From Idea to Solution:


Sensor Solutions for Industrie 4.0 Applications

Sensorik4.0® – the Future Generation of Sensors

The overall vision of an Industrie 4.0

The overall vision of an Industrie 4.0

“Industrie 4.0” means the networking of all components, machines, and plants with the goal to minimize information and media gaps, optimize processes, and save valuable resources. This vision needs new components that enable an intelligent communication and integration—for Pepperl+Fuchs this is “Sensorik 4.0”.
Sensorik4.0 for Industrie 4.0

Sensorik4.0 for Industrie 4.0

Sensorik4.0 redefines the terms identity, communication, and intelligence. The sensor automatically detects its origins and determination. Communication occurs in a new, service-oriented universal language. Collected data is setup specifically to offer the greatest possible benefits to the respective recipient.
Cloud-based information boosting efficiency

Cloud-based information access

Unused data that was previously processed on the control level is now transferred to cloud-based storage systems with internet connection. This allows users to access this valuable data regardless of location or enterprise. Spatial boundaries are eliminated while information accessibility greatly increases.


Additional data for more efficiency

Additional data for more efficiency

Additional real-time data from networked sensors and actuators leads to new opportunities for optimization of processes and plants. The processing, interpretation, and visualization of process and status data in the most diverse software systems is a focal point of Sensorik4.0.

Sensorik4.0: Paving the Way for Industrie 4.0

Pepperl+Fuchs understands Sensorik4.0 is a pioneer for the fourth industrial revolution: it delivers the necessary data. A good example for Sensorik4.0 is the R100 photoelectric sensor—this smart sensor is used in its own manufacture at Pepperl+Fuchs in Berlin. Due to its IO-Link interface, the R100 allows communication down to the sensor level, thus enabling a fully connected plant.

Applied Industrie 4.0 at the Solutions Park

Sensorik4.0 by Pepperl+Fuchs

Data collected by sensors and actuators builds the basis for extensive networking of machines and other objects. To unlock the potential of this “Internet of Things”, innovative solutions are needed which take advantage of the communication ability of modern industrial sensors.

With the “Solutions Park”, Pepperl+Fuchs brings its approach to Industrie 4.0 to trade fairs: process and status data from sensors and actuators is made accessible in internal or external IT systems. Using this data, IT systems perform visualization functions, realize model-based optimization procedures, and plan demand-based preventive maintenance processes.

Learn more about the solutions developed in close partnership with IT companies, their distinct advantages, and the refinements they provide for the future.

Neoception GmbH – the new subsidiary of Pepperl+Fuchs

Think digital, add value

Neoception GmbH – the new subsidiary of Pepperl+Fuchs

Neoception GmbH is your new partner on the path toward digitalization. From connecting your products or plants with central data services to developing completely new business models for your company, we are here to offer guidance and support. 

With individual consulting, flexible engineering services, and core competence in Sensorik4.0® from Pepperl+Fuchs, we take on the implementation, operation, and maintenance of all needed IT services. Creating as much value as possible for you and your customers is always our focus.

To bring your application to life, we draw on our large network of business partners, which you can get a glimpse of on the Solutions Park. This network allows us to find the platform that best fits you and your application in order to immediately add value.

Neoception is your key partner for digital added-value services within the Pepperl+Fuchs group.


IoT for Process Automation

In process plants, field devices produce endless additional data, for example, about their condition and environment. But such data has previously gone virtually unused since it has not been transferred to the control level. Together with four partner companies, Pepperl+Fuchs developed a solution.

Using the WirelessHART adapter BULLET, data can now be transferred via a gateway directly to the cloud, where it is made centrally available. This enables a continuous monitorung of field devices, and maintenance requirements can be identified and planned in time.

Ethernet for Process Automation

Pepperl+Fuchs and several companies are jointly developing the new "Advanced Physical Layer" (APL), enabling comprehensive Ethernet communication in process automation. Via two-wire cables, field devices are directly connected to the Ethernet – gateways are no longer needed.

With 10 Mbit/s, this direct Ethernet connection is almost 10,000 times faster than HART. Thus, data can be transferred and made available much faster. The wealth of information provided by modern field devices and sensors can be fully used, enabling Industry 4.0 applications within process automation.

Advanced Machine Monitoring

This application, developed by Cluetec, a system automation company, and Pepperl+Fuchs, demonstrates a streaming platform for sensor data. The advantage of such platforms lies in the direct processing and evaluation of data streams from the sensor. If there is a deviation from the expected value, the platforms generate a warning message and can thus independently request help to check the technical system.

This is visualized in the exhibit by monitoring a mechanical linear axis. If a fault scenario occurs, it is recognized by the sensor data platform and a corresponding event is generated – for example, a message is sent to a technician.

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Automatic Asset Administration

In addition to pure process data, automation components that communicate digitally provide a multitude of extra information that is seldom fully evaluated by traditional machine control. By using a gateway to access the automation components at the lowest level and a data platform to manage type and instance data, this additional information already offers valuable added benefits for the safe operation of machines and plants.

In cooperation with its partners Hilscher Gesellschaft für Systemautomation mbH and SAP SE, Pepperl+Fuchs is exhibiting a demonstrator that visualizes the benefits of managing component data centrally on a data platform. To do so, a simple automation function is visualized using the Asset Intelligent Network (AIN).

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Cloud-based Type Verification

Cloud-based sensor systems are inherently beneficial whenever data from spatially remote production systems is collected and processed. The joint project “Cloud-based Type Verification” from SAP and Pepperl+Fuchs demonstrates this in a typical just-in-time application where semi-finished components are previously tested by the component supplier so that final processing is more efficient.

During the assembly of the lamp on the carrier, an industrial ultrasonic sensor verifies the lamp type. Then, using Pepperl+Fuchs' SmartBridge technology, a track & trace production process is triggered in the SAP Cloud and sent directly to the higher-level SAP Asset Intelligence Network.

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Cloud-based Sensor Service

Level control management is a common application in many industries. However, smaller machines, as elements of independent production units, are often affected by inefficient monitoring and refilling procedures. Combining Pepperl+Fuchs sensors with the cloud of connectavo offers a solution that establishes economical planning and fully optimized supply-chain management.

Using SmartBridge®, sensor data is submitted to the cloud in real time, where the data is visualized and available for other devices and services. To demonstrate this, an on-demand service uses the sensor data to send a text message to the responsible person as soon as a critical fill level is reached.

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Dimensional Consistency Check

By joining data from several individual sensors, the 3-dimensional analysis of large machine parts is performed quickly and with exceptional precision. Real-world measurements are compared immediately with virtual-world design data. This meets the requirement of Industrie 4.0 to supply digitized data from all phases of the product-lifecycle.

Teaming up with subsidiary VMT, Pepperl+Fuchs has developed an application for the automotive engine assembly process. Several SpinScan sensors evaluate the engine cast for a motor block at various critical points and correlate these dimensions with the respective CAD coordinates. This evaluation takes place so that deviations are detected before the costly casting process is initiated.

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Overall Equipment Effectiveness

In cooperation with Software AG and TE Connectivity, Pepperl+Fuchs has developed an application example visualizing how the availability of production lines and manufacturing processes can be markedly increased through IT systems. In this scenario, two manufacturing pre-processes pass their intermediates to the target process right in time.

This requires only a small number of networked industrial components (e.g. SmartBridge). Moreover, with very little effort, these components can be integrated into existing applications. Here, they generate additional process data allowing the IT system to gain supplemental benefits. These benefits can range from simple process optimization to condition monitoring and cleaning scheduling.

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