The linchpin of modern turnstile systems
Flexible control solution for turnstiles
“We have been working successfully with Eaton for over 12 years and are very satisfied with our partnership.”
Background
Controlled access to property and buildings is becoming increasingly important for corporate security. For many companies, identifying people, controlling foot flow or specifically managing access are all essential security requirements. Subquently, the demand for turnstiles is growing. As turnstiles provide reliable access control for industrial facilities, power plants, sports venues and facilities alike, and in conjunction with modern access control systems, they are vitally important and offer protection while keeping staff costs to a minimum.
One of the leading manufacturers of turnstiles is Zabag Security Engineering GmbH who are based in Grünhainichen, in Germany's Erzgebirge Mountains. With 110 employees, the company is a true global player in the field of high-security solutions and custom-made products. Its solutions are already in use in more than 28 countries around the world, including airports, embassies, logistics centers, security facilities, industrial companies and even nuclear power plants. Turnstiles are an integral part of the company's solution offering.
Challenge
Flexible automation technology is indispensable for the realization of modern turnstile systems. At Zabag, this is used on the one hand for the control of the electromagnetic lock, which is triggered by a card reader or hand switch. In addition, Zabag turnstiles can also be equipped with a light control system with twilight switch, with an electric motor drive, or with an intercom. A special feature of Zabag turnstiles are systems that combine controlled access for people with a separate entrance for bicycles. If an employee activates the turnstile's access control system and the built-in induction loop simultaneously detects a bicycle, the bicycle door will open automatically, and the employee can then pass through the entrance with their bicycle and close again after a predetermined time.
All these functions need to be controlled, and for Zabag, it’s important that the automation solution is able to process all the necessary control commands efficiently, but also easily adapted to the customer's specific needs. Zabag's aim is to deliver high-quality turnstiles, and to the shortest possible delivery times and at competitive prices. Previously, Zabag relied on the Eaton easy800 series of control relays. In addition to control relays, Zabag’s safety devices also include Eaton’s speed starters from the DE1 product range, which control the electro-hydraulic safety bollards, and pilot devices from the RMQ series. The control relay controls the entire system: It processes the signals from various sensors – from position detection and the detection of the direction of rotation of the turnstiles to the twilight switch – and controls actuators such as signal lights or locking magnets. The growing number of functions and thus, inputs and outputs meant that Zabag needed a new system for controlling the turnstiles.
Solution
The Eaton easyE4 is equipped with significantly more powerful hardware than the easy800 series it replaces. For maximum flexibility, each easyE4 basic device comes with four digital outputs, four analog/digital inputs with 12-bit resolution, and four fast digital inputs. Zabag uses the 24 Volt DC version with display, which can handle semi-graphics in addition to text, values and parameters and offers various display and visualization options. For example, the device status can be displayed using three background colors – red, green and white. To connect the sensors and actuators required for the various turnstile functions, Zabag combines the basic device with a module that provides four transistor inputs and outputs each. Together with the basic device, which already comes with eight inputs, two of which Zabag uses as analog inputs, a total of 12 inputs and eight outputs are thus available. In principle, the basic device can be expanded to a maximum of 188 inputs/outputs by adding up to 11 expansion modules. AC, DC and UC devices as well as analog and digital expansions can be combined in mixed operation, depending on the needs of the application, which offers a high degree of flexibility for incorporating new applications into the turnstiles. The expansion modules can be easily connected by means of the plug connector at the front.
A significant advantage of the easyE4 is that it can be easily configured and operated using the intuitive easySoft 7 programming software. easySoft7 offers four different programming options, to ensure that the control relay speaks the user’s “language”: The circuit diagram can be created using function blocks, ladder diagrams, Eaton's own ‘easy’ programming language EDP (easy device programming) or by means of structured text (ST).
The easyE4 offers significantly more features than the previous model, including a micro SD card adapter: The option of transferring firmware updates and programs to other basic devices or systems enables Zabag to save considerable time. The data logger function available with the SD card is also an attractive option for customers.
In addition, the control relay can be connected to all standard LAN/WLAN routers, repeaters or dLANs via the integrated Ethernet interface, which simplifies the programming and networking of systems. This allows both Zabag's service technicians and end customers to display information from the control relay on (HTML 5-based) websites or to visualize it using the integrated ‘easy’ web server. The web server also includes a WEB API interface that enables flexible networking of the easyE4 via Node-RED. Node-RED is a programming tool that allows the implementation of Internet of Things applications based on a simple modular system. Node-RED can be used to monitor, modify, analyze and visualize the programs and data running on an easyE4.
The new easySoft7 programming software also features various ready-made modules such as analog value comparisons or counter modules that will allow Zabag to integrate additional functions into its turnstiles.
And despite the many new functions and the more powerful performance, the easyE4 is more compact than its predecessor model allowing Zabag to easily integrate the control relay into the crossbar located above the turnstile, which also includes optional lighting, for example. This eliminates the need for a separate control cabinet, which would not only mean additional costs, but aesthetic displeasing.
Result
Before Zabag implemented the easyE4 in mass production, it took the opportunity to test the control relay in detail. Eaton offers starter sets specifically for this purpose, consisting of a basic device, the easySoft7 programming software and an RJ45 patch cable. Moreover, Eaton's support team helped Zabag with the changeover from the easy800 to the easyE4. This allowed for a smooth transition, enabling Zabag to introduce a cost-efficient, compact control solution for its turnstiles, which can be easily adapted to meet a wide range of customer requirements and offers sufficient capacity reserves for responding to future demands.
