Customer application
Safe Filling in Hazardous Areas

As a solution provider for explosion-proof cameras in process and system monitoring, TTS Automation has developed a system for safe loading processes. The intelligent industrial camera allows tank loading processes to be monitored and anomalies detected early. As an intelligent interface for image analysis, TTS relies on the IoT Box from WAGO.

TTS Automation and WAGO:

  • Intelligent industrial camera and WAGO IoT Box for process monitoring

  • Early detection of anomalies and irregularities

  • Safety in the Ex area for people, machines and the environment

  • Modular design for green and brownfields

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Detect events before they become dangerous

In 2009, TTS Automation developed the first camera system for Ex areas. The idea was born out of the fact that industries in which hazardous and explosive atmospheres occur in the form of mixtures of air and combustible gases, vapors or mists are subject to explosion protection. When it came to developing an explosion-proof solution for tank loads, the company based in Neustadt an der Weinstraße faced a major challenge: tank loading processes are complex because they go beyond mere process and plant monitoring. Irregularities in the loading must be quickly recognized and remedied. “Our experience has shown that leaks at loading fittings are often preceded by events such as jerking of the pipeline or slumping of the tank vehicle. So we wanted to develop a solution for tank loading that would detect dangers before they arise," recalls Michelle Striegel, who is responsible for marketing and project management at TTS Automation.

It soon became clear that the camera needed intelligence to detect and evaluate potential dangers preventively. For this purpose, controlling the functional sequences must be required on the system side. In search of a suitable system, TTS Automation found the solution at WAGO. “The WAGO IoT Box was exactly the right component for an intelligent camera system,” recalls Wolfgang Laufmann, Global Key Account Manager Digital Plant at WAGO and contact person in the project for TTS Automation.

WAGO IoT Box:

  • A complete ready-to-use solution

  • Expandable hardware/software

  • Customizable

  • Flexible connection via ETHERNET, WLAN or mobile network

The PFC200 Controller

Simplify the engineering, control and visualization of your projects with the PFC200 Controller thanks to e!COCKPIT (CODESYS V3) and Linux®.

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Ready-to-Use Solutions for Industry 4.0

The WAGO IoT Box is the perfect solution for connecting new and existing systems.

Thanks to the flexible and individual WAGO interface, we implemented a system that protects people, machines and the environment when the tank loads.

Michelle Striegel, Marketing and Sales, TTS Automation

The Intelligent Interface Between System and Camera

WAGO provided the core element in the development of the interface: “The WAGO IoT Box finally made the intelligent industrial camera complete and made it possible to link all parts of the system together,” explains Wolfgang Laufmann. The integrated WAGO Controller PFC200, as a component of the IoT Box, is an intelligent gateway that establishes communication between systems on the system side and performs the integration on the IT side. “Virtually an intelligent OT/IT system”, says Laufmann. With its high flexibility, the controller offers two different approaches: The scalable system can either be used as a single component to expand existing control cabinets, or supplied as a complete system solution consisting of a ready-made IoT box. “This saves the end user an enormous amount of planning, time and testing,” says Wolfgang Laufmann. Via the system's floating contacts, the WAGO PFC200's input modules detect the signals and the output modules activate signals such as warning lights, speed cameras or horns during tank loading.

Thanks to the solution of optical process monitoring with the system integrator TTS Automation and the connected WAGO system control, nothing stood in the way of technical implementation.

Julian Loesch, Senior Project Manager, Pitzek GMP Consulting

Moving Away from Separate Camera Control to Integrated DCS Control

With the intelligent industrial camera, TTS Automation has brought meaningful innovation to the Ex area market. Further development of the system is already well under way. “Camera control will no longer run through a separate system; the entire process will be controllable via a uniform process control system,” says Michelle Striegel proudly. “Whether it's enlarging the picture, starting and stopping charging processes or entering parameters, everything is possible via a process control system.” Even though new areas are being explored, much is already planned. “For example, thermal monitoring of reactors is conceivable for detecting anomalies in temperature trends,” says the marketing manager. One thing is certain, though: Whether for trucks, rail vehicles or ship loading and anywhere critical or dangerous process applications occur, intelligent process monitoring and control can make an enormous contribution to human, environmental and system safety in the future.