Laser markings on electronic components, printed circuit boards, or enclosures
• Packaging industry (e.g. pharmaceuticals, F&B, tobacco)
  • Printed or laser markings on folded boxes, plastic containers, etc.
  • Reading through transparent foil packaging
• Aerospace industry
  • Needle punched markings on gas turbine blades
  • Needle punched markings on various aluminum components of propulsion units
• Medical equipment
  • Laser markings on pacemakers and other implantable devices
  • Laser markings on various medical devices and drugs
• Electronics
  • Laser markings on electrostatic-sensitive hard drive components or even printed labels
• Semiconductor
  • Laser markings on rigid and flexible circuit boards
  • Laser markings on packaged semiconductor devices, heat sinks or heat dissipators

The following communication options are available for connecting SIMATIC MV500 optical readers to the automation or IT level:

• Direct connection to PROFINET (via FB79)
• Direct connection to Ethernet (TCP/IP native)
• Direct serial connection via RS232 or with interface converter to RS422
• Connection to PROFIBUS and PROFINET, TCP/IP-XML via communications modules. An optical reader and RFID read/write device can also be combined on a single communications module.

Convenient function blocks are available for uniform integration in STEP 7. The web-based user interface permits simple parameter assignment and monitoring without additional installation complexity.

Via the specified interfaces, the following communications services can be used:

The preferred connection for SIMATIC MV500 readers in the SIMATIC environment (e.g. S7 controller) is the onboard PROFINET interface. The standard function block "Ident Profile" (FB101) is available for this interface. This type of connection is a component of the device library of SIMATIC TIA Portal, Version 13 SP1 or higher, and is suitable for the connection of communications modules.

All readers of the SIMATIC MV500 series are also released for the use of function block FB79 on the onboard PROFINET interface. This function block was introduced to the market long before the standard function block "Ident Profile" (FB101). The current products can be used with the FB79 to innovate long existing plants.

A separate function block called "LDrivers MV4X0" is available for the connection to SIMOTION systems. More information about LDrivers MV4x0 can be found at:
http://support.automation.siemens.com/WW/view/en/67385474 The LDrivers MV4x0 can also be used for the SIMATIC MV500 without restrictions.

Integration of SIMATIC MV420/MV500 with a direct connection to PROFINET or Ethernet, with/without PoE (PLC and HMI via PROFINET/Ethernet; trigger via DI)

Integration of SIMATIC MV420/MV500 with an RS232 connection (PLC via RS232; trigger via DI; HMI via Ethernet)

Via the onboard communications module interface, all communications modules can be used, e.g. for the PROFIBUS connection. The communications module interface is compatible with all available communications modules both electrically and with regard to protocol. The connection via a communications module therefore makes it possible to switch between optical readers and RFID readers, simply by reconnection. The PLC programming is performed with the aid of function blocks that are available for SIMATIC and SIMOTION.

The possibility of connecting SIMATIC MV500 to many different communications modules gives the readers the advantage of being able to connect to a wide range of PLC types and fieldbus systems. Furthermore, with the communications modules, the complete range of cables of these modules is available. For details on this, see chapter "Communications modules".

Integration of SIMATIC MV420/MV500 by means of an ASM 456 communications module (PLC via PROFIBUS; HMI via Ethernet)

Integration of SIMATIC MV420/MV500 by means of a SIMATIC RF180C communications module (PLC via PROFINET; HMI via Ethernet; trigger via DI or RS 422)

A frequently used integration method is the connection of the SIMATIC MV500 readers to the controller (e.g. transmission of the read results) via communications modules. The onboard PROFINET interface is thus available for a separate connection to HMI or a control center.