Checking Hose Connections with RFID

B. Braun Medical AG guarantees reliable mixing and filling processes through fail-safe verification of hose connections in ATEX zone 2 – with an RFID solution from Turck

The medical technology company B. Braun Medical AG manufactures medical disinfection and hygiene products as well as medicines for the treatment of chronic wounds at its Sempach site in Switzerland. This requires the use of highly precise and reliable mixing and filling processes. To meet the strict safety and quality requirements involved, an RFID system using Turck TBEN I/O modules verifies the correct connection of the hoses in ATEX zone 2. Three RFID tags are located in the coupling wheels of the hose connections for this purpose. The Turck solution impressed with its ATEX approvals, high degrees of protection and Ethernet multiprotocol.

Three RFID tags are embedded in each coupling wheel so that a tag can always be read reliably
As soon as the hose is connected, the RFID system verifies the connection
The Turck BL ident system reliably prevents incorrect coupling & thus ensures consistent product quality
The TBEN I/O block modules are installed under the cable trays in ATEX protective housings to save space
Thomas Mühlebach, head of maintenance and technology at the Sempach site, B.Braun

The production facility of B. Braun Medical AG in Sempach in the Swiss canton of Lucerne specializes in the manufacture of medical disinfectants, hygiene products and medicines for the treatment of chronic wounds. Complex mixing and filling processes are carried out here, in which various chemical raw materials are mixed in tanks and then filled. The company is in the process of doubling its production capacity due to a sharp increase in demand.

Identification ensures safety

The core process of the new systems essentially involves feeding the various chemical raw materials from the weighing containers into the mixing tanks and transferring the finished products to the filling line. The nodes in the system are two coupling stations, one of which is located at the feeding station and the other at the interface to the filling line.

During the process, the hoses have to be moved three to four times per batch. To prevent mix-ups with disastrous consequences, the hose stations are integrated into the RFID system, which monitors the entire system. For each connection, one RFID tag on the hose side must interact with a corresponding RFID read/write head. The outlet only opens when the system has identified the correct medium.

The communication-capable coupling wheel

Bachofen used Turck’s BL ident RFID system with TBEN I/O block modules with IP67/IP69K protection to integrate and control the coupling solution. With special protective housing, these are also approved for use in ATEX zone 2, which is rarely the case with Ethernet I/O modules. The read/write heads used can also be used in zone 2, the TN-R42TC-EX even in zone 1. Thanks to the multiprotocol capability of Turck’s TBEN modules, they can be used in any industrial Ethernet network with Profinet, Ethernet/IP or Modbus TCP networks.

Precision with easy handling

The three RFID tags in each coupling wheel ensure that they are read quickly and reliably. The IN TAG 200 tags used are specially designed for use in potentially explosive atmospheres. The TN-EM30WD-H1147-EX read/write head used is also approved for potentially explosive atmospheres up to ATEX zone 2. Its stainless steel and liquid crystal polymer housing meets protection class IP69K and withstands even the harshest cleaning processes.

Hose couplings and RFID verification

As soon as the hose is connected, the read/write head reads the information from the RFID tags in the coupling wheel. The recorded data is immediately compared with the tank information. If a faulty coupling is detected, the system blocks the flow.

Optimized production reliability and reproducible quality

The module also enables the RFID tags to be written with specific data about the completed processes and the materials used. For example, the last time a hose was cleaned can be stored on the RFID tag. If this period is exceeded, the system automatically stops the material flow to ensure the sterility and quality of the production process.

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