SICK Magazine

01 2006 www.sick.
com
Outstanding solution
Collision prevention for stackers
at BMW
Page 12
Interface standard
From the control level to the sensor
and back
Page 32
DS40 distance sensor
Laser time-of-flight better than
evaluating pixels
Page 41
Unique
Unique
S I C K S C U S T O M E R M A G A Z I N E
The new S300 sets safety standards worldwide
Page 36
I NDUSTRI AL SENSORS
I NDUSTRI AL SAFET Y SYSTEMS
AUTO I DENT
Innovation
Industrial Vision Cameras
SICK IVP AB | Wallenbergs Gata 4 | 583 35 Linkping | Sweden
Phone +46 13362- 100 | Fax +46 13211345
SICK AG | Sebastian-Kneipp-Str. 1 | 79183 Waldkirch | Germany
Phone +49 7681 202- 0 | Fax +49 7681 202- 3863
Every day SICK sensor solutions simplify production for thousands of companies around the globe.
The industrial vision cameras from SICK IVP raise sensor intelligence to new levels for flexible
automation solutions. With many inspection tools, powerful configuration software and dedicated
support engineers SICK IVP is your partner of choice.
Meet us at www.sickivp.com
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: Editorial
03
insightTELEGRAM
++ SICK boosts its motor feedback system field
of business Rounds out programme, particu-
larly for direct drives Acquisition in Israel in
January 2006 Technology basis strengthened
through Netzer Precision Motion Sensors Ltd.
in Misgav New company: SICK Sensors Ltd.
++ Special prize for SICK AG Vice-Chancellor
Franz Mntefering presents prize For advanc-
ing employment of older personnel Award is
for deliberate effective integration and support
of older employees in the company and the use
of their potential through work organisation
and training measures Information at www.
greatplacetowork.de and in Capital 4/2006 ++
SICK STEGMANN, a member of the SICK Group,
celebrates 50-year existence After synchro-
nous motors, product range grew with small
motors, drives, program controllers and preci-
sion-engineered components Now leading
producer of encoders and actuators for automa-
tion technology Subsidiary of SICK AG since
October 2002 ++
1/2006
India economically powerful sub-continent
with sensor potential
Dear Readers,
SICK has been represented in the Republic of India with its own majority-owned
subsidiary since February 2005. A step that may initially surprise those who only
consider India to be a major geographical and population centre rather than a
technological power. But India is already one of the worlds ten leading industrial
nations. Last year India achieved economic growth of 8.5% the country is thus
the most rapidly growing democratic market economy in the world. Indian soft-
ware specialists have an excellent reputation in all industrial nations. Moreover,
new technologies, new factories, new products and production processes form
the basis for the high demand for factory and process automation sensors. We
at SICK India have taken on the cause of opening up this potential. From the
central office in New Delhi we have founded, and will continue to found, more
offices in the countrys main industrial centres.
Our aim is to cover all of Indias 25 states locally, offering sensors and expertise
our drive is entrepreneurship, the existing market potential, and support from
the parent company.
All the best from New Delhi
Mohan S. Nair
General Manager SICK India
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: Contents
1/2006
: Know-how
Open interface standard for
fieldbus-neutral sensor dialogue ....... 32
Image processing in safety technology 33
: Internet
The new Partner Portal ....................... 34
: Products
OCR Vision Sensor for label checking 35
TITLE TOPIC: The worlds
smallest safety laser scanner ............. 36
Analogue distance sensor with
very easy installation ............................ 37
Product News .......................................... 38
Safexpert 5.0 CE software ................... 40
Programmable incremental encoder:
greater flexibility, less downtime .......... 40
Basis solution for distance measure-
ment with immunity to ambient light ... 41
Laser measurement systems auto-
mate loading and unloading of ships 42
Currently the fastest safety
controller for presses............................ 43
Flexibility through modularity .............. 44
Motor feedback encoder as
resolute alternative to resolvers ......... 44
Wire draw encoder for up to
5 m measurement length .................... 45
Multiplicator module rapidly
restores machine safety ...................... 45
Automation with miniature
photoelectric switches ......................... 46
: Museum
Parque de las Ciencias ....................... 47
: SICK Tour
AUTOMATION visits Waldkirch ............ 48
From dishwasher to millionaire .......... 48
Silver for Safety Systems catalogue ... 48
SICK Austria ......................................... 49
Training & Education 2006 ................. 49
: Book Corner
Five good minutes ............................ 50
: Info
Imprint/Service .................................... 51
Trade fair dates .................................... 51
: Editorial ............................... 03
: SICK Complete
ATEX sensors not just for
processing grain .................................... 06
Miniature sensors for high-tech
X-ray inspections ................................... 07
Object detection and identification .... 08
SICK sensors on the stackers
of the future ......................................... 09
Preparing paper rolls at the NZZ ........ 10
A compact measuring wheel encoder
for indirect path measurement ............ 11
: Applications
Collision prevention at BMW ............... 12
Monitoring production in
three dimensions .................................. 13
Proximity switches take up the
thread of automation .......................... 14
Safety in an IP67 housing .................. 15
Protecting areas and
checking presence .............................. 16
Checking pallets at Krombacher........ 17
Automation light grid used for
security purposes ................................ 18
SICK and HIMA in combination .......... 19
Safety during the production
of safe sensors .................................... 20
Safety and flexibility in a
single casting....................................... 21
Measurement with laser and
Swiss precision .................................... 22
Inox sensors in Mozzarella
production ............................................ 23
Flight baggage identification: almost
everyone flies with SICK ...................... 24
Separating circuit board panels ........ 25
Electronic entry ticket for pallets ....... 26
Automated iron powder packaging .... 26
Warehouse modernisation
and expansion at Hama ..................... 27
Detailed strategy for suspension
assembly ................................................. 28
: HMI Special .................. 29
: SICK MAIHAK
Waldkirch leads the way with locally
manufactured ultrasonic gas meters . 30
Explosion protection ............................. 31
Checking pallets at Krombacher
17
SICK at FACTORY AUTOMATION
and INTERKAMA
+
2006
29
The worlds smallest safety laser scanner
36
Programmable incremental encoder:
greater flexibility, less downtime
40
04
: News
technology with a hitherto unparalleled
level of sensor miniaturisation.
The first products in which the IES
chip is used are the MZT6 and MZN1
magnetic cylinder sensors, the MM08,
MM12, MM18 magnetic proximity sen-
sors and the standard series of induc-
tive sensors. The new chip technology
opens up wide-ranging new possibilities
for the various sensor series from SICK:
on the one hand because numerous,
hitherto critical, applications can now
be better solved; on the other hand be-
cause the platform contributes towards
a further miniaturisation of sensors for
automation.
A comprehensive article on the new chip
technology can be found on the Internet
at www.sick.com/insight/en
New inductive and magnetic
sensor performance
Sensor innovation:
IES inside
insightBOOK CORNER
Jeffrey Brantley, Wendy Millstine
Five good minutes
This paperback promises you 100 good
ideas for starting the day. This should
be enough to allow a good start to any
day. Find out more on page 50.
HANOVER INDUSTRIAL TRADE FAIR
and INTERKAMA
+

in Hanover from 24 28 April 2006
Hall 9 Stand F 54
www.hannovermesse.de
Control international trade fair
for quality assurance
in Sinsheim from 9 12 May 2006
Hall 4 Stand 4403
www.control-messe.de
Several suppliers one solution
The 2nd VDMA Technology Benchmark
on 11 May 2006, VDMA House, Frank-
furt/Main on the topic of Safety con-
trollers in comparison.
KRONES AG, a specialist in packag-
ing machines and filling plants for bev-
erages, poses the challenge: a modular
labelling machine is to be equipped with
safety technology. An all-round considera-
tion of electrical safety, from the sensors,
through the control system, to operation
and communication, is required.
Seven different suppliers of safety
technology have planned a solution for
this task and will present their results at
the VDMAs Industrial Communication As-
sociation for discussion SICK is one of
them.
www.vdma.org/incom
05
sign and procurement, are the principal
properties of the new IES chip. Externally
noticeable feature: the 1.6 mm narrow
IES chip permits a new type of packaging
SICK is presenting inductive and mag-
netic sensors with a completely new
type of chip technology at the Hanover
Industrial Trade Fair 2006. The integrat-
ed electronic switch (IES) is an extreme-
ly miniaturised platform which offers
flexible sensor solutions with improved
performance, and represents a techno-
logical leap for inductive and magnetic
sensors.
Minimised switching point toler-
ances, increased resistance to environ-
mental effects, and greater flexibility for
new housings within the inductive and
magnetic sensor families, as well as
supplier-independent component de-
2 mm 1 0
Trade fairs with SICK
1/2006
Fulfills the Ex-Directive for Category 3 gas and dusts: W27 Ex photoelectric switches
in metal housings
ATEX sensors not just for processing grain
Automation and
protection in Ex-Zones
From the field to the bags of flour on a pallet dust is a constant compan-
ion during the processing of grain. The Swiss plant constructor Bhler AG
tackles the resulting risks of explosions with, among other things, ATEX-
compliant photoelectric switches.
>> Bhler AG offers solutions for the
complete production process chain in
the area of grain processing. This begins
with plants for unloading ships, contin-
ues with cleaning, sorting, milling, mix-
ing, handling and thermal treatment,
right up to packaging in bags and pal-
letising. Most of the areas involved along
this value-creation chain are classified
as being at risk of explosions as a result
of the development of dust that can al-
ways be expected. The plants must thus
be equipped with appropriately protect-
ed systems and devices. This was also
the case for the newly developed sack
palletiser for up to 20 bags per minute.
3D/3G: awareness of mechanical
device protection
The new sack palletiser is classed as po-
tentially explosive Zone 22 as a result of
the potential presence of flour dust. So
we looked for photoelectric switches in
the necessary Category 3D for the plant,
that could be automatically adjusted for,
among other things, sack sizes and pal-
letising patterns, says Thomas Heierli,
Palletiser Project Manager at Bhler AG.
For this Category, the 94/9/EU direc-
tive stipulates the protection of devices
against mechanical damage. Two ap-
proaches for opto-electronic standard
sensors are available on the market. In
the case of unprotected sensors, us-
ers themselves must ensure that the
sensors are protected from mechani-
cal damage by means of constructive
measures. The better solution is ready-
for-installation sensors with protective
housings that fulfil the inspection re-
quirements, says Thomas Heierli and
adds: If the mechanical protection had
to be provided by the machine supplier
or the user, the construction and, in par-
ticular, the inspections, would generate
considerable extra costs.
Ready-to-use Ex-photoelectric
switches prevent extra work, risks
and inspection costs
The Bhler team therefore chose the
W27 series of photoelectric switches in
a metal housing. We can now integrate
the devices without requiring any further
mechanical measures while completely
complying with the Category 3 Ex-direc-
tive for gas and dust, Thomas Heierli
sums up. The metal housing also looks
really good and underlines the high qual-
ity of our new sack palletiser, he adds.
Other systems from SICKs
EX-perts
In addition to the W27 Ex, SICK also of-
fers cylinder sensors and safety light cur-
tains for areas at risk of explosions. The
straightforward drop-in mounting of the
MZT6 3G/3D cylinder sensors is highly
convincing. The sensor is simply inserted
into the cylinder slot from above and fixed
with a combined slitted/Allen screw. The
C4000 safety light curtain combined
with muting sensors for differentiating
between persons and pallets is ideal
for protecting pallet conveyor sections.
Whether the Standard or Advanced ver-
sion: the shock resistance, for example,
Palletiser plants
06
: SICK Complete
Electronics
ATEX sensors not just for processing grain
Automation and
protection in Ex-Zones
of both types of C4000 has already been
prepared for use in Ex-Zones 2 and 22.
Thus the safety light curtains can sim-
ply be equipped with SICKs ATEX Kit to
meet the requirements of the 94/9/EU
Ex-directive. This offers the principal
advantage that, depending on the ma-
chine and the zone allocation, the same
safety light curtains can be employed for
Ex and non-Ex use so that no duplicate
warehouse stocks are necessary.
In addition to ready-to-install stand-
ard solutions such as the W27-3 Ex, and
systems such as the C4000 ATEX that
allow flexible upgrading, SICK also offers
explosion-protected sensors that can be
used without protective housings if they
are installed in the machine in a pro-
tected position. The latest development
to follow this approach is the WT9L laser
photoelectric switch in Category 3D/3G.
Whether automation or safety technol-
ogy SICK sensors also impress in the
Ex-Zone.
Protecting the pallet conveyor system
with the C4000 safety light curtain
Miniature sensors for high-tech X-ray inspections
Portfolio and global
support decisive
Matrix Technologies X2, the first fully automatic high-speed X-ray inspection
system, went into serial production in early 2006. The system is equipped
with a wide range of inductive, magnetic and opto-electronic miniature sen-
sors from SICK. Though it was not the everything from a single source
aspect that was decisive, but the availability of worldwide support.
>> X2 represents a completely new tech-
nology platform for fully automatic X-ray
inspections (AXIs). The most important
area of use in the electronics industry is
for quality inspections during printed cir-
cuit board production and during wafer
bumping. Apart from its ability to inspect
up to 10,000 components or soldering
spots per minute, the X2 is above all char-
acterised by its compact dimensions and
extremely short load and unload times of
under 6 seconds. This has been made
possible by the systems new conveyor
lift technology, by its highly precise high-
speed table for moving the test-pieces
in the x and y directions, and by power-
ful transport and handling systems. A
variety of miniature sensors from SICK
make a considerable contribution to the
performance capability and accuracy of
the process.
Wide range of products for
position polling
Depending on the particular task, differ-
ent physical principles are best suited for
reliable position polling. Whether photo-
electric switches, proximity initiators or
magnetic cylinder sensors Matrix could
select the optimum sensor technology
from within the various series according
to the intended use.
Worldwide availability
All the sensors used in the X2 have been
successfully employed in numerous ap-
plications throughout the electronics in-
dustry. Moreover, as Matrix intended its
system for the world market it was im-
portant to be able to offer support, and
replacement or supplementary devices,
at short notice worldwide.
As a technology leader with a broad
range of activities and a worldwide sales
organisation, SICK also has decisive ad-
vantages here.
07
: SICK Complete
insightLINK
You can obtain further product
information with the attached card under:
INFO 101
or on the Internet at:
www.sick.com/insight/en
More about the customer:
www.buhlergroup.com
insightLINK
information or on the Internet at:
www.m-xt.com
1/2006
Handling systems
Object detection and identification
Automatic wheel handling: 3-D is best
Both users and integrators rate three-dimensional sensor systems highly
as the basis for complex handling and automation solutions. With the
worlds first and currently only IVC-3D smart camera and the LMS400
Laser Measurement System two different technologies are available for
this purpose, whose specific advantages round out the automatic han-
dling of wheels.
>> In automobile construction, and at
sub-contractors, ever-increasing num-
bers of variants are produced in ever-de-
creasing batch sizes. At the same time,
the assembly parts, e.g. complete car
wheels, must be supplied in the correct
sequence. The feed of components to
the conveyor belt or handling station is
as mixed as the production and assem-
bly orders, i.e. wheels of different sizes,
and with differing rims and tyre types.
Robot guidance through position
detection and type identification
In order to permit automatic supply for
the production step while also ensur-
ing a correct allocation of the wheels to
the particular vehicle, the many types of
wheels must be reliably detected with
suitable sensors. The LMS400 Laser
Measurement System now allows robots
to automatically pick up wheel rims re-
gardless of their differing geometries.
For its part, the IVC-3D smart camera en-
sures a simple and robust identification
of the wheel type by evaluating a slotted
label.
The LMS400 is installed in the ro-
bots gripper tool in such a way that it The LMS400 Laser Measurement System transmits fan-shaped light pulses
detects a defined spatial segment during
movement. During the scanning proc-
ess, the LMS400 continuously emits fan-
shaped light pulses that are reflected by
the target objects. The sequence and
time-of-flight of the detected reflections
provide a distance profile from which the
spatial contours of the target objects, i.e.
the wheels, can be calculated taking
the geometrical arrangement and the
movement of the LMS400 on the robot
into account.
After the robot has picked up a wheel,
its position and orientation in space is
detected. The wheel is now, during the
handling process, passed through the de-
tection field of the IVC-3D in such a way
that the smart camera can detect the
3-D type-coding on the wheel. With its
light section process, the IVC-3D takes
a real 3-D picture of the corresponding
wheel section, searches for the coding
within it, and evaluates it. A simple allo-
cation table then allows the wheel type to
be determined within a few milliseconds.
Realtime-enabled and
easily expanded
Two different measurement tasks are
carried out in a single step with this solu-
tion. This is possible because the wheel
contour data of the LMS is made avail-
able for the robot controller in real time,
within milliseconds. Every wheel can
therefore be transported past the smart
camera with an optimised alignment and
distance. The inspection thus has no ef-
fect on the cycle time of the station nor
the entire plant cycle. Expansion of the
system with further wheel types is eas-
ily carried out. First the external contour
data of the new wheels are taught into
the LMS400. The new wheel type simply
leads to an expansion of the allocation ta-
ble in the IVC-3D smart camera with new
lines containing the corresponding data.
Whether the IVC-3D smart camera or the
LMS400 Laser Measurement System
3-D sensor systems increasingly repre-
sent the best automation concept.
: SICK Complete
08
Simple and robust wheel rim type de-
termination with the IVC-3D 3-D smart
camera
insightLINK
INFO 102
With laser measurement systems and safety laser scanners
SICK sensors
on the stackers of the future
Industrial truck producer Still introduced its Laser Navigator vehicle at
CeMAT 2005. The serial stacker offers a great deal of flexibility not least
thanks to LMS Laser Measurement Systems and the S3000 safety laser
scanner and thus indicates a potential route to the intralogistical future.
>> Increasing automation up to the fully
automatic autonomous organisation of
warehouses is the vision underlying the
concept of the Laser Navigator. In terms
of industrial vehicles, this means that
they must demonstrate a maximum level
of autonomy during navigation, during
the uptake and setting down of loads,
during the monitoring of drive paths, or
in joint operation with other vehicles.
Independent navigation
Stills Laser Navigator solves the problem
of position determination and navigation
with the help of an LMS Laser Measure-
ment System. Mounted in such a way
that it rotates on the vehicles protective
roof, the device detects its surroundings.
The vehicle determines its current posi-
tion and alignment by continuously com-
paring the sensor data with the map
stored in the vehicle controller.
Independent load handling
But in order to transport loads from A to
B, an autonomous stacker must not only
detect its position, but also the goods
to be transported during uptake. For
this purpose the Laser Navigator has a
second Laser Measurement System on
the load uptake equipment. This allows
pallets, for example, to be precisely de-
tected and picked up, even if they are not
resting on the floor absolutely correctly.
As the measurement system travels with
the elevating fork, the vehicle can also
set down, or pick up, a load on a stack
or in a shelf.
Independent area protection
Stills Navigator also independently
ensures safety during operation. The
S3000 safety laser scanner detects per-
sons and objects on the drive path and
in the surroundings of the autonomous
Autonomous navigation with the LMS Laser Measurement System (centre picture) independent area protection with the
S3000 safety laser scanner
stacker. This not only allows the vehicle
to drive around local obstacles, or select
a detour route from the map but, in addi-
tion, the safe protective functions of the
S3000 permit a Laser Navigator to use
the same path at the same time as per-
sons, manually driven vehicles or other
automated guided vehicles.
The demonstration of the Laser
Navigator at CeMAT 2005 showed that
everything works as it should. Naviga-
tion, load detection and area protection
no problem at all thanks to laser tech-
nology from SICK.
09
Industrial trucks : SICK Complete
insightLINK
INFO 103
www.still.de
Preparing paper rolls at the Neue Zrcher Zeitung
Role play in blue and yellow
The Swiss company Metso Paper AG has set up a station for preparing
paper rolls at the Neue Zrcher Zeitungs NZZ Print printing centre. A
variety of automation and safety opto-sensors from SICK monitor and con-
trol the processes of Metsos EcoPrep machine.
the paper rolls, each weighing about
1.2 tonnes, to the paper store. Entry to
the station is protected by MSM muting
safety curtains in such a way as to allow
effective differentiation between a per-
son and a paper roll. WT27L series laser
proximity switches detect the rolls in the
station with great accuracy, while WT34-2
proximity switches determine the roll di-
ameters. The presence of the coloured
coupling band on the prepared paper roll
is confirmed with the help of KT5W con-
trast scanners. WSU/WEU26-2 safety
photoelectric switches monitor access
to the hazardous area during retrieval of
the paper rolls from the daily store.
The individual tasks require very dif-
ferent sensors and methods of function-
ing, says Oliver Colombo. The fact that
we can obtain all the sensors for the Eco-
Prep from a single source was very help-
ful in allowing us to meet the machines
automation and safety requirements in
the best possible way.
>> The paper store set up by Metso at
NZZ Print offers a capacity of 1,000
tonnes. This is equivalent to about
1,100 rolls of varying width or enough
stock for approximately three weeks.
We need about 60 rolls per issue so
the annual store throughput of 16,000
tonnes is correspondingly high, says
Oliver Colombo, the development engi-
neer at Metso Paper with responsibility
for the preparation of paper rolls in the
paper store at NZZ Print.
From the paper store to the prin-
ting press
Fork-lift trucks collect the paper rolls
from stock in good time for printing and
set them down on the floor transport sys-
tem, which transports them to the paper
roll preparation station. Among the most
important tasks at this station is the at-
tachment of a coupling band, with whose
help the printing press can automatically
take up the start of the paper roll. The
station can prepare up to 25 paper rolls
per hour, says Oliver Colombo. From
here, the floor transport system trans-
ports the prepared rolls to the printing
press. A fully automatic high-bay stacker
accepts the roll and stores it in one of
the 100 storage bays of the daily store.
The rolls are then automatically retrieved
during the printing process, according to
the requirements of the individual print-
ing presses, and made available for use
where required.
Automation and safety technology
in a leading role
A variety of sensors undertake important
control and safety functions during the
automated preparation of paper rolls.
S3000 safety laser scanners monitor
the floor transport systems delivery of
insightLINK
INFO 104
www.nzzprint.ch
www.metsopaper.com
Printing and paper
10
: SICK Complete
1/2006
The paper store provides space for about 1,100 rolls of differing widths
Happy with the complete sensor solu-
tion: Theodor Strasser from SICK (left)
and Oliver Colombo from Metso Paper
Sorting plants
11
: SICK Complete
One compact device instead of many components
A compact measuring wheel encoder
for indirect path measurement
With the DKV60 incremental measuring wheel encoder, an easy-to-install
and economical all-in-one solution for the indirect determination of path,
position and speed information is now available.
>> In practice, many measuring wheel
systems turn out to be relatively expensive
because the four individual components
generally involved (the mounting bracket,
spring or pressure system, encoder and
measuring wheel) must be put together,
which can prove difficult, and matched to
one another. In addition, such measuring
wheel systems are relatively large and
use up valuable mounting space. And
the actual installation process is compli-
cated because the retaining and spring
components often have to be mounted
and adjusted separately before the actu-
al measuring wheel encoder itself can be
attached. The resultant installation costs
often considerably exceed the purchase
costs of the actual measuring wheel sys-
tems. The DKV60 has succeeded in com-
pletely eliminating these disadvantages.
DKV60 an economical and com-
plete compact unit
Unlike conventional measuring wheel
systems, the DKV60 merely consists of
a single component for installation. The
measuring drum of the DKV60 with op-
tions for non-skid or smooth surfaces is
mounted directly on a spring arm that
simultaneously serves to offset mechani-
cal fluctuations in different directions on,
for example, conveyor belts. The contact
pressure of the measuring drum can be
ideally adapted during installation. The
drum structure acts as a robust and at-
tractively designed housing for the mini-
disc measuring system (MiDi) and the
electronics of the incremental encoder.
MiDi technology not only makes the
DKV60 extremely precise, but also highly
immune to impacts and vibrations. This,
and the housings enclosure rating of
IP 65, permit use of this measuring wheel
encoder even in locations that are partic-
ularly harsh, e.g. on ALIS Airport Luggage
Identification Systems.
Example of use: sorting plant
for flight baggage
ALIS is the worlds leading system for au-
tomatic flight baggage identification at
airports. The system consists of a gate
frame, on which bar-code scanners are
mounted to identify the flight baggage
labels. The read information is used to
control the flight baggages transport to
the gates or to the baggage retrieval car-
ousels. ALIS makes maximum demands
of measuring wheel encoders like the
DKV60. Belt speeds of 2 m/s, sometimes
even greater, must be very accurately
detected in order to trigger the reading
gates and, if necessary, control a sorter
feed belt. In the process, the sometimes
very strong impacts and vibrations on
the particular conveyor belt section must
not impair speed or path measuring. The
amount of baggage also necessitates
maximum availability. Given, for exam-
ple, a large international airport such as
Frankfurts Rhein-Main Airport with 50
million passengers a year, and assuming
that they only hand in an average of one
piece of flight baggage each, then over
365 days almost 100 pieces of luggage
will be identified by the ALIS gates every
minute. Thus, not only is robust encoder
technology required, but it must also be
easily maintained and allow rapid re-
placement of devices should any fail or
during servicing work.
Construction-friendly, compact and
reasonably priced, the DKV60 is also
the ideal solution for indirect path meas-
urings in textile, packaging or wood
processing machines as well as machine
tools.
Robust and good-looking: the DKV60 measuring wheel encoder in drum form
insightLINK
INFO 105
12 1/2006
Collision prevention for high-bay stackers
An outstanding solution for
parts that stand out
Three high-bay stackers are being made collision-proof at the BMW works
in Dingolfing with the help of LD-PDS laser scanners. The devices monitor
the front areas of shelving along the aisles and detect any parts that jut
out, even slightly, from the stored grid boxes.
>> The high-bay stackers are employed
in the grid box warehouse, in which parts
for the production of vehicle seats are
stored. Under certain circumstances,
it is possible for parts to protrude into
the shelving lanes as a result of shifting
of the load during handling of the grid
boxes, from which the parts are com-
missioned. Collisions could be caused if
these parts were not detected and reg-
istered by a passing high-bay stacker. If
a grid box were to fall, it would not only
damage the parts themselves, but also
the high-bay stackers control box. This
The LD-PDS laser scanner scans the shelving front for projecting objects
would result in blockage of the shelving
lane, repair costs, material loss and im-
paired production.
The solution: area scanning for the
shelving fronts
Attempts to achieve collision preven-
tion with photoelectric switches did not
bring about the desired reliability partly
because only large objects could be re-
liably detected, and partly because the
sender and receiver could lose each
other within the complex structure if the
steel construction was affected by tem-
perature fluctuations. Thus a travelling
sensor system was sought that could
detect the entire shelving front two-di-
mensionally with a high level of accu-
racy. The LD-PDS laser scanner fulfilled
these requirements. The Protection and
Detection System (PDS) is suitable for
horizontal 360 monitoring, as well as
for the vertical use implemented at BMW
to scan the shelving fronts. As a result
of a particularly fine resolution angular
increments of 0.125 are possible and
highly efficient detection capability, even
small dark objects could be detected re-
liably and in good time. CANbus, RS-232
and RS-422 serial interfaces, or four dig-
ital switching outputs are available for
data output. The device can be adapted
to a large variety of operating conditions
thanks to its digital signal processor,
which allows application-specific pro-
gramming.
Through the grid box store without
collisions
Many partners were involved in finding
the solution and supporting the LD-PDS
trials (which lasted several months) in
the grid box stores. These included Sie-
mens, BMW, SICK IBEO (as the producer
of the system) and the External Sales
and Services staff of SICK Vertriebs-
GmbH. Schiller Elektro-Anlagen GmbH
in Osterhofen were responsible for modi-
fication of the stackers and integration
of the four laser scanners per vehicle.
Two LD-PDS units are mounted on each
end of the stackers, i.e. one device per
side and direction of movement. Defini-
Automotive : Applications
: Applications
13
Image processing
tion of the 90 angular segments and
the measurement radius of 7 m was car-
ried out with the user-friendly Zone Pro-
tect user software. The so-called Laser
Beamfinder was helpful for the optimal
placement of the scanning plane in front
of the shelf frontings. This device shows
the laser beams of the LD-PDS (invisible
to the human eye) on its integrated dis-
play and thus permits simple and precise
alignment. While the high-bay stacker is
in motion, the two laser scanners in the
direction of movement are activated by
the vehicle control system. They detect
whether parts are jutting out into the ve-
hicles drive or fork elevation path. The
stacker stops when it detects an obsta-
cle and reports on where the problem is
located allowing rapid and targeted
correction.
The advantages of SICKs LD-PDS
laser scanner which are also demon-
strated during its use at BMW lie in the
simple integration it offers users, and in
the gap-free detection provided by the
individually parameterisable monitoring
fields. These properties currently make
the device unique on the market.
Integrated in the inspection system
Monitoring production
in three dimensions
The Finnish company Master Automation Group has integrated the
IVC-3D three-dimensional smart camera of SICK IVP in its Visor3D quality
inspection system. Decisive factors were the high levels of accuracy and
immunity to ambient light, as well as adaptation of the software to differ-
ing tasks.
>> Visor3D is used to provide quality
control integrated into the production
process. Typical examples of use include
the inspection of assembly process in
the electronics industry, checking the
shapes and surfaces of baked products
in the food industry, or the optical inspec-
tion of die-cast or metal parts.
Accurate and immune to
ambient light
The Visor3D inspection system is charac-
terised by its high level of accuracy and
rapid processing of measured values.
The IVC-3D Industrial Vision Camera
plays a decisive role in this. Unlike con-
ventional image processing systems, the
3D smart camera is capable of detecting
geometrical features regardless of fluc-
tuations in contrast. The system emits a
line of laser light whose reflections are
evaluated using a triangulation process.
The laser optics are integrated directly in
the housing in order to maintain a stable
and uniform geometry between the illu-
mination and the camera throughout the
entire inspection process. Up to 5,000
profile sections per second are com-
bined to form a real 3D picture. Wheth-
er 0.1 mm or 0.5 mm resolution the
camera provides an image of the actual
object contour with great precision, thus
permitting reliable in order or not in
order decisions.
User-friendly through
program library
Visor3D offers user-friendly adaptation
to a wide variety of inspection tasks
thanks to its easy-to-use operator inter-
face and the IVC-3Ds IVC Studio pro-
gramming software. Visor3D operator in-
terface includes functions to quick prod-
uct change, information of measured
values, failed parts, statistics and data
logging. The more than 100 tools pro-
vided in the camera, with which the most
varied of multi-dimensional tasks can be
achieved, contribute towards this ease-
of-use. Shapes, geometries, sizes or de-
signs the IVC-3D can be parameterised
in great detail via the graphic user inter-
face to meet the particular needs of the
object detection task involved.
With the IVC-3D, the Master Automa-
tion Group has succeeded in develop-
ing a highly flexible and reliable inspec-
tion solution with a minimum time-to-
market.
insightLINK
INFO 107
www.masterautomationgroup.com
insightLINK
INFO 106
www.bmw-werk-dingolfing.de
www.schiller-gmbh.com
: Applications Textile industry
1/2006 14
: Applications
14
Perfect solution for Schlafhorst spinning machines
Proximity switches take up
the thread of automation
The detection of pattern tape, empty bobbins, and open spinboxes, as well
as the monitoring of distances textile machine producer Schlafhorst
Saurer solved four different core functions of its Autocoro rotor spinning
machines in one go with the WT18-3 photoelectric proximity switch.
>> Autocoro automatic rotor spinning
machines basically consist of the drive,
the suction system and a customer-spe-
cifically arranged number of sections
with spinning boxes and winding heads,
removal belts for the cross-wound bob-
bins, and mobile Coromat automatic
piecer units equipped with SICK sen-
sors. The pattern tape is fed out from
containers (called spinning cans or tops)
to a rotor revolving at up to 150,000
r.p.m., via a pre-condenser, condenser,
and drawing-in and opening rollers. The
resulting yarn is fed out of the spin box
and then cross-wound onto a bobbin.
When the defined yarn length has been
reached on the bobbin, the spinning
point sends a signal to the Coromat auto-
matic piecer unit, which travels along the
machine and positions itself in front of
the particular spinning point. Depending
on the request, it changes the finished
cross-wound bobbin, starts the winding
on a new empty bobbin, or restarts the
spinning process after a thread has bro-
ken.
Maximum availability is no
threadbare argument
Because, in addition to the quality of the
yarn, machine availability also plays a
decisive role for end users, Schlafhorst
Saurer requires reliable opto-sensors to
automate the Coromat piecer units: the
WT18-3 from SICK. With about 8,000 op-
erating hours per year per Autocoro, the
device must carry out almost half a mil-
lion detections or Coromat switchings in
the four core tasks. The newly developed
detection process provides considerably
more precise detection results than con-
ventional sensors. Thus Schlafhorst has
tested the device on light and dark pat-
tern tapes, against differing backgrounds,
and in varying reflective conditions. The
results showed that with a single param-
eterisation the sensor reliably detects, for
example, pattern tapes of every colour
under all conditions. Moreover, thanks
to teach-in, the scanning distance setting
can now be carried out comfortably and
without tools.
Four-fold functions in Coromat
Detection of the pattern tape takes place
on the particular spinning point between
the pre-condenser and the condenser.
The generally light tape runs just above
a highly reflective machine background.
Electronic setting of the scanning dis-
tance and background suppression per-
mits very precise and reproducible adjust-
ment of the sensor to these conditions, so
that missing material or a broken tape are
reliably detected. Monitoring of the closed
state of the spinboxes is necessary be-
cause the Coromat, which travels at ap-
proximately 20 m/min (i.e. pretty quickly),
is very close to them when it passes by.
Each direction of movement is monitored
with a WT18-3, open boxes are thus de-
tected at a safe distance and the Coromat
stopped in good time. The sensor also
has a positive effect during the detection
of empty bobbins for the Coromat gripper.
Here the sensor must detect the differing
materials, surface structures and colours
of the empty bobbin. The fourth area of
use for the WT18-3 is maintaining separa-
tion of the Coromats (which can get close
to one another while approaching neigh-
bouring spinning points).
Fieldbus option to be threaded into
future machine generations
The WT18-3 photoelectric proximity
switch offers interesting new possibilities
in numerous tasks. Furthermore, as a re-
sult of its fieldbus capability via IO-Link
(see Page 32) the sensor can not only de-
termine and signal switching distances,
but also provide a lot of supplementary
information operating state, the pres-
ence of interfering factors in its vicinity,
the quality of the switching signal, or the
current scanning distance.
Automation of the Coromat automatic piecer units from Schlafhorst was
achieved with the WT18-3 photoelectric proximity switch
insightLINK
INFO 108
www.schlafhorst.saurer.com
: Applications
15
Safety in an IP67 housing
Both fish and fowl!
Time-consuming to operate, bulky, and a hindrance to operators safety
solutions are sometimes neither fish nor fowl in practice. By contrast,
the C2000 safety light curtain in its IP67 housing offers precisely what
customers like the Italian machine producer Nicolino Vitileia want:
safety, ease-of-use, and a compact design.
>> Italians know what they are talking
about after all, the company special-
ises in automatic machines for process-
ing fish and meat. End-customers used
to repeatedly complain that the protec-
tive doors and flaps on the machines
hindered the operators and impaired
machine capacity. Fabrizio Castelli and
Giancarlo Marino fished the ideal solu-
tion from the SICK catalogue: the C2000
in an IP67 protective housing. It not only
fulfils the need for safety and availabil-
ity, but also meets productivity and ergo-
nomic work demands.
Protection during operation,
protected during cleaning
The C2000 safety light curtain from SICK
is Type 2 electro-sensitive protective
equipment complying with IEC 61496
for guarding hazardous points-of-opera-
tion. When one or more light beams are
interrupted, within a few milliseconds
the safety system transmits a signal
via its safe switching outputs to a
machine controller which brings
the hazardous process to an im-
mediate stop. The protective hous-
ing basically consists of a PMMA
acrylic tube and two V4A stainless
steel end-caps with sealed inlets for
the connection cables. The hous-
ing materials are resistant to the
common standard cleaning proc-
esses and detergents. The parts are
constructed in compliance with the
safety and hygiene requirements of
EN 1672-1 and -2, reliably prevent-
ing the accretion of any deposits of
dirt that could be inaccessible dur-
ing cleaning work.
Molto bene
Praise indeed for the opto- electron-
ic safety solution in its protective
housing from those responsible at
Nicolino Vitileia. Better and time-
saving operation, simpler and main-
tenance-free mounting, cool design
grazie, IP67 housing!
The IP67 protective housing developed by SICK offers universal use for
systems Type 2 and Type 4 in compliance with IEC 61496, e.g. C2000 and
M2000 light curtains or the C4000 Micro. Depending on the device, protecti-
ve fields of between 150 mm and 1,200 mm can be obtained with 2-, 3- and
4-beam systems. It therefore represents a solution offering flexible configu-
rability and resistance to harsh environments for non-contact protection of
machines.
So it is not surprising that safety sensors in protective housings have very
quickly become a popular solution in washable applications: more than
700 systems are now in use and in none of them has any liquid yet
succeeded in entering the device from outside. Whereby the various appli-
cations are by no means straightforward: butchers machines with steam
cleaning; machines in cheese production (cleaned with high-pressure hot
water and aggressive acids and alkalis); chemical plants in which aggressive
cleaners are used; presses, in whose environment oily vapours are to be
found; or the production of roofing tiles, during which oily parting compounds
are used for the pressing moulds. The list of examples could go on and on
and new uses are continuously being added to the list.
>> Safety sensors in IP67 housings the success story
The hazardous point is protected with the C2000 safety light curtain in its IP67 pro-
tective housing
Food industry
insightLINK
INFO 109
www.officinevitileia.it
: Applications
1/2006
Steel industry
Protecting areas and checking presence
Safety solutions for
steel processing
The Belgian steel company Tailored Blank Genk NV succeeded in
solving two tasks in harsh environments with non-contact safety systems
from SICK.
>> While areas in which fork-lift trucks
place pallets on conveyor systems are
monitored by S3000 laser scanners, the
IN4000 inductive safety system protects
waste metal discharge from a shearing
machine for steel plate.
A shining performance from
the S3000
During steel processing at Tailored Blank
Genk, a stationary roller conveyor sys-
tem is used to transport empty pallets
and those loaded with sheets of steel.
Fork-lift trucks put the pallets on the con-
veyor and remove them. It is important
to ensure that the vehicles have enough
room to manoeuvre in the transfer areas
as some of the pallets can be up to 3 m
wide, says Bert Keulen, responsible for
automation tasks at the steel works.
Finding a scanner with a protective field
large enough to monitor the manoeuvring
areas was not the problem but the first
solution didnt work. This was because
the numerous reflections from the steel
sheets and the forks of the trucks, as
well as adverse light incidence, made
the device respond, says Bert Keulen.
We then went to SICK and straight away
were given an S3000 safety laser scan-
ner to try out. This solved the problem
since their installation, the devices have
been absolutely reliable and error-free.
IN4000: safety position monitoring
A few metres away on a steel plate
shearing machine a further safety
function needed to be integrated. Metal
scraps left over after shearing are eject-
ed into a waste metal container that
requires regular replacement by fork-lift
trucks. Though the machine can also be
operated without the waste container,
the metal then falls on the floor, says
Bert Keulen. Which is why the protec-
tive fence around the machine also has
to be generously proportioned so that no
bits can fall beyond the barrier. With the
IN4000 inductive safety system, a solu-
tion has been found to ensure that the
machine only operates when the waste
container is present. Whats special
about this is that the system reliably
detects the containers even without an
actuator Bert Keulen emphasises two
important advantages. As a result, we
can now make the fence so small that
it surrounds the waste container exactly.
We have achieved process reliability on
the machine and safety at work for the
fork-lift drivers, gained valuable space
for drive paths and storage by reducing
the fenced-off area, as well as largely
eliminating collisions between the fork-
lifts and the fence.
Whether optic or inductive the right
non-contact safety systems are also suit-
able for use in harsh environments.
Left: A finger points to the S3000 safety
laser scanner
Top: The inductive IN4000 detects the
scrap container without an actuator
16
insightLINK
INFO 110
: Applications
17
Checking pallets at Krombacher
Laser Measurement Systems
ensure dependable beer supplies
Are the beer crates OK? At Krombacher, this question is answered by
several LMS400 Laser Measurement Systems. They ensure that off-
licences or beer aficionados never have to do without natures pearl
(as advertised).
>> Pure, fresh spring water that is low in
minerals, together with high-quality ingre-
dients are the secret of the unique taste
of Krombacher Pils. A compact housing,
3 m range and 0.1 angular resolution
these are the ingredients of the LMS400
Laser Measurement Systems with which
system integrator Novatec Lsungen has
implemented pallet inspection at Krom-
bacher.
Meeting demands not
mounting demands
Staff at Krombacher are proud that their
brewing meets the demanding tastes
of many beer drinkers. On the other
hand, mounting demands, in the form
of complicated camera and illumina-
tion technology, were to be avoided for
the pallet inspection. Instead of this,
the laser measurement technology of
the LMS400 is employed to detect the
height of the pallet load and the number
of crates on it. One device is mounted
about 2 m above the conveyor belt of
each pallet line. As the pallet passes be-
low the LMS400, the sensor measures
the height while simultaneously detect-
ing any missing cases in the topmost
layer. The data are transferred from the
machine controller to the operating data
registration system, where they are com-
pared with the current customer or com-
missioning order.
Integration during multi-shift
operation
The solution with the LMS400 was devel-
oped and optimised on an automation
system parallel to plant operation, mak-
ing subsequent integration rapid and
simple. In addition, the compact housing
permitted a very much quicker and more
space-saving installation than would
have been possible for a camera solu-
tion with separate lighting gear. Finally,
the laser solution is characterised by
great user-friendliness and easy service:
Krombacher can use their own mainte-
nance staff to check and correct any er-
ror messages that may crop up, without
requiring any expensive specialists.
The LMS400 is a versatile automa-
tion solution for inspection tasks, or for
palletising & depalletising applications
especially as it provides flexible con-
nection to external evaluation systems
via Ethernet, RS 422, RS 232, and dig-
ital inputs and outputs.
The LMS400 measures pallet height
and detects missing crates in the top
layer
Beverages industry
insightLINK
INFO 111
www.krombacher.com
www.novatec-v.de
: Applications
18 1/2006
Automation light grid used for security purposes
Secure gates at Stuttgart Airport
Unobtrusively integrated into the glass and stainless steel design of
the corridors at Stuttgart Airport, MLG Security light grids detect
both persons and dangerous objects passing through security gates in
the wrong direction.
>> The modular system approach, in
particular, makes the MLG light grid
interesting for security applications as it
allows individual solution concepts, like
that at Stuttgart Airport, to be rapidly and
efficiently implemented.
Reliable separation of the
land- and air-sides
8.8 million passengers, and 156,885
take offs and landings at Stuttgart Air-
port in 2004, bring about enormous
security demands. These include the
reliable separation of the land-side, ac-
cessible to the public, from the air-side.
Departing passengers move from the
terminal areas of the land-side to the
air-side the area behind the security
check on travellers and hand baggage.
Arrivals transfer from the air-side to the
land-side via halls in which the baggage
collection carousels are located. Gates
here must ensure that nobody can get
back to the air-side from here against
the direction of movement. Objects, too,
cannot be permitted to reach the air-side
in this way, regardless of how small they
may be. Which is why a suitable sensor
solution was sought to allow arriving pas-
sengers and their hand luggage to pass,
while detecting any persons or objects
that go through the gates in the wrong
direction. If this were to occur, the sen-
sors had to immediately lock the gate
and raise the alarm.
The MLG Security light grid:
for individual configurations
The task was solved with the MLG Secu-
rity light grid. An individually configured
light grid (with selectable resolution) is
generated between the sender and re-
ceiver housings. When at least one light
beam is interrupted by a person or
object this is signalled via the switch-
ing output. The software ensures that,
for example, reflections from aluminium
hand luggage or the fluorescent lamps
in the vicinity of the gates cannot impair
the reliable detection of persons or ob-
jects.
Reliable direction and
object detection
Each gate is equipped with two MLG
systems installed alongside one anoth-
er. The resolution of these light grids is
so fine that even a flat object pushed
through along the hall floor or along the
top of the gate is reliably detected and
reported. Detection of direction takes
place in the control system via the time
difference between responses from the
two light curtains. An output signal is
generated to inform the central alarm
control system if a person or object
passes through in the wrong direction
and the camera pictures for this area
are locked on.
The equipped terminals at Stuttgart Air-
port have proven themselves in 24-hour
operation for over a year now.
Even flat objects pushed along on the
floor are reliably detected by the
Security MLG
Arriving passengers pass through the gates in the correct direction on their way
from the runway to baggage retrieval
Transport and traffic
insightLINK
INFO 112
www.stuttgart-airport.com
: Applications
19
SICK safety sensors and HIMA safety controls in combination
Safe Sprinter production
in safe Ethernet
S3000 safety laser scanners and C4000 safety light curtains from SICK,
together with safety controllers and devices from HIMA, ensure the pro-
tection of persons and plant via safe Ethernet during the construction of
shells for Sprinter vans at DaimlerChrysler in Dsseldorf.
>> The BWS-Plug plug-in hardware
adaptation connector ensures efficient
interaction between the individual sen-
sors and the fast HIMatrix controllers
and remote I/O modules (RIOs). This
adaptor plug permits use of the rapid
digital inputs of the safety controllers,
and thus ensures that all the HIMatrix
systems distributed throughout the
Sprinter shell construction area exhibit
typical reaction times of well under
100 ms with up to 600 decentralised
safe inputs and outputs each.
Positive safety evaluation
The HIMatrix system, consisting of safe
PLCs and remote I/O modules, process-
es safety input signals (e.g. from protec-
tive doors, C4000 light curtains, S3000
scanners or sliding gates), and output
signals for welding robots and conveyor
systems, etc.
RIO 1
CP
*
BWS-Plug
Scanner
S3000
Light curtain
C4000
BWS-Plug
RIO 8 RIO 20
SWITCH
*control panel

View of Sprinter production plant in Dsseldorf
The failure mode error analysis (FMEA)
carried out to evaluate the safety of the
adaptor plug showed that the entire sys-
tem mastered all the failures that could
be expected to occur and is fully stand-
ard-compliant: IEC 61508 up to SIL3,
and EN 954-1 up to Category 4.
This application also shows that it is
possible, without any great difficulty, to
integrate safe sensors from one produc-
er and safe controllers from another.
Sensor adaptation between the HIMatrix system family and sensors from SICK by
means of the BWS-Plug
Automotive
insightLINK
INFO 113
www.hima.de
www.daimlerchrysler.com
: Applications
20 1/2006
Safety during the production of safe sensors
A boon for the sawing centre
>> Optimum and flexible adaptation of
the safety process was achieved using
the UE440 safety controller.
From raw profiles to tailor-
made safety
The vertical store known as a storage
tower accepts the six-metre-long raw
profiles from which the housing lengths
required for the C4000 and M4000 are
then sawn to order. The storage cartridges
are stored using long transporters; re-
trieval and feed to the saw takes place
using lateral transport with a manual in-
sertion process and automated forward
feed insertion of the raw profiles. Both
processes are monitored with Category 4
safety technology to protect personnel.
Safe storage with M4000 multiple
light beam safety devices
Storage is protected by an M4000 with
muting. The UE403 safety controller
processes the signals of the IQ40 muting
sensors triggered by the traversing vehi-
cles so that automatic storage can be
carried out through the protective field
of the M4000. This solution structure
cuts costs considerably, as the UE403
is mounted on the M4000 itself and the
muting sensors can thus be directly con-
nected to the switching device in situ
reducing cable requirements.
Safe retrieval with the C4000
Host/Guest safety light curtain
A comprehensive safety concept has
been set up on the retrieval side. A
C4000 Host/Guest (mounted in an L
shape) monitors retrieval, lateral trans-
port in the direction of the roller con-
veyor, and the forward feed to the saw.
As soon as the end of the hazardous
lateral transport is detected by the IQ40
non-contact proximity switch, it gener-
ates a signal to the UE440 safety con-
troller which then mutes the C4000 for
the lateral transport. The operator can
A German proverb (an old saw) says that the cobbler wears the worst
shoes. But this is not always the case: in its new production building in
Waldkirch, SICK employs its own C4000 Host/Guest safety light curtains
and M4000 multiple light beam safety devices to protect storage and re-
trieval processes in a vertical store and in the neighbouring sawing centre.
The sawing centre with all-round safety concept
now pass through the light curtain into
the hazardous area and transfer the raw
profile from the storage container onto
the forward feed table.
A C4000 with blanking function is
used to cut out the roller system sup-
ports in order to save space during inte-
gration in the roller conveyor. Regardless
of the cartridge position on the lateral
transport belt, the C4000 switches off
the supply of profiles. Thus the UE440s
signal to switch off the C4000 covers
both the monitoring of the lateral trans-
port path as well as the forward feeding
of the raw profiles to the saw, whereby
the IQ40 sensor mutes the C4000 dur-
ing final position detection of the storage
cartridges, i.e. in a safe machine state. A
further M4000 is integrated in the pro-
tective solution for point-of-operation
guarding.
This flexible, installation-friendly and
safe monitoring solution on the storage
tower and sawing centre really does dis-
prove the old cobblers saw.
Storing cartridges with the M4000
Muting (UE403) and IQ40 sensors
Handling and warehousing systems
insightLINK
INFO 114
: Applications
21
Safety and flexibility in a single casting
Injection moulding machi-
nes with guardian angels
The Austrian machine constructor Engel (angel in English) has developed
a new Category 4 safety concept for its plastic injection moulding machines.
The company exploited the flexibility opportunities offered by the C4000
Advanced light curtain, the S3000 laser scanner and the UE402 multifunc-
tional interface.
>> The initial spur for the new safety
concept was the development of a verti-
cal rubber injection moulding machine to
produce coolant hose for the automotive
industry. The design for maximum possi-
ble machine capacity utilisation resulted
in two important constructional features.
Firstly, the use of alternating frames for
casting the workpieces. The frames jut
out of the machine and alternately move
to and from the opposite side during run-
ning machine operation. Secondly, it was
decided to do without mechanical safety
barriers in order to permit unhindered
work on the machine. Safety and flex-
ibility we had to consider both aspects
when designing the necessary Category
4 machine protection, Engels Project
Manager, Fritz Khberger, explains the
original thinking.
Outstanding access protection
One S3000 safety laser scanner was in-
stalled below the projecting alternating
frames on each side of the machine to
protect access. Each one monitors the
horizontal area beneath the workpiece
carrier that moves downwards. The ma-
chine is stopped as soon as a person en-
ters the programmed protective field.
Three-sided solution with floating
blanking
The protection of the machines actual
working area was far more complex.
We had to protect three open sides,
whereby at the same time we had to be
able to remove the alternating frames on
two opposite sides without the machine
switching off, Fritz Khberger describes
the safety and production aspects. The
C4000 proved to be the ideal solution.
The installation of one system on each
of the three open sides of the machine
ensures maximum safety and does not
impair machine operation at all. The
floating blanking function of the light
curtain permits flexible and precise in-
terruption of the particular protective
field in the area in which the alternating
frame protrudes during removal. All the
other areas maintain active safety. This
prevents a machine stop and the un-
wanted interruption of the process while
retaining maximum safety, explains
Fritz Khberger.
Two light curtains protect
alternately
The floating blanking function may only,
however, be active on the side of the
machine on which the alternating frame
is currently being inserted or removed.
The automatic deactivation of the float-
ing blanking of the currently opposite
C4000 was achieved with the help of the
UE402 safety controller, which switches
between the front and back light curtains
depending on the process.
Simple integration, easy
programming
The integration and programming of the
SICK safety components take place us-
ing CDS configuration and diagnosis
software. After a single training course
from SICK, we were able to program
and parameterise the next machines
ourselves. CDS simplifies and acceler-
ates commissioning. We can also easily
implement modifications ourselves at
any time without any specialist knowl-
edge, Fritz Khberger enthuses about
the software tool.
Guardian angels included in
delivery program
Machine constructor Engel has included
this successful safety concept in its ma-
chine portfolio and has already equipped
several machines in this way. It is thus
one of the few companies that offers
proverbial guardian angels as stand-
ard in its delivery range.
The injection moulding machine with
its guardian angels: the S3000 laser
scanner and C4000 Advanced light
curtain
Plastics and rubber
Engels Project Manager Fritz Khberger
shows Christian Aschauer from SICK
(right) how the scanners are integrated
in the machine controller
insightLINK
INFO 115
www.engelglobal.com
: Applications
22 1/2006
Measurement with laser and Swiss precision
Terras tracking trolley
When a train journey has been a safe and comfortable experience,
passengers can ultimately thank Terra International Surveys Ltd. Because
the swiss trolley that the engineers of this Swiss company have de-
veloped is a measurement system that can be driven on rails to detect
track gauge, excessive height, or any deformation of rails with legendary
Swiss precision.
>> While GPS or target-tracking tachom-
eters locate the position of the swiss trol-
ley to within a few millimetres, the two
LMS Laser Measurement Systems in-
stalled on the trolley detect the contours
of embankments, rails, contact lines and
the surroundings.
swiss trolley: rail vehicle with GPS
and measurement intelligence
The swiss trolley measurement vehicle is
used for a kinematic structural detection
of rails and track-like objects. The meas-
urement vehicles can be folded up to save
space, are easy to transport to where they
are needed, and are quickly put on the
rails and ready for work. In addition, the
modular system concept offers us flex-
ible adaptation to new circumstances or
project requirements, Marc Amsler, from
Terra International Surveys Ltd., quotes
some of the important advantages for eve-
ryday use. swiss trolley is now the most
innovative mobile measurement system
of its type. It offers absolute position de-
termination with such high resolution and
measurement accuracy that even contact
lines are reliably detected.
Virtual flight through a cloud of
measurement value points
During the measurement run, the swiss
trolley generates numerous measure-
ment values for the subsequent control
of tamping machines. These include the
effective orientation of the track axis or
the two rails, the horizontal and vertical
gradient of the track, lateral inclination
variance, and deformation, as well as
variations in track gauge. The corre-
sponding correction files for the tamping
machines are derived from these data,
so that they can drive directly and pre-
cisely to these locations and carry out the
necessary underfilling of the track bal-
last, says Marc Amsler. Moreover, the
data of the LMS200 are used to display
the surroundings of the track in the form
of a dense, three-dimensional, cloud of
points. As in a virtual world, we can start
a geo-referenced flight through the cloud
of points and navigate with the mouse, to
allow the analysis of cross-sections, the
detection of platform edges, facades or
growth along the tracks, and the deter-
mination of deviations of the contact line
from the centre of the track, and then we
can document all this in individual single
images, explains Marc Amsler.
Light measure of dimensions
in dark tunnels
Building on the positive experience
with the rail-borne swiss trolley, those
at Terra International Surveys Ltd. have
also developed a measurement solution
for roads. For this purpose, the meas-
urement technology was appropriately
adapted for use on a Defender Land
Rover. This allows, for example, monitor-
ing of the advance heading during the
construction of tunnels, or as in the
new 57-kilometre-long Gotthard Basis
Tunnel checking the inner dimensions
of completed carriageway pipes.
Whether track or tunnel a wide vari-
ety of tasks in rail and tunnel measure-
ment can be carried out accurately and
economically with swiss trolley and the
LMS200.
Rail-mounted trolley measurement vehicle with LMS Laser Measurement System
insightLINK
INFO 116
www.terra.ch
: Applications
23
Ejection yes, rejection no
Inox sensors in
Mozzarella production
Inductive stainless steel initiators from the IM18 series are responsible
for synchronising two process steps during Mozzarella production at the
Jger dairy in Haag. Their precise position detection minimises rejections,
while their high level of robustness maximises their availability in the
harsh conditions present in food production.
>> Bavarella is the name of the tasty
Mozzarella pizza cheese produced in
the Jger dairy. The so-called 300-gram
carousel plays a decisive role in the
production of the cheese. This is where
the liquid Mozzarella cheese is given its
typical shape. At the carousels ejection
station the cheeses are taken up by the
after-shaping belt and transported in the
direction of the packaging machine. For
a long time, uptake was a problem be-
cause the position of a chain wheel on
the after-shaping belt was only monitored
indirectly. Inaccurate positioning during
acceptance of the cheese resulted in
too many Mozzarellas landing in the re-
ceiving basins. The company wanted to
prevent this product loss, as well as the
time-consuming and strenuous observa-
tion of the basins by an employee.
Stainless steel initiators:
highly robust thanks to IP 69K
enclosure rating
The tactile solution in the 300-gram car-
ousel was solved using direct detection
of the chain wheel with the help of IM18
sensors in Inox design with fully encap-
sulated V4A stainless steel housings.
The resulting enclosure rating of IP 69K
is particularly important because this is
the only way to ensure lasting availability
of the sensors despite frequent cleaning
with acids, alkalis and hot steam. The
same applies for the high tightness re-
quirements for the connector technology.
Thus the M12 plug connector also has
an enclosure rating of IP 69K. Moreover,
its cable, contact bearers and extrusion
are all designed in PVC.
Direct queries increase availability
The IM18 detects the teeth of the chain
wheel and passes on the pulses to a PLC
controller. This counts the pulses and re-
duces the speed of the after-shaping belt
after every fifth pulse (when the transfer
position for a new Mozzarella is reached)
via a frequency converter and a geared
motor. The cheese is thus considerably
more precisely and reliably taken over
from the ejection station the amount
of Mozzarella ending up in the receiving
basin has been drastically reduced, and
the general availability of the machine
could be increased.
IM18 Inox the Bellissima solution for
Bavarella Mozzarella.
The IM18 inductive proximity sensor in stainless steel housing withstands frequent
cleaning with acids, alkalis and steam
Food industry
insightLINK
INFO 117
www.milchwerk-jaeger.com
: Applications
The number one, with 1,100 installations worldwide
Flight baggage identification:
almost everyone flies with SICK
In 2005, South Koreas Seoul-Incheon Airport became the 1,000
th
to in-
stall the ALIS flight baggage identification system for conveyor systems.
More than 1,100 systems have been installed worldwide since 1993 if one
includes the 160 self-check-in counters equipped with ALIS gates.
>> Whether on a business trip to Amer-
ica, on holiday to the shores of Europe
or more distant destinations, or attend-
ing the World Cup in Germany almost
every passenger whose luggage arrives
at the same time and in the same place
has ALIS gates to thank.
The worlds number one
ALIS (Airport Luggage Identification
System) is the worlds leading identifi-
cation solution for flight baggage. ALIS
identifies thousands of cases, bags, and
holdalls an hour, and control their guid-
ance to the correct departure gates or
the right baggage collection carousels at
almost all major European airports, e.g.
Madrid, Frankfurt and London Heathrow;
the most important Asian hubs, such as
Hong Kong, Seoul or Singapore; and the
largest American airports, including Den-
ver, Chicago, Los Angeles or New Yorks
John F. Kennedy. Self-check-in counters
(e.g. at Munichs Franz Josef Strauss
Airport) also use ALIS gates, with whose
help passengers can hand in their lug-
gage without having to face long waits.
Guarantee of success: flexible sy-
stem concept, high read reliability,
simple maintenance
The success of ALIS is based on a number
of factors. Firstly, with its flexibly config-
urable and alignable CLV scanners the
gate system offers maximum adaptation
to the particular system environment. The
scanners themselves are devices proven
in industrial use which, thanks to real-
time autofocus and the SMART decoder
algorithm, among other things, achieve
unparalleled first-read rates. The robust
scanners also guarantee high plant avail-
ability because, if the worst comes to the
worst, they are easily replaced manually
thanks to quick clip mounting, and pa-
rameter data can be rapidly downloaded
from storage in the device plug memory.
THE technology standard for
identifying flight baggage
With the expertise of more than 1,100
installations ALIS sets the technology
standard. Thus the constant further de-
velopment of the CLV scanners increas-
es overall system performance. Both the
reading performance of a complete ALIS,
and that of the individual scanners in a
gate, can be monitored and optimised
with the RDT400 Remote Diagnostic
Tool, a graphic visualisation system. Pat-
ented adaptive code assignment (ACA)
for the optimised allocation of codes to
objects is an important supplementary
feature in this application.
Thus, in the recent past, SICK has
repeatedly proven that reading rates of
over 99% are easily achieved given ap-
propriate bar-code quality. Integration
of VMS Volume Measurement Systems
allows the classification of luggage sizes
an important quantity for controlling
baggage transfer from the conveyor belt
to the sorting shells and for the automat-
ic adjustment of X-ray systems.
Thanks to its robustness, simplic-
ity and consistent applicability, ALIS will
continue to define the state-of-the-art for
years to come. Thus bar-code technology
will also come to the fore in the current
invitations to tender for major future
projects.
At home all over the world: the ALIS
flight baggage identification system
(picture above)
24 1/2006
insightLINK
information on the Internet at:
: Applications
25
Separating circuit board panels
When background suppression
makes all the difference
Many opto-sensors hate reflective backgrounds. But not the photoelectric
proximity switches of SICKs 3 series. Thus the WT4-3 masters the elec-
tronic background suppression of even dazzle and specular reflections,
e.g. in ASYS panel separators (depanelers).
>> In electronics production, ASYS is one
of the leading producers of loading and
unloading systems, turn and flip trans-
port systems, buffer and portal systems,
and depanelers. The latter are used for
cutting out many small printed circuit
boards (PCBs) from a large circuit board
a multiple panel. Accurate position de-
tection is essential during insertion and
in the machine itself in order to be able
to carry out this process step accurately.
At the same time, a variety of machine
components, e.g. the spindles of drives,
generate a large number of interfering
pulses that cannot be permitted to elicit
any response from the sensor.
WT4-3: dazzle-free space-saver
The WT4-3s flat miniature housing,
guaranteeing excellent integration how-
ever limited the space in the machine
environment, is a basic prerequisite for
use in depanelers. Then there is the
method of function of the new sensor
chip within the scanner: a second trans-
mitter LED, together with a logarithmic
reception line, provides a kind of spatial
vision. This achieves a hitherto unpar-
alleled detection reliability for objects
with the most varied of characteristics
within a restricted machine environment
even with fluctuating brightness or col-
our contrasts. The WT4-3 concept also
allows electronic background suppres-
sion. Effects on sensor function caused
by vibrations, active and passive sources
of interference (e.g. reflections), or elec-
tromagnetic fields have thus been mini-
mised. A series of trials with other de-
vices available on the market shows that
the WT4-3 really is considerably superior
to other miniature sensors regarding im-
munity to ambient light. Suppression of
a highly reflective background achieved
the best values under all test conditions.
Similarly clear results were provided by
tests on the suppression of active and
passive sources of interference, e.g.
with chromium tubes, galvanised metal
plates or HF lamps (frequently found in
electronic production).
A useful solution
The WT4-3 accurately detects a multiple
panel when it enters the depaneler. A
robot fixes the circuit board before the
individual PCBs are cut out by milling
at the defined locations. If no multiple
panel is present, the sensors adjusted
scanning plane ensures its background
suppression so that neither reflections
from the background, nor the incidence
of ambient light from above (from neon
lamps), can lead to spurious switching.
SICK inductives also in use
In addition to the WT4-3 photoelectric
proximity switch, ASYS relies on IQ10
inductive proximity switches. The sensor
offers ASYS the decisive advantage of
increased switching distances of 3 mm
for flush and 6 mm for non-flush instal-
lation. Thus the same sensor can cover
the most varied of applications and
not just provide the limit stop warning on
the milling machines X/Y table in the de-
paneler. These include detecting the po-
sition of transport bearers, cassette de-
tection in buffer systems, the detection
of shielding plates during the movement
of shuttle belts in automatic loading sta-
tions, reference switching for lifting axles
in PCB cassettes, or detecting the posi-
tion of the uptake equipment in turn and
flip systems.
Whether opto-electronic or inductive
sensors the highly automated produc-
tion plants in the electronics industry of-
fer multiple advantages and not only
for multiple panels.
Electronics
insightLINK
INFO 118 and on page 46
www.asys-llc.com
1/2006
Electronic entry ticket for pallets
Safe vertical monitoring with detection of persons
What intelligent sensors are capable of is ably demonstrated by the use
of the UE440 safety controller with the S3000 safety laser scanner for
protecting an automated double-feed system for workpieces. This solution
not only detects four different feed states, but also efficiently differenti-
ates between workers and workpiece carriers.
>> This solution was designed for a met-
al-processing company in Germany. The
task consisted of protecting a two-lane
feed station for a metal processing plant
with workpiece carriers stacked eight-
high on pallets. The solution not only
had to comply with safety category 3, but
also had to permit material transport to
the machine while carrying out a contour
inspection in order to reliably detect per-
sons. A top priority here was to make the
system extremely tamperproof.
The solution: safety controller with
laser scanner in vertical operation
This complex task was solved with the
UE440 safety controller and the S3000
safety laser scanner. With the Profes-
sional version selected, the scanner has
eight differently programmable protective
and warning fields. Triggered by inductive
IQ40 proximity switches on the conveyor
system, these are switched according to
the conveyor situation. The S3000 is ap-
proved for vertical protection as a result
of its contour as reference function.
This allows the scanner to detect, for
example, tampering or misalignment, as
well as the shape and size of the trans-
ported objects. No pallet, pallet left, pal-
let right, pallets on both lanes the pro-
tective field of the S3000 detects all the
machines possible feed situations.
Contour as an electronic
entry ticket
It simultaneously checks whether the
stack of workpiece carriers per pallet is
exactly eight units high as it should be.
If a pallet conforms to the geometric defi-
nition it is permitted to pass through the
light curtain generated by the scanner.
Pallet transport is, however, immediately
stopped if the S3000 detects the contour
of the wrong number of workpiece carri-
ers or even a person. The UE440 safety
controller monitors the correct function-
ing of the proximity initiators for activat-
ing protective field switching, and their
necessary concurrence, as well as ensur-
ing that the system is tamperproof.
INFO 119
Automated iron powder packaging
Dusty but not too dusty for SICK sensors
The Danish machine producer C&H System recently received a follow-up
order after 30 years from the Swedish company Hgans for a com-
plete iron powder packaging plant. SICK sensors ensure that this new
plant also provides the accustomed quality and reliability.
>> WT4-2 photoelectric proximity switch-
es for foil detection, IM18 inductive cyl-
inder sensors for detecting the positions
of a variety of machine components, and
the WT18-3 for detecting the product
packages are used, among other devices.
Measuring the filling height of the iron
powder in the plastic bags was a particu-
lar challenge: the precisely adjustable
background suppression of the WTV18-2
photoelectric proximity switch allowed a
high-level solution to be found.
Mobile 20-tonners
The 20-tonne rail mounted packaging
machine (involving the same constructor
as the 1976 plant, by the way) is a real
multi-talent. First, plastic bags are pro-
duced from foil material simultaneously
on four webs. The bags are then opened
and unfolded at the powder filling pipes.
The weighed iron powder (20 kg or
25 kg) is put into the bag and the content
shaken down. Here, the WTV18-2 now
detects the actual filling height unaf-
fected by the dust or reflections so that
the bag can be folded with the minimum
of air within and sealed at the top.
The operating environment of use
and the processes involved make it
clear just how important both robust
and reliable sensors are for this ma-
chine. SICKs blue sensors will do eve-
rything possible to be a reliable com-
panion to the machine for as long as
possible perhaps even until the next
follow-up order in 2036!
www.chsystem.dk INFO 120
The small WT4-2 photoelectric proximity
switch detecting foils
26
: Applications
: Applications
27
of its contour as reference function.
This allows the scanner to detect, for
example, tampering or misalignment, as
well as the shape and size of the trans-
ported objects. No pallet, pallet left, pal-
let right, pallets on both lanes the pro-
tective field of the S3000 detects all the
machines possible feed situations.
Contour as an electronic
entry ticket
It simultaneously checks whether the
stack of workpiece carriers per pallet is
exactly eight units high as it should be.
If a pallet conforms to the geometric defi-
nition it is permitted to pass through the
light curtain generated by the scanner.
Pallet transport is, however, immediately
stopped if the S3000 detects the contour
of the wrong number of workpiece carri-
ers or even a person. The UE440 safety
controller monitors the correct function-
ing of the proximity initiators for activat-
ing protective field switching, and their
necessary concurrence, as well as ensur-
ing that the system is tamperproof.
INFO 119
Warehouse modernisation and expansion at accessories specialist Hama
Sensors dazzle in a storm of flashlights
Backlighting, undesirable reflections, highly reflective surfaces what
ambitious photographers or video makers often find difficult have also fre-
quently proved to be a source of trouble for sensors in handling systems.
These times are over at least in Hamas modernised and expanded logis-
tics centre, where the W27-3 series of photoelectric switches is used.
>> Install, connect, adjust and forget
this applies for the new W27-3 as for no
other series of photoelectric switches.
The new technology the third genera-
tion from SICK and particularly the new
type of electronic setting of scanning dis-
tance, gives the sensor a hitherto unpar-
alleled level of robustness, user-friendli-
ness and detection reliability, despite all
possible influences, e.g. in a fully auto-
matic high-bay warehouse.
Modernisation with tomorrows
sensor technology
With more than 16,000 products, Hama
is one of the leading accessory special-
ists in photography, audio, video, com-
puters and telecommunications. The
highly modern logistics centre built in
1997 supplies subsidiaries and custom-
ers in Germany, Europe and overseas.
A consistent increase in logistical de-
mands led to the modernisation and ex-
pansion of the warehouse in 2005. The
pallet store has been enlarged by 50 %
and an automatic package warehouse
built. As Hama has had very positive ex-
perience with SICK sensors including,
among others, photoelectric switches,
bar-code readers and distance meas-
urement devices, the plant suppliers
Aberle Steuerungstechnik GmbH and
TGW Transportgerte GmbH wanted to
stick with the brand for the plant expan-
sion too. In the area of photoelectric
switches, the checking of storage bay oc-
cupancy came under particular scrutiny.
This apparently straightforward applica-
tion turned out to be a real challenge for
the sensor technology in some locations.
Light beams from sensors or other light
sources, scattered by reflective metal
parts, led to awkward reflections that
are well suppressed by the photoelectric
proximity switches of the WT27-3 series.
W27-3: the professional sensor
against passive interference
The sensors are extremely well screened
against optical interference and electro-
magnetic fields. When detecting reflec-
tive objects and foil surfaces, or coping
with undesirable optical reflections from
the plant environment, the WTB27-3
photoelectric reflex switch is just getting
into its stride where other sensors give
up in the face of such passive forms of
interference. The WTB27-3 is also im-
mune to mechanical vibrations, so that
the scanning distance setting remains
constant even under harsh operating
conditions.
During the checking of storage bay
occupancy in the pallet stores, the sen-
sors installed on the high-bay stackers
are aimed at the pallets middle foot.
The scanning distance is set to between
300 mm and 500 mm. The electronic
setting of background suppression is
so precise that even light pulses from
the background of the storage bay have
no effect on detection reliability. In the
package stores, Hama profits from an-
other strength of the WTB27-3: pack-
ages with differing surfaces are equally
reliably detected.
The detection reliability of the sen-
sors has had enormous effects on the
operation of the logistics centre. The new
W27-3 series of photoelectric switches
has played a major role in this, as it has
become far more independent of electri-
cal, mechanical, thermal and optical in-
terference.
The WTB27-3 photoelectric proximity switch checks storage bay occupancy
Logistics
insightLINK
INFO 121
www.hama.de
www.a-s.de and www.tgw.at
: Applications
28 1/2006
When the devil is in the detail
Detailed strategy for
suspension assembly
Detail is called for at Frances TRW automotive sub-contractor in Ramon-
champ: OD Max series displacement sensors classify swivel joints on the
basis of features with only minute differences.
>> Displacement sensors with CMOS
technology, such as the OD Max, meas-
ure in the -range and monitor the pres-
ence and position of objects; measure
profiles, diameters and thicknesses;
regulate processes; and take on other
quality inspection functions.
OD Max the displacement sensor
offering special advantages
The OD Max displacement sensor, with
its excellent price/performance relation-
ship, is characterised by a number of
special features. Its design, with sepa-
rate sensor and evaluation units, offers
a high level of functionality with simple
and intuitive operation. The possibility
of connecting two sensors, and particu-
larly their internal balancing, makes it
easy to solve customer-specific applica-
tions, such as thickness measurement.
With its CMOS technology and enormous
accuracy (ten times better than that of
previous models), the OD Max offers -
precision and extremely reliable meas-
urement, even with highly reflective or
similarly critical surfaces. Which is why
the sensor is primarily used to solve the
most varied of tasks in sectors, such as
the automobile or electronics industries,
in which maximum quality demands are
an everyday challenge. In addition to
quality assurance, typical areas of use
include process control or, as at TRW Ra-
monchamp, object classification.
Inspecting details on
swivel joints
With almost 170 sites worldwide, TRW
is a global player in the automobile
sub-contractor segment and is a world
market leader in many areas, e.g. disk
brake, steering and restraint systems.
Among other things, the approximately
550 employees at the Ramonchamp
works in France produce suspension
systems. Swivel joints must be installed
on the suspension bracket but, depend-
ing on the suspension type, two different
swivel joints can be mounted. In order
to guarantee smooth function of the
cars suspension it is essential to en-
sure that the correct turning knuckle is
always installed. The OD Max fitted into
the restricted machine environment and
thanks to CMOS technology could re-
liably detect and precisely measure the
minute differences in features, despite
the highly reflective metal surfaces of
the swivel joints. The extremely small dif-
ference of just 0.2 mm was no problem
for this sensor because, with a measure-
ment range of 65 to 105 mm, a resolu-
tion of 5 m and an accuracy of 40 m,
it still had more than enough reserve.
Thus the OD Max offers maximum reli-
ability and represents a safe investment
for the future, capable of meeting ever-
increasing demands.
The solution achieved at TRW is just
one of the many examples of the use of
sensors, like the OD Max, that can meas-
ure with -accuracy. In addition to the au-
tomobile and electronics industries, new
areas of use are being found on a daily
basis in the most varied of segments
wherever the devil is in the detail.
Guarantees the correct swivel joints: the OD Max displacement sensor
Reliable measurement in the -range
even with metal surfaces
Automotive
insightLINK
INFO 122
www.trw.com
Highlights from SICK:
n The S300 laser scanner: high-end
safety in a compact format
n Vision solutions for all industrial
segments
n A wide range of safety controller
variants
n Automation solutions, e.g. a light
curtain uniting sensor, job LED and
reflector in a single device.
A magnetic cylinder sensor with two
adjustable switching points, and
many others
n Identification and laser measure-
ment systems, e.g. RFID solutions,
outdoor laser scanners, a high-end
CCD camera system for 1-D and
2-D codes
n Service and e-business offers
n Solutions for process automation
SICK at FACTORY AUTOMATION and INTERKAMA
+
2006
Welcome to the Hanover
Industrial Trade Fair 2006
Visit us at
Stand F 54
in Hall 9
We look forward
to seeing you!
SICK is participating again in Hano-
ver this year with a wide range of
new developments to familiarise
visitors from all over the world with
the latest automation solutions.
The focus is again, of course, on
examples of solutions for the manu-
facturing, packaging and logistics
sectors.
We offer a decidedly wide-ranging pro-
gramme a visit to SICK at the HMI will
be particularly rewarding this year.
SICKs stand, logically designed, offers
you precisely the information you need.
And in order to ensure that the entertain-
ment factor is not neglected, the trade
fair world will again meet at SICK on
25.04. from 6.00 p.m. Fine catering, ac-
companied by superb music, offers the
perfect framework for social interaction.
More on the HMI at www.sick.de/hmi
: HMI Special
29
NEWS
Information
Sensor Solutions
for Logistics
Service
Partner Portal
Sensor Solutions for
Packaging & Small
Part Assembly
Sensor Solutions
for Manufacturing
Sensors for
Factory Automation
Waldkirch leads the way with locally
manufactured ultrasonic gas meters
In the past, the natural gas industry has always been somewhat conserva-
tive but that looks set to change. An increasing number of gas distribu-
tors are implementing the FLOWSIC600 from SICK MAIHAK to conduct
ultrasonic gas flow measurements that meet billing requirements. The
biggest German natural gas suppliers, such as E.ON-Ruhrgas, Wingas, and
VNG, are not the only ones to lead the way. Small local council services,
situated in Waldkirch, Southern Baden, where SICK has its headquarters,
have implemented two state-of-the-art FLOWSIC600 ultrasonic gas me-
ters in their recently acquired network of 2,300 households as well.
>> Public services manager Dieter Nagel
had just completed a tough round of
purchase price negotiations with the
predecessor Badenova. His aim was to
continue offering gas at prices approxi-
mately 20 % less than the German av-
erage and it was not just a sense of
community pride that clinched his deci-
sion to implement local products in the
two DN 150 main lines at the new joint
transfer station in Buchholz and Kollnau:
The most important thing for us was to
reach an agreement with Badenova re-
garding the practicality of the counters
and to ensure that the price was worth
the performance. Although we were
open-minded towards new technology,
we were not really passionate.
There were initial doubts, however,
regarding the legal calibration inter-
vals. Since FLOWSIC600 has only been
on the market for three years, the bu-
reau of standards still specifies short
recalibration intervals of 5 years. The
FLOWSIC600 really does not need to be
recalibrated because it conducts non-
contact measurements within the pipe-
line, which prevents wear and tear, ex-
plains product manager Jrgen Ruschke.
Time is on our side.
The numerous benefits of the meas-
uring principle, which was originally only
used for conducting volume flow meas-
urements of exhaust gases (it was not
until 1996 that SICK MAIHAK experts en-
hanced it for measuring natural gas), were
also deciding factors. The FLOWSIC600
can carry out highly accurate gas volume
measurements. Arranged in four paral-
lel measuring paths, the sensors send
ultrasonic signals to the sensor oppo-
site. The time-of-flight required by these
signals is used as a basis for measuring
the volumetric flow to an accuracy of
1.5 nanoseconds and it is this level
of accuracy that gas suppliers need
because when you are handling
millions of cubic meters, even inac-
curacies of just a 0.1 % can result in
significant losses.
With its miniature high-frequency
converter and innovative titan wave
guide structure, the FLOWSIC600 is
compact and robust. It looks like a
flanged short core, hardly bigger than
the pipeline itself and without plugs
or excess cables. That was certain-
ly impressive, says project leader
Jrgen Mendorf from Badenova, consid-
ering the competitors models.
Another benefit is that the running
maintenance costs are comparatively
much lower. Not only does the device
carry out self-monitoring, but it can also
be queried anywhere, anytime. Every
detail and every status of FLOWSIC600
can be accurately represented with
mathematical methods, said the prod-
uct manager, keen to stress this point.
If one of the four measuring paths fails,
it can simply be replaced locally under
pressurized conditions without having to
abort the measurements, cut off the gas
flow, or remove the whole device.
In addition, the FLOWSIC600 can op-
erate on just one watt of power supplied
by solar cells, which is ideal for large
desert pipelines, although this left the
natives of southern Baden, who are oth-
erwise famous for their love of solar en-
ergy, somewhat cold: We would much
rather rely on our own safe power supply
system, laughs Dieter Nagel.
: S P E C I A L
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FLOWSIC600 can be used everywhere in the natural gas industry:
production, transport, transfer stations, stores and at large end-users.
Here: a transfer station in Kollnau
30 1/2006
Explosion protection for a safe
and economical production process
So that the spark doesnt arc
Flammable gases, vapors, liquids or even solids such as dust or chips etc.
all of them can generate a potentially explosive atmosphere in combi-
nation with oxygen during processes and in the worst case can lead to
explosions. These flammable substances cant be eliminated all the time.
Thats why everyone involved in the production process must take more
personal responsibility. Safety at work and operator protection are gov-
erned by legally binding device construction regulations. SICK MAIHAKs
expertise, integrated into its entire range of explosion-protected
measuring and analyzing systems, contributes torwards greater safety
and efficiency.
>> ATEX-certified equipment is used,
for example, in the chemical and petro-
chemical and paint and varnish indus-
tries. Also in landfill sites and coal mills,
in bunkers and grain silos. At Hanovers
HMI trade fair in April, and at ACHEMA
in Frankfurt in May, SICK MAIHAK is
showing some of its explosion-proof
equipment for gas, liquids and dust.
All instrumentation used in explosive
areas in Europe is subject to the ATEX
directive 94/9/EC effective July 1st,
2003.
p Gas analysis: For this purpose, SICK
MAIHAK offers a wide range of appro-
priately certified analyzers and instru-
mentation for example the NDIR gas
analyzer SIDOR, used for monitoring
landfill gas. S720 is an explosion-proof
analyzer for process gases, which can
be equipped with up to three measuring
modules with different measuring princi-
ples. The housing permits industrial use
in Ex zone 1. Especially for coil coating
and wood impregnation, the EuroFID
continuously measuring analyzer is used
to measure total carbon in the air, in cor-
rosive and condensed gases. This instru-
ment is certified according to ATEX and
is also used to monitor the lower explo-
sion limit LEL.
p Liquid analysis: If required the liquid
analyzer MCS100 Ex is also available for
Ex zone 2. Used in chemical processes, it
: S P E C I A L
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is mainly emloyed for humidity determi-
nation of organic media, e.g. 1,2-dichlo-
rethane.
p Volume flow measurement: Gas
volume flow measurement by FLOW-
SIC100 Ex now also for Ex zone 1 and 2.
p Dust measurement: In pipelines and
in production halls, the laser transmissi-
ometer FW300 applied for emission and
filter monitoring can be designed in Ex
version to monitor to monitor dust con-
centration in gases (zone 1 and 2) or to
monitor dust (zone 22).
p Level measurement: The stringent re-
quirements of bulk level measurement
in Ex zone 20 are fulfilled by the rotating
level indicator MaihakMBA200.
Large concerns or SMEs processes run day and night.
Dont leave anything to chance. And certainly not explosion protection!
31
>> Trade Fair Information
For further information call:
+49 7641 469-0

Hall 9, Stand F 54
Hall 10.2, Stand B 32-E 35
Open interface standard for fieldbus-neutral sensor dialogue
From the control level to the sensor
and back via IO-Link
HMI 2005: SICK presented the first fieldbus-enabled standard sensor
the WT18-3 photoelectric proximity switch. Interpack 2005: packaging
system producer Meurer introduced the first machine with the new
sensor generation. One year later: the technology trend has become es-
tablished the IO-Link open standard initiated by SICK, and supported
by numerous sensor producers, is accepted by the German Electrotechni-
cal Commission (GEC) as a standardisation proposal for the International
Electrotechnical Commission (IEC).
>> The most important advantages of-
fered by IO-Link are increased plant avail-
ability, comprehensive remote diagnosis
capability, automatic plant documenta-
tion, and of importance for the chemi-
cal and pharmaceutical industries the
possibility of validating entire machines.
Which is why the fieldbus-enabled IO-
Link sensor has very quickly received the
attention that experts predicted.
Basis: the special sensor concept
The technological background is the eco-
nomical upgrading of an output signal
switching device to a communication in-
terface, initiated by SICK. The scanners
of the 3rd generation series, with their
ASIC-based sensor concept, and the
WL12G glass photoelectric switch, pro-
vide the best prerequisites for IO-Link.
Physically, IO-Link sensors can be cou-
pled to fieldbuses via a connection mod-
ule allowing detection, communication,
and state information to be called up
both from the machine operating panel
as well as from a distant control room.
Sensors perceive more than just
objects
IO-Link is not a classical bus system, but
a fieldbus-neutral point-to-point connec-
tion for dialogue between sensor and
controller. The new concept, however,
not only permits the transfer of digital
switching states and digitalised analogue
values. Considerable supplementary in-
formation, e.g. pre-contamination warn-
ings, the presence of sources of inter-
ference in the sensor surroundings, the
quality of the switching signal, the cur-
rent scanning distance, or the sensors
serial number can also be transmitted.
Dialogue capability between the sensor
and the automation system also opens
up completely new perspectives during
the design, construction, installation, op-
eration and maintenance of machines.
These potential advantages have also
been recognised by other sensor produ-
cers, automation suppliers and machine
manufacturers. Which is why they sup-
port the standardisation proposal for
IO-Link at the IEC (via the GEC).
Open, easily implemented and a
safe investment for the future
Machine constructors, as well as their
users, can easily and rapidly profit from
the advantages offered by IO-Link. In ad-
dition to the use of dialogue-enabled
photoelectric proximity switches, e.g.
WT4-3, WT18-3, WT27-3 or WL12G from
SICK (or corresponding sensors from oth-
er producers), only an IO-Link connection
module is required for a fieldbus connec-
tion. This now permits connection of up
to four sensors via unscreened, three-
pin standard cables. The concept is thus
compatible with the switching and con-
nection technology common up to now. It
is also possible to connect sensors that
are not communication-enabled, though
these cannot use the dialogue advan-
tages offered by IO-Link.
Consistent communication down to sensor/actuator level
Control room
Control level
Sensor/actuator
level
2/3/4 Wire 2/3/4 Wire
Information
Engineering tool
Controller
IO-Link module IO module
: Know-how
32 1/2006
Sensor communication
: Know-how
33
Image processing in safety technology
Value-added control
The V4000 Press Brake safety camera system is the first image process-
ing system to achieve Category 4 electro-sensitive protective equipment
status. Operation shows that, in addition to safety, the system can offer
abundant added value for machine and process control.
>> Image processing is no new technol-
ogy, but the possibility of using it to pro-
tect machines is indeed relatively new.
The V4000 Press Brake, first shown at
Euroblech 2004, is the first electro-sen-
sitive protective equipment based on
an image processing system. While the
otherwise common, rather simple, safety
solutions on presses detect dangers by
means of the interruption of light beams
in front of the hazardous point-of-opera-
tion below the upper tool, the safe vi-
sion system evaluates the image of the
hazardous point-of-operation itself. This
picture speaks volumes and not just
from a safety standpoint but also from
the technical control point-of-view.
Picture information for flexible
machine operation
The data supplied by the safe image
processing system primarily serves to
protect the machine operator but also
permits improvement of work processes,
the prevention of errors, and the simpli-
fication of maintenance. Thus with the
V4000 Press Brake it is possible, for
example, to activate different protective
modes via the machine controller de-
pending on the particular bending tasks:
Standard for simple one-dimensional
bending, Box for bending multi-dimen-
sional objects such as boxes, and Limit
stop to take into account workpieces
close to the limit stop.
Error prevention before
machine start
Safe image processing thus has a deci-
sive influence on the machines perform-
ance potential and flexibility, as well as
being able to detect operator errors.
An incorrect tool or wrong workpiece
is detected because it generates a dif-
ferent picture of the protected volume,
i.e. the monitored area, than the cam-
era system expects for the current pro-
cess. The machine simply does not run
in this state or stops above the wrong
workpiece in good time actively pre-
venting expensive damage to tools or
workpieces.
Intelligent maintenance
Active is also the term for the advan-
tages the safe image processing solu-
tion offers regarding maintenance. The
protective system continuously assesses
dirt, process parameters and environ-
mental effects on the side and adapts
to them so it can be integrated in the
planning of preventive maintenance.
Surprise machine failures, with all their
side-effects (wasted time, procurement
of spare parts, lost production) can thus
be considerably reduced. And if a fault
should occur, the operator and the main-
tenance staff have a variety of indicators
available permitting unambiguous loca-
tion of the problem. Thus the worker can
directly see from the device whether, and
in which location, there is a fault. Main-
tenance staff can log-in via the machine
controller or directly in the V4000, carry
out an unambiguous diagnosis, and rap-
idly correct the fault itself directly.
Thus added value for machine and pro-
cess control is no vision, but a reality.
INFO 123
Processing images to protect machines
Speed is unimpaired
The numerous advantages offered by
IO-Link are not achieved at the cost of
process speed. The rapidity of the com-
munication dialogue is sufficient to ex-
change process data within two millisec-
onds. The concept can be expanded with
a real-time output for very rapid switch-
ing processes.
Standardisation almost achieved,
users in the starting blocks
The standardisation of IO-Link, initiated
by SICK and supported by other com-
panies, will shortly be completed. Most
of the specification has already been
defined and agreed. Correspondingly,
numerous users and machine produ-
cers are merely waiting for the products
to become available. Three sectors will
be the first out of the starting blocks. In
the pharmaceutical industry IO-Link sup-
ports, among other things, rapid changes
in ingredients and the validation of en-
tire machines and plants. The packaging
industry profits through the automation
of format-changing processes, as well as
the dialogue-controlled adjustability of
critical applications in which high accu-
racy and reliable reproducibility are vital.
In handling and warehousing systems,
IO-Link makes it possible to see with the
eyes of the sensor from distant loca-
tions. As a result sensor optimisations,
e.g. to suppress passive background
interference, can be carried out decen-
trally without impairing the performance
of a high-bay warehouse, for example.
Summary: IO-Link will have positive
effects on the design and control tech-
nology of machines and plants in future.
Largely passive function elements will
become active participants that are in
dialogue with the control level and, in
addition to switching signals, can au-
tonomously report errors and supply
state information. IO-Link is thus the
sensor communication of the future. In
the simplest of ways, it also integrates
the technologies that have hitherto been
common, and is thus an investment with
a very safe future.
Protective equipment
The new Partner Portal:
SICK innovations accessible 24/7!
SICK offers all interested customers a really attractive service on its web-
site: the new Partner Portal. This new facility is a very comfortable tool
that not only simplifies the finding and assignment of products and appli-
cations but also, for the first time, permits online orders. Which means: a
24-hour connection to innovations from SICK!
The Product Finder:
search & find in seconds
The point of the portal is to provide cus-
tomers with direct and rapid access to
SICKs innovations. A Product Finder and
Application Finder are integrated here
to guarantee this. The Product Finder of-
fers the possibility of choosing the right
device for your application from a very
large number of products for all areas of
factory automation. Clicking on a selec-
tion table leads you to the right product
rapidly and unerringly. In addition to the
main product you can, of course, also or-
der accessories, spare parts or circuits
directly online.
The Application Finder: the reliab-
le route to the desired solution
Expertise with no risk: we want our cus-
tomers to have first-class advice. Which
is why, with the Application Finder, we
offer the opportunity of displaying the
various areas of sensor use. We have
therefore prepared reports, photos
and graphics for you in the Application
Finder, reflecting SICKs many years
experience and also supporting you dur-
ing selection of the optimum product.
Here, too, the Portals intelligent techni-
cal structure ensures a very rapid and
efficient search.
Well-informed in specialist
matters: with the Literature Finder
The Literature Finder offers a large
number of wide-ranging speciaist
publications because technical doc-
umentation is frequently indispen-
sable, and well-designed operating
instructions help you implement our
products in your processes. Reliably
and rapidly. The customer magazine
and other literature on all aspects the
SICK Groups products keep you well-
informed in a variety of language
versions, if desired.
: Internet
34 1/2006
The Partner Portal:
profit from registering now
If you would like to take a look at the
advantages of the Partner Portal in prac-
tice, first visit SICKs web site (www.sick.
de). On the start page you will find infor-
mation on the Partner Portal: from here
you can take an animated guided tour
that offers you a glimpse of exactly how
the Partner Portal works. A single reg-
istration is all that is necessary to gain
access to all the tools. You define the rel-
evant access rights for your company so
that orders can be approved by you or by
another person or department. And you
can access your purchase history and
the processing status of your order, re-
gardless of how it was placed. Of course,
in the Portal you also receive data on
how to get in touch with your contact
an automatic workflow, in other words,
from which you can profit every day.
By the way, you can reach the Partner
Portal directly at www.mysick.com after
registration.
Your Partner Portal: a lot of innovative
expertise with individual comfort at
a click!
: Products
For numbers and characters
OCR Vision Sensor
for checking your label
Whether the date, the time or the batch number the new CVS4 OCR
Vision Sensor, is ideally suited for every type of label checking.
>> The CVS4 is a user-friendly and com-
pact plug & play image processing sen-
sor. Camera, optics, illumination and
evaluation are accommodated in a sin-
gle housing. While this design is familiar
from the series colour sensors, there is
a completely different technology hidden
within this housing.
Simple correctness detection
to advanced reading!
At the heart of the CVS4 is a 2-D image
capture unit a CMOS chip (with 512 x
244 active pixels) and integrated high-
speed signal processors. The devices
correct or not correct decision is
made by comparing the detected char-
acters with the stored reference code.
The CVS4 not only checks correctness,
but actually reads out the characters
within the view. 60 characters on up to
six lines and in several formats, e.g. two
dates and times, are reliably identified.
A pre-defined reference library is used
for detection but additional symbols can
be taught-in via the serial interface. In
all, 16 different reference codes can be
stored in the sensor. A variety of optical
versions permits detection within differ-
ent operating distances. Moreover, the
CVS4 is always up-to-date: the sensor
can, for example, automatically increase
a serial batch number via a trigger input.
The same applies for its internal clock: it
ensures that at midnight the date chang-
es to that of the next day.
Simple installation and operation
The CVS4s single-housing concept
considerably simplifies installation, op-
eration and maintenance. Thanks to its
CMOS technology, the device is largely
immune to such interfering factors as
dazzle, reflections or an unfavourable
background. An easily understandable
user interface, menu guidance and clear
status indications on the device itself
allow operators to optimise a machine
by making their own settings in situ.
CVS4 the economical solution for a
wide variety of code detection tasks.
insightLINK
INFO 124
35
Image processing
: Products
36
The new S300 is by far the most flexible solution for monitoring small-
er hazardous areas with a maximum protective field radius of 2 m. The
safety laser scanner is currently the smallest device of its type worldwide.
Compact, reliable and equipped with a full overview of 270, numerous
applications can be solved particularly economically with the S300.
Can also be used vertically the small flexible S300 safety laser scanner
>> The S300 is suitable for a variety of
applications, depending on the variant
Standard, Advanced or Professional,
with one, two or four monitoring areas:
for replacing safety mats (that are sub-
ject to friction), for space-saving point-
of-operation protecting, for monitoring
insertion stations on machines, or as
personnel protection equipment for
mobile transport systems or service ro-
bots. With Type 3 approval in compliance
with IEC 61496-3 and SIL2 according
to IEC 61508, the device meets the
most up-to-date standards and can al-
so like its big brother, the S3000 be
operated vertically. Users can select
the desired scope of functions via the
variants on offer and thus obtain a
made-to-measure and economical
solution.
Costs cut but not corners
A new scanner technology was used dur-
ing development so that right from the
start the S300 could be designed to cut
space requirements, weight and power
consumption. This is advantageous for
use on small manoeuvrable transport
vehicles and for maintaining gaps on
telpher lines (suspension hanger con-
veyors). But no corners have been cut
in the S300. Its integrated functions en-
sure even greater economic efficiency
for plant. This applies for the plug & play
configuration memory in the connection
plug, as well as for the 7-segment dis-
play for rapid commissioning, diagnosis
and maintenance. The Enhanced Func-
:
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Compact, reasonably priced, unrivalled
The worlds smallest
safety laser scanner
The S300 offers safety competence
in a small format:
n Small: 102 x 152 x 105 mm (W x H x D)
n Light: 1.2 kg
n Strong: 8 m warning and
2 m protective field
n Superior: 270 scanning angle
>> Product info
1/2006
Safety systems
: Products
37
tion Interface (EFI) data connection al-
lows access to one of the many safety
bus modules available. The S300 can
be parameterised with CDS software,
uniform for all SICK safety systems,
which offers users a familiar look and
feel.
270 viewing angle provides
all-round protection
The S300s unusual 270 angle of view
is of particular interest for the ever-grow-
ing market segment of compact trans-
port vehicles and service robots. Thus
when the scanner is corner-mounted it
can not only simultaneously monitor the
sides, but also offer all-round protection
for a vehicle without any use of bump-
ers and control wires when mounted di-
agonally. The switchability of protective
and warning fields permits dynamic ad-
aptation to the particular velocities and
spatial conditions.
Precise distance measurement between 90 mm and 1,000 mm
Analogue distance sensor
with very easy installation
SICKs new DT20 supplements the product family of analogue distance sen-
sors with a device for medium ranges. The sensor, pre-parameterised in the
factory according to the requirements ordered by the customer, unites high
measurement accuracy, particular robustness and simple mounting.
>> In its compact metal housing, the
DT20 operates with an infrared transmis-
sion LED and has an output signal switch-
ing device in addition to its 420 mA
analogue output. The distance sensors
highly accurate measurement is impor-
tant in many applications: +/ 4 mm
within the measuring range of between
90 mm and 600 mm (largely independ-
ently of object reflectivity). Thus numer-
ous processes can be automated with
a high level of precision, e.g. packaging
applications, the measurement of filling
levels, or the regulation of thread. In ad-
dition, the special front screen increases
the DT20s immunity to ambient light.
Intelligent type key for
plug & play use
Users can order the DT20 directly as a
plug & play version. This has been made
possible by the intelligent type key inte-
grated in the device order number. This
allows the 420 mA analogue output to
be linked with an individually definable
measuring range. Thus the user obtains
a device that is immediately ready for
operation and that can be re-ordered as
an identical device years later, because
the parameterisation data is contained in
the type number on the device. However,
those who would prefer to parameterise
the device themselves, instead of using
the plug & play version, can also purchase
the DT20 as a teach-in version.
Trouble-free installation
The DT20 offers extremely easy installa-
tion thanks to its 5-pin M12 device plug
which can be rotated through 180 and,
if necessary, use of the special mounting
bracket. Transmitter/receiver markings
on the housing act as an optical adjust-
ment aid. Thus the DT20 can be optimally
aligned onto the particular target object.
All this makes the DT20 a precise and
practical solution for analogue position
detection at medium ranges.
insightLINK
INFO 126
insightLINK
INFO 125
Corner mounting offers all-round
protection
The S300 is the ideal solution wherever
great importance is placed on safety and
economic efficiency in small areas.
Distance measurement
: Products
38
Eco-version with top features
New price/performance dimension
for laser photoelectric switches
With the new W100 Laser, SICK
rounds out its range of efficient
miniature photoelectric switches
with reasonably priced and power-
ful laser sensors.
>> Small light spot, smaller price the
new W100 is both technically and
economically convincing in numerous
standard applications. The eco-laser
offers long ranges: the through-beam
photoelectric switch is suitable for dis-
tances of up to 30 m, the reflex system
reaches 8 m, and the energetic scan-
ner 400 mm. The attractive price of the
W100 Laser is as minimal as the light
spot at the particular distances. As the
sensors are also easy to install and
space-saving they offer a large number
of potential uses.
Mind you, so do the other miniature
sensors from SICK! INFO 127
Certified volume measurement
for courier, express and package centres
A calibration-enabled sensor solution
Packages, cuboid and rectangular objects these are all within the sights
of the VMS410 Volume Measurement System. And the VMS510 system
version, soon to be certified, even offers courier, express and package
service providers a calibration-enabled solution.
>> Volume is one of the relevant values for
invoicing transport service performance
in many distribution logistics segments.
While in practice the volume or size infor-
mation on the goods to be despatched,
and their invoicing, is frequently based on
imprecise estimates or past figures, Vol-
ume Measurement Systems now provide
unambiguous actual values that can be
documented. Instead of simply adding
something on, these measurements now
allow transport service providers to draw
up realistic (justifiable) follow-up invoices
based on the actual goods transported.
VMS410 for compact
cuboid objects
The VMS410 Volume Measurement Sys-
tem is designed for detecting individual
cuboid or rectangular objects. The sensor
head of the VMS410 is generally installed
centrally above the conveyor system. The
time-of-flight of the laser beam is evalu-
ated to within a few millimetres. The sys-
tem then calculates the dimensions of the
particular package.
VMS510:
calibration-enabled precision
While the VMS410 is already character-
ised by its great accuracy, the VMS510
complements this with its potential
calibration. This will be documented by
the system tests soon to be completed
by the Nederlands Meetinstituut in Dor-
drecht according to the definitions of
the International Organisation of Le-
gal Metrology. The VMS510 fulfils all
the test parameters of the OIML R129
standard. Thus, among other things, the
scale value and calibration error rate are
just 5 mm both based on a maximum
transport velocity of 1.2 m/s and 10
mm at a maximum transport speed of
2m/s. The smallest distance to be meas-
ured is 5 cm which means that even
objects with an edge length of just 5 cm
can be accurately measured.
At the same time, the OIML R129
testing process also takes into account
the test parameters of the Measuring
Instruments Directive (MID) that comes
into force in Europe in October 2006,
after which the generally valid European
Certificate can be issued. This allows
the VMS510, in combination with a le-
gal-for-trade weighing system and bar-
code scanners, to be integrated into a
complete calibration-enabled system for
testing and calibration by local inspec-
tion authorities. INFO 128
:
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Powerful: the new W100 Laser miniature sensor
1/2006
: Products
39
Contour Vision Sensor for inspecting shapes
Focused on corners and edges
The success story of SICKs vision sensors continues. With the new CVS3,
the concept of image-processing automation sensors now opens up the
broad field of contour detection.
>> A CMOS chip for detecting images
that can be very rapidly read out is at
the heart of every CVS3. This enables very
short cycle times of down to 7 ms. Long
operating distances, a large field of view,
the ability to store a variety of detection
programs, and the integrated monitor are
further highlights of the CVS3.
A perfect or complete shape?
Shape, size and orientation detection;
checking the presence of print; or detect-
ing damage or contamination of parts
are the uses for which the CVS3 has
been designed. The sensor compares the
captured object contour with a taught-in
correct pattern. A total of 15 different
reference patterns can be stored in the
device either through direct teach-in or
as a download from a PC. In this way the
sensor can help structure assembly or
packaging processes, for example, more
efficiently and in a manner less suscepti-
ble to problems. In addition to the stand-
ard CVS3, with an operating range of
between 90 mm and 150 mm, there is a
near-range version for 30 mm to 40 mm.
Always in top shape for checking shape
the CVS3. INFO 130
Differing combinations specified
Muting module for electro-sensitive
protective equipment
The new UE49 muting modules allow efficient muting functions to be set
up for person/material differentiation using electro-sensitive protective
equipment (ESPE) from SICK with actively monitored output signal switch-
ing device. A variety of combinations have been specified regarding the
number of ESPEs and muting sensors that can be connected.
>> The UE49 is designed for use with the
following systems: C2000, M2000 and
C4000 safety light curtains; the S3000
safety laser scanner; and the M4000
multiple light beam safety device.
A variety of versions
The UE49-2 (with two N/O contacts and
one N/C output contact) and UE49-3
(with three N/O output contacts) allow
protective mode on two-channel ESPEs
from SICK in compliance with EN 954,
with and without muting function. In the
case of protective mode with muting
function, the modules reliably differen-
tiate between goods transported into a
machines hazardous area and persons
on the basis of the sequence of signals
from two or four muting sensors. If a
transported good is detected, e.g. a pal-
let loaded with material, the monitoring
function is muted (i.e. temporarily put
out of action) for the period of transport
through the safety light beams of the
particular ESPE. The duration of the mut-
ing state which can be steplessly set
from 10 seconds to infinity is signalled
by a monitored muting lamp.
Configuration by rotary switch
The UE49 offers a variety of configura-
tion possibilities for the use of ESPEs
in combination with muting sensors.
Functions are set using a rotary switch
in a protected location behind the front
panel of the IP 20 device housing. In ad-
dition, several LEDs provide status and
diagnosis information.
:
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The CVS3
compares the
object contour
with the correct
taught-in pattern
As a result of its features, the UE49
offers the flexibility necessary to cover
differing machine or plant muting re-
quirements and protective conditions.
INFO 129
: Products
40
EN ISO 12100 published in EUs official journal without transition period
Up-to-date machine safety
with Safexpert 5.0 CE software
Producers, and those bringing
machines and plant into circula-
tion, who use the network-enabled
Safexpert 5.0 safety software with
Service Pack 2 are on the safe
path to CE-certification in compli-
ance with the Machine Directive,
even after the publication of the
EN ISO 12100-1 and -2 stand-
ards in the EUs official journal on
31.12.2005.
>> Publication in effect dictates that EN
ISO 12100 is to be used for the conform-
ity process. The predecessor standards
EN 292-1 and -2 may no longer be ap-
plied, but are still listed in the documen-
tation and in the conformity declarations
of purchased machines.
Programmable incremental encoder: greater flexibility, less downtime
Thousands of adjustments,
singular availability
Individual programmability is the strength of the new DRS61 incremental
encoder. With the help of the programming tool, consisting of a USB cable
and software with a PC or laptop, any line number between 1 and 8,192 can
be selected and the desired zero-impulse width of 90 or 180 defined.
>> This programming freedom means
that a total of 16,384 settings can be in-
dividually selected. Application-specific
device versions are thus a thing of the
past, as it is now no longer necessary
to purchase and prepare individual ma-
chine-oriented line number variants. And
the DRS61 also offers maximum flexibil-
ity of use. A basis version is sufficient to
solve the most varied of tasks by means
of individual programming. Stock-keep-
ing is simple and reasonably priced;
downtimes are minimised because the
DRS61 is quickly available and program-
mable for each application.
Encoder programming: childs play,
a matter of seconds and
re-usable
Programming takes place with the help
of a common PC or laptop. The DRS61
is connected via the USB programming
cable (no external power supply is nec-
essary). The encoder data, e.g. type
number and current parameterisation,
is automatically read out, taken up by
the encoder programming software and
displayed. The user can now update the
adjustable line number and zero-impulse
width parameters and transfer them to
the DRS61.
Its programmability makes the
DRS61 a universal solution for determin-
ing angles, positions, velocities or accel-
erations in automation technology.
INFO 131
1/2006
41
Important changes
The changes have decisive effects on,
in particular, the construction and risk
evaluations of machines. Terminological
definitions have been edited and sup-
plemented, and must also be taken into
account during the creation of operating
instructions. Existing Type B standards
have been more solidly embedded, and
the topic of inherent safe construction
expanded with important aspects.
Conversion and update
with Safexpert
With Service Pack 2, users of Safex-
pert are in a position to convert running
projects at the click of a mouse. This
means that the list of hazards in the risk
analysis corresponding to EN 1050 has
automatically set the cross-references
to the new EN ISO 12100. All 160 new
standard titles published in the EUs
official journal are available within the
framework of the updating service for
the titles database of standards and
directives. Filter functions rapidly clarify
which standards are relevant for the us-
er. Safexperts Standard Plus package of
standards has also been expanded with
the new A and B standards. The Stand-
ard Plus package also contains EN IEC
62061 in full text (it too was published in
the EUs official journal on 31.12.2005).
With Service Pack 2, Safexpert 5.0
ensures that new and existing cus-
tomers have an uncomplicated path
to the CE label in conformity with the
Machine Directive. Earlier Safexpert ver-
sions, on the other hand, no longer cor-
respond to the harmonised standards
those still using this software should
exploit the advantages offered by the
update.
Laser time-of-flight no compromises
Basis solution for distance
measurement with
immunity to ambient light
Technology without compromises is the philosophy behind the new DS40
distance sensor. The device, for scanning distances of between 200 mm and
5,000 mm, is particularly intended for applications in which high immunity
to ambient light, precise background suppression and a reasonable price
are required for distance detection and where is this not the case ...
>> Compact plastic housing, red-light
laser diode, light time-of-flight meas-
urement, teach-in and an output signal
switching device the core functions are
concentrated in the DS40. Complete and
without compromises. The DS40 brings
together the entire technological exper-
tise of SICK distance sensors. A high
level of application-oriented consultancy
competence on the part of internal and
external service teams, and decades of
experience in laser time-of-flight meas-
urement, make SICK the ideal partner
for users in the solving of distance ques-
tions. Long scanning ranges, simple op-
eration, maximum immunity to ambient
light and precise background suppres-
sion: these are the ingredients of the
DS40 distance sensor which offers
universal use. This not only applies for
basic applications, but also for demand-
ing tasks such as the reliable detection
of dark, critical or small objects.
The DS40 offers top technology, tightly
calculated, and a unique price/perform-
ance relationship.
insightLINK
INFO 132
www.sick.com/safexpert
No compromises the DS40 distance sensor for universal use
:
H
I
G
H
L
I
G
H
T
insightLINK
INFO 133
: Products Distance sensors
: Products
42
For containers and bulk materials
Laser measurement systems automate
loading and unloading of ships
Measurement of the stack heights of containers in ports, or the detection
of bulk materials in a silo the speed and precision of the LD-LRS laser
measurement system in both cases is highly impressive.
>> The systems measurement data are
used, among other things, to determine
positions, detect obstacles or control
conveyor and (un)loading systems.
Laser measurement scanning
The LD-LRS laser measurement system
scans a stack of containers or a cone of
bulk material without contact. Thanks to
powerful laser optics it achieves ranges
of up to 250 m with high object reflectiv-
ity. The range is still a hefty 80 m even
with low reflective values of about 10 %.
This is sufficient to detect, for example,
dark containers or bulk materials reli-
ably and accurately from a crane jib. In
addition to a first digital signal proces-
sor (DSP) to control the measurement
system, every LD-LRS has a second DSP
that carries out an application-specific
conversion of the measurement values
and can transmit them via Ethernet,
RS 232 or RS 422 interfaces.
Suitable for outdoor use
The device is available in an IP 67 hous-
ing for outdoor use. The near-range
blanking specially developed for this pur-
pose ensures that the front screen of the
protective housing does not impair the
function and accuracy of the measure-
ment system within it.
Determining stack heights in ports
One area of application is the automa-
tion of ship-to-shore (sts) cranes for load-
ing and unloading container ships. Stud-
ies show that the more rapid raising and
lowering movements of the trolleys on
jib cranes, and the optimised transport
paths of the containers, can bring about
time savings of up to 15 %. There is also
greater handling safety, as the measure-
ment system installed on the jib often
has a better view of the container than
the crane operator. The pivoting or travel-
ling LD-LRS determines the width, height
and length of a stack of containers.
The measurement system constructs a
3-D image from the profile data and then
the target position to be approached for
container uptake. At the same time, the
measurement values contribute towards
optimising the transport path of the trol-
ley.
Profile measurement of loose
bulk material
Bulk materials stored on open ground or
in silos can also be very accurately de-
tected with the LD-LRS. The bulk material
filling state is translated into a 3-D mod-
el, in effect making the piles or pools of
material visible to the loading systems
controller. Removal can then always be
carried out where the most material is
present. Varying material constituents,
particle sizes, levels of dampness, mate-
rial compactness or light conditions do
not lead to any spurious measurements.
Laser measurement technology is
in at ports numerous laser measure-
ment systems from SICK are employed
for a wide variety of port automation
tasks worldwide.
insightLINK
INFO 134
1/2006
Port automation
Rapid and precise the LD-LRS laser measurement system
: Products
43
Currently the fastest safety controller for presses
Maximum safety through
minimum reaction time
Just 10 milliseconds and often
even less is all that the UE470
safety controller from SICK needs to
switch off the hazardous movement
of an eccentric, hydraulic or pneu-
matic press. But the fastest safety
device of its type can do much
more.
The UE470 offers flexible protecting of eccentric, hydraulic or pneumatic
presses. In the case of frontal protection, the Category 4 safety light cur-
tain C4000, for example, can be connected either via output signal swit-
ching devices, or via the internal communication interface (with the possi-
bility of operating mode switching and automatic parameter downloads if
devices need replacement), or via both. As the safety controller has a test
pulse function it can, for example, provide economical protection of the
back of presses with Category 2 photoelectric switches, e.g. WS/WE27.
The test pulse allows several sensors connected in series to be monitored
in compliance with the demands of Category 4. A variety of switching-off
paths for frontal and back protection further increase operator safety
and machine availability. The signal processing of 3-stage pedal switches
or two-hand push buttons, the static monitoring of valves every time the
press starts, single- or double-break mode, operating
mode switching and a wide range of safety functions (such as emergency
stop, external device monitoring or restart) illustrate the wide range
of functions offered by the controller.
>> Versatile protection and monitoring options
insightLINK
INFO 135
>> The UE470 is a safety controller for
presses and revolving tables. It is Cat-
egory 4 in compliance with EN 954-1
and SIL3 according to EN 61508. Its
integrated connection options, the five
possible operating modes, and its test
and protection functions make it a ver-
satile and flexible solution for protecting
presses.
High-speed shutdown
Nevertheless, its speed is the absolute
highlight of the UE470: the reaction
time of maximum 10 ms. No compar-
able controller is quicker. It is thus pos-
sible to locate safety systems closer to
the machine. This can be of advantage,
for example, when space is limited at
the installation location, or machine op-
eration involves frequent operator inter-
ventions, e.g. for inserting and removing
workpieces.
Control functionality combined with ra-
pidity makes the UE470 the right safety
solution for presses.
The safety solution for presses: the UE470 safety controller
Press safety
: Products
Flexibility through modularity
Connect. Combine. Control.
UE410 FLEXI is the name of the new softwareless safety controller
from SICK. Connect, combine, control three features that offer many
advantages.
>> No software, no laptop a simple
screwdriver is all that is required to con-
figure the safety system.
Connect: professional safety
integration
The UE410 FLEXI is suitable for numer-
ous tactile and non-contact safety sen-
sors such as the IN4000, RE300 and
T4000C, door safety interlocks, emer-
gency stop devices, Type 2 two-hand
controls, testable photoelectric switches
and light curtains. The systems can be
connected, and the individual functions
that are necessary can be defined up
to muting or override. Communication
with the higher-ranking machine control-
ler is possible when the diagnostic mod-
ule is integrated in a PROFIBUS DP or
DeviceNet coupling.
Combine: logic without software
A main unit forms the basic element
of the UE410 FLEXI. Further expan-
sion units, input and output expansion
modules, relay output expansions and a
diagnosis module for fieldbus coupling
to PROFIBUS DP or DeviceNet can be
plugged in from the side, one after the
other. The individual modules commu-
nicate with one another via a rear panel
bus. The functions of each module can
be selected by rotary switch on the
front. AND/OR, bypass, or two and four
sensor muting can also be achieved via
terminal configuration, as can numer-
ous supplementary functions, e.g. auto-
matic start, restart interlock or release
delay.
Control: grows as the
system grows
The modular concept of the UE410 FLEXI
can be expanded according to need. It
also cuts device costs and space in the
control cabinet. A single module with
eight different functions replaces two
conventional safety relays. With maxi-
mum development, up to 50 two-channel
safety sensors can be monitored and
this with Category 4 safety in compliance
with EN 954-1 and SIL 3 according to EN
61508.
Plug-in and adjustable by screwdriver,
the UE410 FLEXI is a new type of safety
controller. See for yourself at
www.ue410flexi.com
Motor feedback encoder as resolute alternative to resolvers
Ace of trumps for new quality and economic efficiency
A 16-fold improvement in resolution, an electronic type label and the
HIPERFACE interface are the trumps with which the new SEK52 capac-
itive encoder is stirring up resolvers in the lower segment of industrial
path, position and r.p.m. detection applications.
>> In the long run, as the device is also
mechanically compatible with the re-
solvers, many of them will be forced to
withdraw from the motor and regulator
market.
Precise and open for
automation structures
With its capacitive functional principle,
the SEK52 offers a level of robust-
ness comparable to resolvers. The de-
cisively important advantages are its
considerably greater accuracy resulting
from a total of 16 sine/cosine periods,
its significantly improved dynamic
regulatory behaviour, and its integra-
bility in modern automation structures
thanks to its electronic type label and
HIPERFACE interface. Then there is
its attractive pricing position, which
together with the low installation
and commissioning costs, also proves
advantageous.
Use in standard and
economy applications
With these features, the SEK52 brings a
new quality to the basic market segment
of rotative position and path measure-
ment systems. The resolver solutions
that used to dominate came up against
their technological limits some time ago,
and for years have only survived at all for
reasons of cost.
Advantageous for basis applications:
the new SEK52 unites SICK STEGMANNs
years of experience in high-end applica-
tions with the development, production
and cost synergies that result from its
wide motor feedback range.
INFO 136
Software-free safety: the UE410 FLEXI
44 1/2006
: Products
Multiplicator module rapidly
restores machine safety
Quicker than a
Formula One
pit stop
>> Turbo-rapid replacement of a C4000
safety light curtain, complete copying of
a configuration on as many other M4000
multiple light beam safety devices as de-
sired no problem with the Clone Plug
external parameter store.
Wire draw encoder for up to 5 meter
measurement length
Compact class:
compact housing,
class performance
The new BKS absolute, and PKS incremental, wire draw encoders from
SICK STEGMANN are the right choice when reasonably priced and com-
pact position and path detection is required. Both devices are available
for measurement lengths of 2 m and 5 m and provide extremely precise
and reproducible measurement results.
>> This has been made possible by a
highly accurate measurement drum
within the small but very robust alumin-
ium housing, as well as the high resolu-
tion of 0.05 mm. The interfaces of the
Wire draw encoders are used wherever positions must be determined
or paths measured but the measurement path goes around a corner,
because of a jointed or hinge mechanism, for example. In these situations,
the integrated wire draw mechanism allows accurate position and path
data acquisition without requiring precise linear guidance: the integrated
encoder detects the rotations of the wire draw drum and converts them to
a measurement signal proportional to the length, providing high-resolution
position or path information.
>> Why path measurement via wire draw?
wire draw encoders SSI for the BKS
absolute system and TTL for the PKS in-
cremental system meet the demands
of industrial automation technology.
Compact, complete, robust
These compact wire draw encoders,
with edge lengths of 90 mm each,
were specially developed for applica-
tions where mounting space is limited,
a robust complete unit is needed, and
short to medium measurement lengths
require detection. With their robust
compact housings, stable plastic-coated
stainless steel wire, and measurement
length variants of 2 m and 5 m, BKS and
PKS wire draw encoders cover the typi-
cal requirements for presses, stamping
and spraying machines, wood and metal
processing machines, apparatus con-
struction or medical technology, etc.
If longer measurement distances
are to be determined, e.g. for lifting plat-
forms, construction machines, high-bay
stackers or theatre stages, big broth-
ers of the compact BTF and PRF wire
draw encoders also offer tailor-made,
precise path measurement and position
detection. INFO 137
Machine downtimes cost money. So its
good that when replacement is neces-
sary one can simply, and extremely rap-
idly, download a configuration that has
been stored in the Clone Plug onto the
new C4000 or M4000. The same ap-
plies for construction and commission-
ing. Thanks to Clone Plug, a parameter
that has been defined once can be cop-
ied as often as desired, without having to
connect a PC or laptop. Even application
names, blanking fields and operating
modes are reliably stored and can be
called up at any time.
Clone Plug the safe memory mod-
ule for greater productivity in construc-
tion, commissioning and production
processes. INFO 138
Save data reliably in the Clone Plug
external parameter memory plug
45
: Products
46
Automation with miniature photoelectric switches
New possibilities in the
smallest of spaces
Sugar cubes, matches, postage stamps those considering miniature
sensors want top automation solutions in the smallest of spaces. SICKs
W2 and W4-3 series offer high-tech space-saving sensations for numerous
applications.
>> Whether as a matchstick-thin slim
version or as flat as a postage stamp
the W2 is among the smallest, and
therefore for many users the most valu-
able, series of opto-sensors for industrial
uses. The W4-3 technological trendset-
ter in sugar cube design impresses
through its numerous new technologies
and its fieldbus capability via IO-Link.
W2: precise positioning,
transparent scanning
Whether particularly narrow or extremely
flat the W2 series, with its through-
beam and photoelectric reflex switches
and proximity switches, offers the right
housing for every mounting situation.
While the photoelectric switches have
long ranges and high performance re-
serves, the laser-like light spot ensures
that the photoelectric proximity switch-
es with background suppression offer
maximum precision and resistance to
interference, e.g. during circuit board
detection or the positioning of handling
systems. Thanks to their V-optics, the en-
ergetic scanners are top for transparent
and reflective objects, e.g. for the detec-
tion of test tubes in automatic analysers.
In addition, the slim and flat versions
reliably fulfil users high EMC, impact
and vibration resistance demands.
W4-3: series with best-in-class
scanner
With the through-beam and reflex pho-
toelectric switches, and the best-in-class
photoelectric proximity switch, the W4-
3 series also offers suitable alternative
solutions with impressive performance
data. The photoelectric switches are ca-
pable of reliably detecting small objects
even over ranges of up to 4 m. Several
new technologies make the WT4-3 photo-
electric proximity switch the benchmark
in its market segment. A new sensor
chip allows not only electronic scanning
distance adjustment and background
suppression, but also fieldbus connec-
tion of the sensor via IO-Link (more on
this in the article on p. 32). Even jet black
objects are reliably detected, thanks to
pin-point LEDs. Moreover, they prevent
spill-over reflections and thus ensure
high repeatability. Furthermore, the
optics are specially coated so that am-
bient and third-party light are reliably
filtered out. The poured cable fittings
offer maximum robustness and tight-
ness providing an enclosure rating of
IP 69K. That the WT4-3 can deservedly
be described as top of its class has
been shown by a range of tests against
devices available on the market. Under
all test conditions, the high-tech scanner
achieved top values both in the suppres-
sion of reflective backgrounds and in the
suppression of active and passive sour-
ces of interference.
Whether the electronics industry,
handling and robotics, or pharmaceu-
ticals both series offer maximum in-
stallation freedom and top performance
features in the booming market of mini-
ature sensors.
View of the inner life of the WT4-3 miniature photoelectric switch
insightLINK
INFO 139
W2 not much bigger than an ant
1/2006
Miniature sensors
: Museum
An interactive experience in sunny Andalusia
A journey
through science
and the universe
With 270 interactive exhibits with which to discover and understand in-
teractions in the natural sciences, the Parque de las Ciencias in Granada
inspires both young and old. No wonder that some holiday-makers are hap-
py to exchange their deckchairs on the beach for, e.g. the 50-metre-high
observation tower.
>> The Parque de las Ciencias is an
open-air museum that continues the
scientific tradition started by the Moors
during their several-centuries-long reign
over the Iberian peninsula. First, two
exhibition buildings in the 30,000 m
2

theme park area draw visitors into the
world of science. In the Biosphere Hall
one can observe piranhas by camera,
take a look at human DNA, or gain an
understanding of how the world was cre-
ated with all its fragile natural checks
and balances. The Eureka Hall is another
of the many permanent exhibitions. Here
one can examine how the senses per-
ceive our environment and sometimes
thoroughly mislead our brains.
The Marie Curie Plaza is a
centre of interest
Outdoors again, the visitors programme
focuses on the Marie Curie Plaza. It is
surrounded by the observation tower,
the Garden of Astronomy, the tropical
butterfly house, paths of botanical in-
terest, a maze of plants, and the Alma-
zara olive oil mill. The planetarium is a
further highlight. 110 projectors bring
more than 7,000 stars to life during a
virtual journey through the universe. The
Parque de las Ciencas offers interesting
exhibitions in the Pavilion, looking at a
different scientific subject of topical in-
terest each year.
So there is a lot to see and to experience
for those interested in the natural sci-
ences. Its hardly surprising that some
deckchairs often remain unoccupied.
The tropical butterfly house
Fun and games at the open-air museum
View of the Parque des las Ciencias in Granada
insightLINK
Further information on the Internet at:
www.parqueciencias.com
47
First-hand information
Editor of AUTOMATION
visits Waldkirch
Michael Lind, Chief Editor of the respected specialist magazine
AUTOMATION, recently visited Waldkirch. He gained first-hand informa-
tion on the technical safety opportunities of access protection during
automatic material transport.
>> A team of Product Managers from
the Industrial Safety Systems Division
explains the possibilities offered here by
SICKs Entry/Exit portfolio. Whether mut-
ing, pattern detection or vertical contour
monitoring each solution offers spe-
cific advantages: which can be found in
Issue 2/2006 of AUTOMATION.
www.automationnet.de
Silver medal for Safety
Systems catalogue
Attractive,
informative,
user-friendly
Special dimensions, special housing:
the MH sensor
A modern sensor fairy tale comes true
From dishwasher to millionaire
Flexibility, customer-orientation and,
in particular, the right product and a
product strategy adapted to the mar-
ket, have made the MH (Multi Head)
sensor a hot seller in the USA. Albeit
(as is so often the case in fairy tales
as well as in real life) by a somewhat
circuitous route ...
>> In early 2000, SICK completed its
development of the MH with the aim of
offering a basis sensor for the simplest
applications. Although highly impressive
in terms of its performance data and
functionality, market access turned out
to be problematic with such an unusual
product. Its housing and design, in par-
ticular, proved too strange for the usual
markets so the MH spent some time as
a niche presence.
First flop, then top!
You can see how what was originally
feared to be a flop for niche applica-
tions became a top sensor for a market
segment with enormous market poten-
tial on the Internet at
: SICK Tour
48 1/2006
Michael Lind (right) in conversation
with Product Manager Simon Kpfer
from SICK
>> SICKs printed Industrial Safety
Systems catalogue has won second place
from among 105 participants in The Big
Catalogue Benchmark 2005 competition.
The jury praised its comprehensibility and
respectable appearance, in particular.
Above all, navigation via the list of
contents, chapter introductions and
cross-references works without a hitch.
The ease of comparison of the individ-
ual products with one another, and the
comprehensibly presented and easily ac-
cessible order data, were also positively
evaluated. Finally, the catalogue offers
an impressive look and feel.
The jurys summary: A carefully im-
plemented and well thought-out design.
Thus finding, selecting and ordering prod-
ucts via the catalogue is just as reliable
with SICK as the products themselves.
INFO 140
www.katalogbenchmark.org
Training & Education 2006
Practical experience for practical use
7
th
in Lower Austria, 38
th
from almost 350 participants nationwide SICK
is also one of Austrias finest and most successful business addresses.
>> Every year, the Austrian newspaper
Wirtschaftsblatt selects the leading
companies in the country both na-
tionwide and in the individual states.
Split up into a variety of company size
classes, participants are evaluated on
the basis of their sales development,
average sales returns and company
earnings. Not quite enough for the vic-
tors rostrum in Lower Austria but
with 7
th
place SICK Austria came close
this year. And nationwide the team,
led by General Manager Alexander
Haslauer, achieved a successful 38
th

position.
The status of the Austrias Leading
Companies competition in the Alpine
republic can be judged by glancing at
the field of participants. Sales and job gi-
ants, such as Voest Alpine, participated
alongside a Viennese one-man compa-
ny, and a sales minnow from the state
of Burgenland. A total of almost 350
companies participated in the competi-
tion (jointly organised by the Wirtschafts-
blatt, Austrias trade protection society,
and the consultancy firm Pricewater-
houseCoopers), which gave both large
and small companies the same chance
by exploiting a sophisticated system of
coefficients.
SICK Austria company building in Viennas Neudorf district
: SICK Tour
>> Knowledge provides security and
leads to success this is the central
theme under which SICK is present-
ing its Training & Education 2006 pro-
gramme.
The brochure provides more than
100 pages of information on the wide-
ranging and differentiated spectrum of
international user training courses and
seminars. The focus is on Industrial
Safety Systems, Auto Ident, Industrial
Sensors, and Analyzers and Process In-
strumentation. SICKs trainers are sup-
ported by independent specialists from
industry, monitoring organisations, cer-
tification authorities and the Trade As-
sociations.
The seminar programme is available
in English and German. More informa-
tion can be found on the Internet at
www.sick.com/training INFO 141
49
Excellent results in region and nationwide
SICK Austria is one of
Austrias Leading Companies
50
100 ideas for starting the day
A good day starts
in the morning
Dear readers,
A wonderful morning to you! I hope you
are feeling fit and looking forward to an
interesting, if arduous, working day.
But is it always really like this? Dont
you sometimes feel like I do? The morn-
ing cant be held responsible, but it is
extraordinarily tiresome. There goes
the alarm clock again. But I didnt do
it any harm. Why is the night already
over? I only just got into bed. Its so
snug and warm. Its always so unpleas-
ant outside in April, its so cosy here
its just not fair.
Because, as a working woman, I am
confronted with this situation about
200 times a year (sometimes the
weather is better, sometimes worse)
I have decided to read the paperback
Five Good Minutes: 100 Morning Prac-
tices to Help You Stay Calm and Fo-
cused All Day Long and hope it really
will help me.
100 ideas on starting the day. That
should be enough to get the morn-
ing behind me successfully and per-
haps profit from this for a few days. Of
course, one cannot necessarily exploit
all the ideas oneself, everybody has to
find the ones that are most suitable for
them, but a brief overview may be of
some assistance.
Jeffrey Brantley and Wendy Millstine
begin with the basics, explaining how
five minutes can become five good
: Book Corner
minutes. Five minutes thats some-
times all it takes to get me philosophis-
ing. For me, this is a relatively short
time that sometimes passes unno-
ticed, but for an Olympic ice skater in
the middle of a performance it could be
the most decisive moment of their life.
But back to the book: the five good
minutes should be filled with medita-
tion exercises which can lead us to
lightness, inner relaxation and peace.
They show how one should handle
relationships and how one can become
wiser and more loving. These important
points are structured in numerous sub-
sections. They explain, for example,
how one can learn to laugh more about
oneself; the emotions released by
singing; how negative thoughts can
ebb away; the positive effects of a beau-
tiful piece of music. They recommend
seeing the world through the eyes of
a child; gaining pleasure from the
happiness of others; treating yourself
like a good friend; letting go of the
past; opening the door to wisdom;
praising yourself. The book ends
with the 100th meditation on
opening up the secret of how
to be a real person.
Many of the exercises begin with
breathing mindfully and the recom-
mendation of defining an intention that
one wants to achieve during the next
five minutes. Thus, for example, for the
point Listen to others intensively, a
possible intention is suggested: May
I achieve a deeper relationship to oth-
ers by deliberately listening. I can
really understand the point of this ex-
ample, and also that a beautiful piece
of music gives the day a more positive
start. And there are many suggestions
that help me think about myself. Some
meditations, however, seem somewhat
abstract to me, and I cannot really im-
agine that I will let go of my past in
five minutes.
But all in all a rewarding 128-page pa-
perback that gives me assistance and
suggestions for both my everyday life
and my working life.
This Book Corner is by
Ingrid Rathfelder, Editor of the
SICK insight e-mail newsletter
Five Good Minutes: 100 Morning
Practices to Help You Stay Calm
and Focused All Day Long
(ISBN 1-57224-414-3, approx. 14.50)
1/2006
51
: Info
51
insightLINK
Weitere Infos erhalten Sie mit der
Karte am Ende des Magazins unter:
INFO 121
oder im Internet unter:
insightSERVICE
Imprint
Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com
Phone +49 7681 202-0 Fax +49 7681 202-38 63 info@sick.de
Co-ordination: Anette Gasche Customer Magazine Project Manager, SICK AG
Anette.Gasche@sick.de
Specialist editors: TOP MEDIA Dirk S. Heyden 69469 Weinheim info@topmedia-weinheim.de
Layout: johnson][braun Direktwerbung 76133 Karlsruhe jb@johnsonbraun.de
Translator: Richard Dennis 79194 Gundelfingen richarddennis@t-online.de
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