Visualizing industrial processes with light

The importance of optical signals in industrial environments is increasing. With appropriate signaling solutions, processes in production and logistics can be made more transparent and secure. Standardized communication interfaces enable simple and individually configurable transmission of data and diagnostic information.

Optical signals play an important role in everyday life. Everyone understands the colors of traffic lights: red means stop, green means you can proceed. The situation is similar in industrial environments. Here, too, machine traffic lights use their colors to indicate whether there are machine malfunctions or material shortages. The classification is similar to that used in road traffic. A green light signals that everything is OK. If the machine traffic light is red, immediate action is required. Signaling technology thus makes it easy to visualize process states. Information is transmitted to the recipient quickly and nonverbally; there are no language barriers, and no technical device is required to decode the signal.

Making Processes More Transparent

"The market for process signaling is growing," says Jens-Uwe Gustmann, Product Manager at item Industrietechnik GmbH. "The reasons for this are, on the one hand, advances in LED technology and, on the other, the prevailing staff shortages in many warehouses and production facilities." A small number of employees have to monitor a multitude of processes – often in large warehouse, logistics, and production areas. With the help of suitable signaling solutions, these processes can be recorded quickly and easily. This makes processes more secure. This is also a particular advantage over complex dashboards, which – installed at individual workstations – can also display process information. However, from a distance, it is often not immediately clear from the screens whether a malfunction has occurred or which process stage is currently being completed.

With modern signaling, however, processes become more transparent. For example, it would be possible to integrate an LED strip within a machine cabin, with individual segments extinguished depending on the process progress, or the entire process level illuminated in a signal color. This allows for an ideal visualization of the process flow or status. If the LED strip lights up green, everything is OK. If it lights up yellow, the employee knows that a critical condition is about to be reached and, for example, they need to refill material. If the strip lights up completely red, rapid intervention is required. The machine's status can be clearly seen even from a distance.

The LED strip can also be used to signal a running process time. As the illuminated segment becomes longer or shorter, the employee receives information about the remaining process time. With the help of appropriate signaling, the employee intuitively knows how long the machine will be running and when it will stop. They don't have to constantly walk to the machine and check the process progress; they can rely on the display and thus see, even from a distance, whether and when intervention is necessary.

Easily visualize fill levels

Modern signaling technology enables improved communication and supports the training of new or non-specialist employees. With the help of intuitive signaling, processes can be visualized using clear colors, regardless of language. This also shortens training times. Operating errors can be avoided and process reliability increased. Furthermore, processes can be optimized and efficiency improvements achieved. This makes it easier to visualize fill levels in warehouses. For example: A forklift truck transports pallets to different stations and collects them there for reuse. The driver therefore makes multiple trips to the warehouse to retrieve new pallets. If LED lights at the stations indicate when new pallets are needed, the driver can optimize their transport process. They don't need additional information; they know exactly when and where to deliver a new stack of pallets.
Flexible control via IO-Link

In the past, machine traffic lights were often the only ones used, electrically controlled via a 24 V signal from the machine control system. Nowadays, there are additional signaling solutions with intelligent communication interfaces. This allows for the implementation of customized signal patterns and special functions via IO-Link. "Our multi-segment LED strips can be controlled section by section via IO-Link," explains Jens-Uwe Gustmann. "The appropriate controller makes connecting to a control system very easy."

The LED strip is simply integrated into the profile groove of item constructions, it can illuminate the entire surface or individual segments. The durable, bright RGB strip is available in lengths of up to 6,000 mm. It can be shortened in 17 mm sections for customized adjustment. The IO-Link controller then determines the length of the LED strip using an innovative process. IO-Link can be used to transmit not only process data but also parameterization and diagnostic information. The lights then display operating temperatures and operating hours, for example. When using the IO-Link controller, users can access preset operating modes.

"We define the operating modes for level indicator, countdown, segment display, and marker light," explains Jens-Uwe Gustmann. "This significantly simplifies commissioning, as no programming knowledge is required." Further options for displaying machine status are offered by the item multi-segment RGB light, the 3-segment RGB signal light, and the 1-segment RGB signal light, which can also be connected to the controller via IO-Link. Colors and light functions such as flashing or blinking can be freely configured for each segment. The 3-segment RGB signal light is also available with a buzzer for acoustic signaling.

Different operating modes for versatile applications

Difficult-to-see tank levels can be easily visualized using the "Level Indicator" operating mode, or it can be used to indicate the output of a system. The "Countdown" operating mode, for example, shows a machine operator when to remove a workpiece or add more material. The "Segment Display" allows the LED strips to be configured like a classic machine traffic light. Changing the color assignment or expanding to multiple segments is also possible. A combination with a switching or operating element is also possible.

If a problem occurs at a workstation, the employee presses the switch and the segment immediately switches to red. The control center immediately knows which workstation needs assistance. In "marker light" mode, the LED strip lights up in a single color, signaling a process status. For example, the strip can be defined to glow blue when the machine is being serviced. If a problem occurs during maintenance, the LEDs switch to red. If necessary, the operating modes can also be combined. This gives users a wide range of options for individually presenting their signaling needs.

User Benefits

By expanding its product portfolio, item now offers numerous signaling solutions for visualizing processes and machine statuses. The products can be attached directly to item constructions using the included fastening kits. Customers thus receive a complete system that they can easily assemble and connect. It is then immediately ready for use. The lights meet the requirements of protection classes IP20 to IP67 and can therefore be individually selected depending on the application and requirements. The signaling technology can be easily integrated into the existing system control system via IO-Link. Freely adjustable colors and lighting functions offer maximum flexibility and enable efficient visualization in production and logistics environments, increasing process reliability and transparency.