SICK Magazine

insight
The building security laser measurement system

LD PDS protects valuables
and prevents vandalism
Page 40
2004
www.sick.com
2
SICKs customer magazine
TPM servo actuators from WITTENSTEIN
Perfect positioning with the
SRM 50 motor feedback system
Page 12
Curtains down!
The vertical protective field of
the S 3000 safety laser scanner
Curtains down!
The vertical protective field of
the S 3000 safety laser scanner
Page 06
10 years success in the Middle Kingdom
It is exactly one decade since SICK turned its attention to the Chinese market
with its SICK Hong Kong subsidiary. It all started in Guangzhou with the first of-
fice, which was soon followed by another in Hong Kong itself. What originally be-
gan with just four personnel has since developed into a company with almost
60 employees at a total of four sites Beijing and Shanghai came later.
The quality of the products, the enormous industrialisation boom of recent years,
and the support received from the German headquarters in Waldkirch meeting all
our technical and commercial needs, were undoubtedly of decisive importance in
this success. But also of decisive importance was, and remains, the fact that ba-
sically it is the Chinese who run the business in China and Hong Kong. Thus the
mentality interface, with all its challenges, remains within the company commu-
nication in the Group, instead of a clash of cultures in customer contacts.
In the next decade, too, China the Middle Kingdom will remain a market of di-
verse challenges. What SICK Hong Kong began ten years ago will be continued by
SICK Optic-Electronic Co. Ltd., Guangzhou China, founded last year: the success-
ful opening up of one of the worlds largest markets for industrial sensors. We
thank all those who have accompanied us along the path up to now, and all
those who will help shape our future path.
With best wishes from the Far East
Danny Chan,
Managing Director, SICK Hong Kong
and SICK China
03 Editorial
insightTELEGRAM
++ New Safexpert 4.2 update of CE-software
Straightforward adaptation of hazard analyses:
checklists, lists of hazards, cross-references,
etc. The Check and Acceptance Assistant
Simple checks complying with the Machine
Directive or German Safety at Work Legisla-
tion (BetrSichVer) EN 292 withdrawn and
replaced by EN ISO 12100 Info on new stan-
dard and Safexpert www.sick.de/safexpert
++ Three wide-awake trainees at SICK AG de-
velop pulse-controlled sleeping aid for tinnitus
patients Win Jugend forscht competition
(for young researchers) Appear on television
and receive Gallileo Prize from Pro7 TV
channel Prize: a new Toyota Prius ++ Inter-
esting info on Year of Technology 2004 from
Federal Ministry for Education and Research
at www.bmbf.de and www.jahr-der-technik.de
Reports, events and brochures on all
aspects of technology and the future ++
Product spotlight ..................... 28+29
UE 440/470 safety controllers:
flexible, compact and reliable......... 30
New W 190L series of laser
photoelectric switches ..................... 31
SICK IVP innovative cameras for
industrial image processing ........... 32
The IN 4000 safety system
switches on metal ......................... 33
The KT 3 Laser compact
contrast scanner ........................... 34
The IT 3810 hand-held
scanner: bar codes in focus........... 34
The DKS 40 incremental
encoder the compact and
robust cost-cutter.......................... 35
UM 18 when space is limited ...... 35
Reliable image processing on
press brakes.................................. 36
The KT 5 contrast scanner
display: a straight back for
comfortable use............................. 37
The ELG 1 short range the reason-
ably priced automation light grid..... 38
Automatic counting of persons
with LD PeCo ................................. 38
DT 500/DS 500 distance scanners
offer long range and great accuracy 39
and prevents vandalism.................. 40
Large-format colour detection
with the CVS 1............................... 41
SICK supports standardised teach-in 42
Parameterisation and diagnosis
via Bluetooth................................. 42
Autoworld in Brussels.................... 43
Company founded in Turkey............ 44
DeviceNet Safety on the march....... 44
ecatalog.sick.com...........................45
10 years SICK Hong Kong............. 45
Eat that frog ............................. 46
Imprint/Service ............................. 47
Trade fair dates ............................. 47
................................................... 03
Valo validates vertical
S 3000 Standard............................ 06
S 3000 double safety for
travelling production gantry............ 07
S 3000 Vertical protective field
for safety on wafer robots.............. 07
Encoders in blue kit regulate
knitting machines.......................... 08
Phoenix commissioning
rises from the ashes ...................... 09
Safer punching machines with
greater productivity........................ 09
The DRS 60 encoder: printing
and packaging in tandem................ 10
SICK sensors dominate at
Hansen Transmissions .................. 11
Perfect positioning with the SRM 50
motor feedback system ................. 12
Staying on the go with the
driverless metro............................ 13
LMS 400 top pot-picking ............. 14
Whether cheese sticks or contact
lenses into the box with them...... 15
Machine safety with ATEX
light curtains................................. 16
Coca Cola Beverages Polska
checks with the CM 30.................. 17
Protective field zapping
with the DME 5000 ...................... 17
On the right path with illuminated
guidance ....................................... 18
Stationary and mobile bar code read-
ers control recycling process.......... 19
SICK sensors control
automatic egg labelling.................. 20
Seamless identification of sutures 21
The ATM 60 absolute encoder: the
robust solution for a harsh
environment .................................. 22
LMS 200 laser measurement
systems detect projecting car parts 23
DT 500 laying it on the
line for mattresses............................ 24
WL 2S handles auto-filling shelves.. 24
Device and product safety legislation
(GPSG) clears up uncertainties........ 25
In conversation with Dr. Werner
Jansen of the BGFE....................... 26
SICK insight 2/2004 04 Contents
Book corner
Products
Standards
Info
06
Curtains down! The S 3000 sets standards
The ATM 60 absolute encoder: the
robust solution for harsh conditions
The V 4000 Press Brake optimises
safety and processes
22
SICK insight in conversation with
Dr. Werner Jansen of the BGFE
26
36
Interview
Museum
Applications
SICK Tour
Editorial
Know-how
SICK insight 2/2004
05 News in brief
insightBOOK CORNER
Brian Tracy
Eat that frog
Eat a frog? Not particularly appetising
at first glance. Whats it all about? Is
this a book offering advice on unusu-
al delicacies? The puzzle is solved on
Page 46.
Corn fields as far as the eye can see.
But theres no 500-tonne monster of
a combine harvester in sight. Just
a small, smart, high-tech robot with
an LMS Laser Measurement System
for navigation.
The agBot (agricultural robot) was
developed at the University of Illinois,
USA. As industrious as an ant, it works
through fields row by row, and will soon
be used for weeding, watching out for
harmful insects and taking soil sam-
ples. Its LMS Laser Measurement Sys-
tem ensures that the agBot stays strict-
ly on path, doesnt run anything over
and, at the end of the field, easily
Free download service from SICK
Laser classes:
greater clarity for
users
Those who produce or distribute laser
sensors or other devices with point-form-
ing light sources must comply with
standards such as IEC 60825 or
EN 60826. But users must also observe
other regulations. In Germany these
principally include the Trade Associa-
tions BGV B2 regulation and its
BGI 832 information sheet.
Both works, however, not only refer
to more detailed sub-divisions within the
individual laser classes, but also include
a range of secondary content. For users
this raises the concrete question: What
is of relevance to me, and what do I re-
ally have to comply with?
The comprehensive, practical de-
scriptions and graphic explanations in
the article Laser classes and their ap-
plication for users of laser devices pro-
vide answers to questions on all aspects
of the classification and use of lasers.
It is available at www.sick.de/infopool
as a free download.
Current trade fair info:
From 2325 November in Nuremberg...
... as usual, SICK is offering an overview of its product
range at this years SPS/IPC/DRIVES. We are looking for-
ward to your visit at
Stand 7-370 in Hall 7
See our special trade fair page at: www.sick.de/sps2004
General information direct from the organisers at:
www.mesago.de
From 610 December in Paris...
... the biennial international ELEC fair: with a new design,
and integrating MESUCORA for the first time. Drop in and
visit us at
Stand 13k4 in Hall 6
Further information on the trade fair at: www.eleclive.com
A-MAIZE-ing achievement from the land of unlimited opportunity
Watchful robots tend cornfields
moves into the next aisle between the
plants with two elegant 90 turns. The
ultimate goal will be to check plants in-
dividually and perhaps protect them
from pests by precision-spitting pesti-
cides where necessary. Our farm robot
only costs US$ 7,000, agricultural en-
gineer Tony Grift is proud of the elec-
tronic farm helper that is very reason-
ably priced despite its high level of
technological sophistication.
LMS in agriculture another task
CORNered!
www.gizmodo.com, search for: agbots
INFO 201
SICK insight 2/2004
Title topic: The vertical protective field of the S 3000 safety laser scanner 06 Applications
When unhindered machine access is essential
Valo validates vertical
S 3000 Standard
The French automotive supplier Valo has validated the S 3000 Stan-
dard safety laser scanner for vertical machine protection in several ap-
plications at their La Suze sur Sarthe works. Apart from its Safety
Category 3 according to EN 954-1, the possibility of unhindered ma-
chine access for operators was the decisive argument.
insightLINK
You can obtain further product informa-
tion with the attached card under:
INFO 202
or on the Internet at:
www.sick.de/S3000
More about the customer:
www.valeo.com
Vertical machine protection with the
non-contact electro-sensitive S 3000
safety laser scanner at Valo in France
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>> With sales of over EUR 9 bn. and
more than 68,000 employees at almost
130 production sites in 26 countries,
Valo is one of the leaders in the auto-
motive supplier market. The product
programme split into ten application-
specific divisions enjoys a high-tech
reputation. Correspondingly, production
at the various sites not only exploits the
latest production technologies, but also
utilises safety technology of the highest
standards.
Manual handling of parts
requires free access
The machines protected with the
S 3000 at Valo require the manual in-
sertion and removal of workpieces.
This immediately ruled out a mechani-
cal protective system, reports Thierry
Pouchol of SICK France, who provided
support for the project. The S 3000
non-contact safety laser scanner simul-
taneously safeguards the work area and
raises machine performance.
The first choice for vertical use
thanks to contour monitoring
Response time: 60 ms, resolution:
30 mm, protective field height: about
2 m, with 450 mm distance to the haz-
ardous machine area these are the
facts of the application at Valo. In prac-
tice, this task was only soluble because
the S 3000 had the necessary auxiliary
contour as reference function. With-
out this it would have been impossible
to gain certification for vertical use in
compliance with EN 61496-3. The scan-
ner exploits this function to reliably de-
tect when a protective field edge, in this
case the floor of the hall, changes its
relative position to the scanner. This re-
liably detects any mechanical misalign-
ment of the scanner, and thus any un-
guarded access to the hazardous area.
The device immediately switches off the
protected plant if the actual contour de-
viates from the reference contour be-
cause of any re-alignment of the sensor
in its supporting bracket.
Thus the S 3000 offers Valo and
other users a currently unique, real lead
in vertical machine protection.
SICK insight 2/2004
07 Applications
Wing production for the Airbus A380
S 3000 double safety for travelling production gantry
>> The plants produced by the Spanish
company M. Torres join carbon fibre
tape together, layer for layer, for the
production of wings and other compo-
nents of the Airbus A380. As a result of
the size of the wings they are, after
Only the S 3000 could do it
Vertical protective field for
safety on wafer robots
With its reliable view from above, an S 3000 Standard
protects the operators of a wafer-polishing plant from
reaching into the workspace of the handling robot. Only
the S 3000 could solve this task because it is the only
safety scanner of its type to be approved for vertical pro-
tection.
all, 40 m long the processing tool
travels over the aeroplane part under
production by means of a gantry.
Four S 3000s for the drive path
Two S 3000 laser scanners per direc-
tion of transport ensure that no per-
sons or objects are present on the
tracks along which the gantry moves.
An automatic switching of the two scan-
ner pairs takes place to match the di-
rection of gantry movement.
Four S 3000s for the production
zone
Employees put down layers of the car-
bon fibre tape while the gantry is in mo-
tion. The application tool on the gantry
then applies a glue-like material to join
the individual carbon fibre tape layers
together. Four further S 3000s form an
invisible protective barrier around the
tools operating area in order to protect
workers.
Eight S 3000s for the Airbus A380
not an everyday application.
>> Peter Wolters Surface Technologies
GmbH & Co. KG in Rendsburg, one of the
leading producers of highly accurate fine-
smoothing and polishing machine tool
systems, was looking for a reliable solu-
tion that prevented operators reaching
into the robots workspace during opera-
tion but did not hinder access to the dou-
ble-sided wafer polishing plant. The
S 3000 Standard was best suited for the
machine conditions. The device is in-
stalled on the upper section of the ma-
chine framework with a sufficient safety
distance. With its resolution of 30 mm
the scanner instantly detects if a hand
reaches into the machine. The haz-
ardous movement of the robot in the pol-
ishing plant is then immediately halted.
Vertical monitoring with the S 3000
the perpendicular safety solution.
insightLINK
INFO 202
www.sick.de/S3000
www.peter-wolters.com
insightLINK
INFO 202
www.sick.de/S3000
www.mtorres.es
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Polishing plant protected with the
S 3000
Eight safety laser scanners in use on a production gantry for Airbus components
in Spain
S 3000 safety laser scanners not only monitor the 50 m long and 11 m
wide path of a giant production gantry for Airbus components they al-
so protect employees who are working below the gantry.
SICK insight 2/2004
Incremental encoders in automated machines for warp-knitted fabrics at Karl Mayer 08 Applications
For jerseys and lingerie
Encoders in blue kit
regulate knitting machines
>> Almost any textile application, from
the finest lace to materials for lingerie,
girdles and sports clothing, from home
textiles to carrier materials for reinforc-
ing concrete, can be economically pro-
duced with the computer-controlled
high-performance automatic warp-knit-
ting machines.
Three areas of use
one encoder type
The driven components of HKS 2 warp-
knitting machines (particularly suitable
for producing heavy velour and lighter
tulle net, as well as materials for jer-
seys) are the machines main shaft,
the roller system for output of the
Automated machines for warp-knitted fabrics (otherwise known as tricot
machines) are one of the main areas of production at Karl Mayers tex-
tile machine works in Obertshausen, Germany. DGS 60 series incremen-
tal encoders from SICK-STEGMANN detect the number of revolutions
and the positions of various machine shafts rotating at speeds of up to
3,500 r.p.m. allowing nifty knitting process control by the computer.
goods, the rolling-up attachment, and
the two so-called warp beams with the
reels of yarn. Although the power and
the number of revolutions of the indi-
vidual drives vary, the same version of
the DGS 60 is used for each of them.
This keeps purchasing and storage
costs down to a minimum and simpli-
fies rapid encoder replacement should
it become necessary. The encoders
cover three different functions on the
machine. First they are used as the
main encoder for the thread guide com-
puter (as the machines control system
is called) on the machines main shaft
rotating at speeds of up to
3,500 r.p.m. The second function is
regulating the number of revolutions in
connection with the drive amplifiers.
The DGS 60s third task on the warp-
knitting machines is to regulate posi-
tion for process control by the thread
guide computer. The circumferences of
the warp beams reels of yarn de-
crease as they are unwound from full to
empty (known as beam travel in the
trade). The thread guide computer cor-
respondingly modifies the rate of drive
revolutions up to 3,000 r.p.m. to en-
sure constant, and thus error-free, ma-
terial feed to the knitting process with
minimum thread tensions.
Encoders for the worlds
quickest bathing suits
The DGS 60 is also an important com-
ponent of the worlds quickest warp-
knitting machine (also developed by
Karl Mayer) that produces material for
bathing suits at record speeds far ex-
ceeding 3,300 r.p.m.
Nifty knitting processes with the
DGS 60 encoder.
insightLINK
INFO 203
www.sick.de/insight/en
www.karlmayer.de
Encoders detect the number of rotations and positions of rotating machine shafts on
Karl Mayers high-performance automated machines for warp-knitted fabrics
A variety of materials are produced on
the warp-knitting machines
SICK insight 2/2004
Bar code scanners at Phoenix Pharma in the Czech Republic Safe punching machines 09 Applications
insightLINK
You can obtain further product
information on the Internet at:
www.mypin.cz and www.phoenix-ag.de
Bildtext
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Protection and PSDI mode with the C 4000
Safer punching machines with greater productivity
Customers of punching machine pro-
ducer Busch in Seevetal, Germany,
profit doubly from the use of C 4000
Standard safety light curtains on the
machines: operators are reliably pro-
tected against the risk of accidents,
and PSDI mode increases machine
performance by up to 30%.
>> Labels, brochures, credit cards,
childrens books and saving books are
typical examples of punched products.
Naturally, with sharp blades and
punching pressures of 5.7 tonnes,
safety is our top priority, says owner
Burkhardt Busch. Non-contact moni-
toring with C 4000 light curtains
means that we can also offer our cus-
tomers production advantages.
Standard safety with additional
advantages
Busch punching machines are
equipped with the C 4000 Standard
that has a protective field height of
300 mm and a resolution of 14 mm.
The light curtains signals are evaluat-
ed in the UE 402 switching unit. The
advantage: in this way the machine can
be operated in either single- or double-
break mode. Thus there is neither a
mechanical barrier to be opened and
closed on insertion or removal of the
goods to be punched, nor does the
punching process require manual initia-
tion. This simplest possible handling
saves a lot of time and therefore short-
ens the machine cycle. Compared to
using mechanical protection, machine
productivity has been increased by up
to 30% thanks to the C 4000 Standard
and the possibility of employing PSDI
mode, confirms Burkhardt Busch.
www.buschgraph.de
SICK scanners at the Czech Republics largest pharmaceutical distributor
Phoenix: commissioning rises from the ashes
>> More than two dozen CLV 420 bar-
code scanners have started work at a
recently equipped first depot. With the
help of CDB 420 connection boxes,
a SICK-CAN scanner network was cre-
ated without any major installation
problems and connected to the host
computer via Profibus. A CMC 400 Con-
nection Module Cloning was also inte-
grated in each connection box.
Pharma commissioning without
side effects
The new commissioning processes at
Phoenix prevent the side effects of
manual data handling such as delays,
lack of transparency or spurious com-
missioning. Each order is stored on
computer and printed out on a card
placed inside the commissioning boxes,
which are also externally labelled with
a permanent bar code. CLV 420 scan-
ners along the conveyor system read
the bar code on the box and guide it to
the first storage location for the goods.
These are placed in the box. After ac-
knowledgement, the box travels to the
storage location for the next article.
When the order has been completely
processed, the box is transported to
the despatch area. Online transmis-
sion of scanner data within the network
ensures optimum synchronisation of
material and information flow.
New commissioning processes at Phoenix Pharma controlled by SICK scanner networks
Light curtain on an automatic punch-
ing machine
Clonable parameter sets min-
imise parameterisation
These plug-in memory modules store
all the inheritance information of
the connected bar code scanner. Thus
new scanners can be cloned by
back-transfer as often as required. This
allows individual devices to be ex-
changed very rapidly and without
extra parameterisation costs.
Phoenix, the Czech Republics top pharmaceutical distributor, has
completely revamped commissioning at its nationwide distribution
centres with SICK scanner networks. The old documentation lies in
ashes (so to speak) and, in its place, bar codes and Profibus have given
Phoenix flight.
Substantial time-savings and fewer rejects with the DRS 60 incremental encoder
Simple electronic zero-impulse alloca-
tion at the touch of a button
SICK insight 2/2004
British printing system with CoreTech series incremental encoders 10 Applications
>> An increasing number of cigarette
manufacturers have relocated their ad-
vertising messages to the inside of the
pack since the introduction of legisla-
tion stipulating that warnings about the
risks of smoking must be prominently
displayed on the outside. The text must
be accurately positioned as the area
available for printing is relatively small.
As a result, printing and cutting sys-
tems for the inner frames of packs
must be synchronised with extreme
precision.
ACCU-PAC has it down to a turn
ACCU-PAC, produced by Britains Indus-
trial Automation Systems, is a registra-
tion system which can be retrofitted to
any make of cigarette packaging ma-
chine. ACCU-PAC registration systems
have been designed as a retro-fit kit to
Those who use DRS 60 incremental encoders, from the CoreTech se-
ries, in their printing and packaging systems can reduce the time re-
quired for zero-pulse adjustment by 90%. Instead of an intuitive
co-ordination of devices as is necessary with conventional encoders
pressing a button suffices with the DRS 60.
register film, tear tape, inner foil or in-
ner frame, all components of the fin-
ished cigarette packet. But how can
one synchronise the cutting and regis-
tration systems? How does the regis-
tration system know the knife cut posi-
tion? The encoder zero pulse triggers
at the cut position, reports Peter
Evans of Industrial Automation Sys-
tems. It used to be necessary to ad-
just an estimated offset, based on
where the cut occurred, to synchronise
the registration and cutting systems
after the encoder had been fitted. This
offset was entered into the system and
the machine operated again. The
process was repeated until synchroni-
sation had been achieved. This method
was far from ideal in a modern au-
tomation environment. It can be done
more intelligently with the DRS 60.
insightLINK
INFO 204
www.accupac.co.uk
Pressing a button in the device is suffi-
cient to electronically assign a me-
chanical reference point to the zero
pulse.
Incredible savings potential
achieved
What used to take up to 20 minutes
can now be completed in two minutes
at most, reports Peter Evans. Re-
move the cover, press the button and
off you go its as easy as that. And
one doesnt have to reject up to 50
packs like before; at most just one or
two.
So its no wonder that the DRS 60
is not only now standard equipment for
Industrial Automation Systems, but
has also been retrofitted to many ma-
chines that have already been deliv-
ered worldwide.
Zero-pulse adjustment (teach-in) by button
The DRS 60 encoder: printing
and packaging in tandem
SICK insight 2/2004
SICK sensors in automatic pallet warehouse at Egemin in Belgium 11 Applications
Single-source automation of three pallet
warehouses
SICK sensors dominate at
Hansen Transmissions
>> Hansen Transmissions produces
components and drives for wind-driven
power stations, among other things,
at the new factory in Lommel. Of deci-
sive importance in choosing SICK was
that Egemin, as system integrator for
the most varied of tasks, can always
offer the most suitable, technologically
high-quality sensor solutions from
a single source.
Detection and measurement
WL 27 series photoelectric reflex
switches detect pallets and transport
Egemin, one of Belgiums leading system integrators of automation and
safety technology, has equipped three new warehouses in Lommel for
machine and drive constructor Hansen Transmissions entirely with
SICK sensors.
containers at a wide variety of points in
the material flow. Long range, simple
commissioning and reliable operation
characterise these devices. Elsewhere
in the warehouses and production area
it is important to reliably detect per-
sons, not pallets, to prevent the risk of
accidents. M 2000 multi-beam photo-
electric safety switch here meet all the
demands. Their particular advantage:
the machines to be protected are di-
rectly accessible for maintenance work
or equipping purposes, for example.
The MLG automation light grid handles
measurement functions at Hansen
Transmissions. Checking for projec-
tions and overheights, as well as in-
specting pallets for damage, are the
principal areas of use. As these tasks
were already known about when the
systems were ordered, the MLG units
could be pre-parameterised in advance
at SICKs works and were therefore im-
mediately ready for use.
Identification and communication
Which pallet is where on the conveyor
system, and its intended destination, is
determined by CLV 410 and CLV 420 se-
ries stationary bar code scanners. Com-
pact and easy to install, with a reading
distance of up to 400 mm and a rapid
frequency of 1.2 kHz, these are the right
devices in the right place. Finally, ISD da-
ta-transmission photoelectric switches
handles online communication between
the storage and retrieval devices and
the appropriate aisle or plant control
systems at the three pallet warehouses.
Rapid installation of the ISD, with me-
chanical, optical and electronic adjust-
ment aids, soon got storage and re-
trieval devices ready for operation.
The all-round sensor package that
Egemin has assembled with SICK
products has proved to be an all-round
trouble-free package at Hansen Trans-
missions.
insightLINK
www.egemin.com and
www.hansentransmissions.com
Bildtext Bildtext Bildtext Bildtext
Left: Equipped with SICK sensors by
Egemin: the new automated pallet
warehouse
Top: Safe maintenance work with
M 2000 multi-beam photoelectric safety
switch
Losing weight with the TPM:
The weight of this robot from SIG Pack
Systems could be reduced from 130 kg
to 46 kg by using innovative TPM
servo actuators.
SICK insight 2/2004
Motor feedback systems in geared motors at WITTENSTEIN AG 12 Applications
For compact, light and highly dynamic TPM servo actuators
Perfect positioning with the SRM 50
motor feedback system
Unique dynamism, extremely compact housings and high rigidity char-
acterise the new TPM series of geared motors, so-called servo actua-
tors, from WITTENSTEIN Motion Control GmbH. Further advantages, in-
cluding automatic parameterisation of the control system, precise posi-
tioning and a high level of user-friendliness are provided by the
integrated SRM 50 motor feedback system from SICK-STEGMANN.
>> High-tech machine constructor,
top employer and a trend-setter in
drive technology are phrases often
used by the specialist and business
press to describe WITTENSTEIN AG. So
it is no surprise that the Igersheimer-
based group of companies, with its
800 employees, achieves double-digit
annual growth rates, reinvests 10% of
its profits in research and develop-
ment, has a training ratio of 11% and
personnel with an average age of 34.
85% of WITTENSTEIN products sold
are less than five years old, Siegfried
Wallauer, Product Manager responsible
for the TPM series, underlines the in-
novative strength of all Group mem-
bers. The best example of this is the
highly developed series of servo actua-
tors developed by WITTENSTEIN Motion
Control. The compact SRM 50 motor
feedback system has made a consider-
able contribution towards motor sizes
that offer substantial space savings.
TPM compact combination
of gears and motor
The TPM is a rotary actuator consisting
of an AC servomotor and a low clear-
ance, precision planetary gear. One
of the special features of the TPM is
its short length, explains Siegfried
Wallauer. Thanks to its integrated
design, the smallest TPM is just
113 mm long thats 50% smaller
than conventional motor/gear combi-
nations. And it weighs considerably
less too. Further features are its ac-
celeration of up to 100,000 1/s
2
,
achieved with state-of-the-art motor
technology, and its high gear rigidity
that permits optimum control.
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SICK insight 2/2004
The driverless metro in Denmark 13 Applications
Easy riding in Copenhagen thanks to LMS
Staying on the go with the
driverless metro
>> The LMS units are an important
component of the obstacle detection
system (ODS). All objects larger than
450 x 450 x 450 mm
3
are detected by
one of the six scanners at each station
and evaluated by the ODS, then a sig-
nal is transmitted to the automatic traf-
fic alarm control system (ATC).
Great safety reserves
The projects safety planning was ex-
cellent. The entire system structure (in-
cluding the sensors) is designed with
redundancy. Each metro station has its
own warning and visualisation system.
The scanners themselves are designed
for outdoor use and programmed in
such a way that spurious signals are re-
liably prevented. All in all, the entire
system has a mean time between fail-
ure (MTBF) of 115 years according to
the system integrator.
So its easy riding in Copenhagen: sta-
tistically speaking, the first system
breakdown can be expected in 2119.
Not only is the metro new for Copenhagen, but also its driverless con-
cept. The central control system and the metros complete automation
could not be completed until laser measurement systems were in place
at each station to provide warnings about objects on the tracks.
insightLINK
INFO 205
www.wittenstein.de and
www.sigpacksystems.com
New metro system in Copenhagen with
the obstacle detection system
The SRM 50: communication,
precision and ease of use in all
TPM applications
The TPM is ideally suited for use, for
example, as a drive for compressing hy-
giene articles in packaging; in automat-
ic feed systems for wood processing
machines and machine tools; as a
drive for dosing pumps; as an axle
drive on spraying robots (theres an Ex-
protected TPM version for use here); or
as a part-turn valve actuator in plants
for producing optical media and semi-
conductors. Whatever the application,
the SRM 50 Multiturn motor feedback
system integrated in every TPM unit
ensures bi-directional communication
between the drive and the plant control
system via its standardised Hiperface
interface. Information on commutation
and rotor position is transmitted as ab-
solute values when the TPM is
switched on, thereafter counting con-
tinues incrementally via sine/cosine
signals. In this regard, the EEPROM
offers important advantages as a so-
called electronic type label in the
SRM 50, Siegfried Wallauer mentions
the devices integrated control system
parameterisation. Gear and motor
characteristics, and commissioning
data, can be stored here and used for
autonomous setting of TPM parame-
ters. Programming data for the motor
feedback system, such as resolution or
a shift in zero position, can be stored in
a different EEPROM memory area and
called up from there.
This feature of the integrated motor
feedback system (which has been test-
ed and approved by WITTENSTEIN for
connection to more than 20 different
control systems) provides easy and
reliable commissioning of the TPM. The
TPM can also fully exploit the
SRM 50s resolution of more than
134 m. increments and its high preci-
sion of less than 1 minute of angle.
insightLINK
INFO 206
www.m.dk
The measurement system (above), installed at a height of 2.7 m, moves over pots
and pans stacked up to 1.6 m (below)
SICK insight 2/2004
Three-dimensional object detection at WMF with the LMS 400 laser measurement system 14 Applications
For high-precision pick & place
LMS 400 top pot-picking
Precise object detection in three dimensions is the great strength of the
LMS 400 laser measurement system. Automatic pick & place robots, in
particular, profit from this because parts of different sizes can now be
gripped in mixed operation, e.g. pots and pans of differing diameters at
WMF AG.
>> Cutlery, tableware, cutting devices,
coffee machines, as well as pots and
pans from WMF AG, based in Geis-
linger, are greatly appreciated by
housewives, amateur cooks and pro-
fessional chefs. The high quality
requirements are reflected in the mod-
ern production sites. Thus WMF has re-
cently started using the LMS 400 for
three-dimensional visual guidance
of robots during the production of pots
and pans. The robot must reliably move
pots and pans with varying heights,
differing diameters and optically
dissimilar appearance, on and off
pallets. The LMS 400 allows this
without the need to adapt robot
programs, mechanical components or
control system software.
The new view of the robots visual
guidance system
The LMS 400 offers visible advantages
in pick & place applications. Only iden-
tical goods could be transported in the
past to ensure the precise position-
ing required by the robot. The third
object dimension and gripping point
of each object was known. This is now
no longer necessary because the
LMS 400 provides data with which all
the necessary robot information is pro-
vided rapidly and accurately. This not
only convinced end-user WMF, but also
those responsible at robot integrator
Komatec. At WMF the measurement
system, installed 2.7 m above the
ground, moves over the stack of pots
(that can reach heights of up to 1.6 m)
measuring each pot with 0.1 resolu-
tion and a scanning rate of 500 scans
per second. A major advantage over
solutions based on camera systems
is that ambient light and reflections do
not interfere with the measurement
process. All the positional and
distance information required for
targeted and reliable robot activity is
provided within milliseconds thanks to
rapid evaluation.
Rapid, precise and flexible, the
LMS 400 sets new standards in 3-D
object detection.
insightLINK
INFO 207
www.wmf.com and www.komatec.de
SICK insight 2/2004
Safe sensors on high-speed packaging machines in the Netherlands 15 Applications
>> Langenpac mainly produces pack-
aging machines for cakes and biscuits
(e.g. cheese sticks), dry food, tissues,
and industrial non-food products such
as film spools, batteries and lamps.
These are all mass-produced articles
that require high throughput capacities
during packaging and cartoning, says
Pieter van Summeren, Manager of Elec-
trical Engineering at Langepac. And
we are particularly strong here.
SICK sensors ensure rapid and in-
telligent system solutions
The tasks that Langenpac machines
handle differ in complexity. The vertical
cartoning machine for cheese sticks
fills sales trays at high speed. Type
WT 12-2 photoelectric proximity switch-
es, mechanically robust sensors with a
rapid switching frequency of 1.5 KHz,
monitor the continuous flow of sales
packaging. A special high-speed pack-
aging machine for 200 boxes per
minute was constructed for a producer
of tissues. The requirements of a con-
tact lens producer were complex: apart
from the pure packing function, this al-
so involved coding and sorting accord-
ing to lens strength, sell-by date and
batch number. SICK scanners are
first-class here, confirms Pieter van
Summeren. Finally, a really futuristic
cartoning machine for food products
was developed with the Canadian com-
pany Langen. The machine is charac-
terised by a high speed and a wide
range of formats. In addition to a vari-
ety of detection functions, safety tech-
nology here reliably protects machine
operators.
insightLINK
tion on the Internet at:
www.langenpac.com
Monitoring gap-free feed of sales packaging with the WT 12-2 photoelectric proximity switch
High-speed packaging machines and cartoning equipment are staples
for Dutch producer Langenpac. Capacities of 450 and more boxes per
minute require reliably functioning sensors. Thus safety systems, bar-
code readers and photoelectric switches from SICK (e.g. the W 12-2)
have become standards at Langenpac.
SICK is standard
Whether cheese sticks or contact lenses
into the box with them
ATEX package offers reasonably
priced retrofitting
Certification of the C 4000 for cate-
gories 3G (G = gas) and 3D (D = dust)
has been obtained in compliance with
the demands of the ATEX directive for
protection by mechanical safety meas-
ures. This applies for a variety of
protective field heights, as well as all
possible resolutions or single-beam
separation distances. Even the nor-
mal C 4000 fulfils many of the ATEX
requirements among other things,
the front screens of the transmitter and
receiver are made of shockproof
polycarbonate. The ATEX package nec-
essary to provide the remaining
supplementary safety measures basi-
cally consists of end caps for the
housing (which protect the connection
areas from dust in a non-connected
state), and the ATEX plate to be at-
tached to the device. This ATEX up-
grade offers plant planners high levels
of flexibility and safety. They can
locate individual C 4000 units accord-
ing to the demands to be met in situ,
and the systems can then be rapidly
and extremely cost-effectively supple-
mented with the ATEX package when
necessary.
SICK sensors also for 2G and 2D
In addition to the C 4000 in its various
versions for 3G and 3D applications,
safety light curtains are also available
as electro-sensitive protective devices
for Category 2G. Their certification for
2D is also in preparation, as is ap-
proval of a multi-beam photoelectric
safety switch for 2G and 2D. Moreover
the W 24 Exi series of 2G-certified pho-
toelectric switches is available for gen-
eral object detection tasks in automa-
tion technology.
ATEX light curtains safe and cost-ef-
fective solutions for the Ex-Zone.
SICK insight 2/2004
Safety light curtains on spraying plants at BMWs Regensburg works 16 Applications
Machine safety with ATEX light curtains
EXcellent solutions
>> This electro-sensitive protective
equipment (ESPE) can be used in
Zones 2 and 22 according to directive
94/9/EG (ATEX). Application examples
include filter presses in sewage plants;
printing machines; filling plants in the
chemical and food industries and
spraying lines in the automobile indus-
try. This is where BMWs Regensburg
works has installed numerous ATEX-
conforming C 4000 light curtains in a
co-operation with spraying plant pro-
ducer Drr Systems.
insightLINK
INFO 208
More about the customer
www.bmw.com and www.durr.com
Standard and Advanced:
C 4000 ATEX with graduated functionalities
The safety light curtains of the C 4000 series are used for protecting hazardous
points of operation on machines and plants. They all comply with EN 61496,
Type 4 as well as IEC 61508, SIL 3. The Standard and Advanced device ver-
sions are designed to meet different levels of automation and functional re-
quirements. The Standard version is available with, among other features,
ranges of up to 19 m, resolutions of 14 mm, 20 mm, 30 mm or 40 mm, and
protective field heights of between 300 mm and 1,800 mm. Compared to the
Standard version, the C 4000 Advanced offers a variety of additional functions
that can, for example, reliably differentiate between workpieces that temporari-
ly jut into the protective field (for process-related reasons) and a finger or arm.
With the new C 4000 ATEX series of safety light curtains it is now also
possible to prevent persons from reaching into the hazardous areas of
machines during operation in which sporadic or temporary potentially
explosive mixtures of gases or non-conducting dust can occur.
The C 4000 safety light curtain for
ATEX applications in Zone 2 for gas,
and in Zone 22 with a connector end
cap for dust.
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SICK insight 2/2004
Counting bottles with capacitive sensors Distance measurement system 17 Applications
Bottle present, cap on?
Coca Cola Beverages Polska checks with the CM 30
>> After filling, the bottles are com-
bined into multi-packs with the help
of shrink foil. Then its straight onto
the pallets and off to the shops.
It is, of course, annoying if packs
arriving there are missing a bottle
or have overflowed. So Coca Cola
Beverages Polska wanted to ensure
that every pack was complete and
that every bottle was in perfect
condition.
Four in a row per line
For this purpose, Coca Cola Beverages
Polska engineers installed four
CM 30 capacitive sensors next to one
another above every transport line.
Are all the bottles behind the shrink foil, and does each bottle have a
cap? CM 30 capacitive sensors at two Coca Cola Beverages Polska
works put the in order ticks on the checklist.
The plastic housing of the CM 30 is ev-
idence of their IP 67 enclosure rating,
so repeated cleaning work on the
machines cannot affect them. Sensitiv-
ity and the switching distance are set
on the sensors themselves. As soon
as the multi-pack, held together by the
foil, passes through the sensor gate, a
CM 30 detects the absence of a bottle
or a cap by means of the constant ca-
pacity of its condenser. Such packs are
immediately diverted out of the flow.
If, however, the capacity of the
CM 30 changes in accordance with the
defined value,the pack is in order and
can be palleted.
Make it clear with the CM 30.
insightLINK
You can obtain further information about
the product on page 29.
www.cocacola.com
Always active in the right direction
Protective field zapping with the DME 5000
>> Protective field switching was origi-
nally triggered by initiators at least
that was what was supposed to hap-
pen. But other operations in the area,
and above all stacker traffic, kept de-
Paper rolls, weighing up to five tonnes, are transported on a rail-mount-
ed transport vehicle at Nordland Papier in Drpen. PLS laser scanners
monitor both directions of movement. Two DME distance measuring de-
vices activate the PLS protective fields according to their position.
stroying the initiators switching flags
glued to the floor of the hall. The result:
switching proved impossible.
Robust and precise
the DME 5000
Two DME 5000 laser distance measur-
ing devices recently installed on the
transport vehicle manage far better.
During transport, the two sensors (re-
dundant for the particular direction of
transport) continuously measure the
time-of-flight of their transmitted light
pulses to the end of the drive path and
back. The electronics determine the
position of the transport vehicle from
these measurements and transmit this
information to the vehicle PLC via
Profibus. The data is processed here
and the appropriate binary signals are
generated. These are passed on to the
LSI, that activates switching of the PLS
protective field. This solution has
proved very robust and reliable during
operation this is hardly surprising
when one considers that the
DME 5000 was specially developed for
distance measurement and position
determination in conveyor systems and
warehouses. And it has an extraordi-
narily high measurement accuracy of
+/2 mm with a reproducibility of
0.5 mm, whereby an up-to-date meas-
urement value is transmitted every mil-
lisecond more precise distance
measurement is hardly possible in
such applications.
Precision in any position the
DME 5000 is the right choice for dis-
tance measurement in automatic
small-parts stores, for vehicle position-
ing, and for crane distancing.
insightLINK
www.nordlandpapier.de
Transport line with four capacitive sensors
Distance measurement devices on trans-
port vehicles
insightLINK
INFO 209
SICK insight 2/2004
The solution: the LUT luminescence scanner for detecting guidance paths 18 Applications
Flexible when destinations change
On the right path with illuminated
guidance
>> Unlike expensive inductive guid-
ance, or complicated optical naviga-
tion systems, this is a reasonably
priced flexible solution for free-moving
and self-positioning industrial trucks.
Follow that light
Whether adhesive tape or paint lu-
minophores are available in a wide va-
Whether in production plants for large-scale machines and systems, or
during storage and logistical transport movements within works there
are individual cases where the destinations of free-moving industrial
trucks are only temporary or used during a specific project, and are
therefore often subject to change. In such cases, following removable
fluorescent guidance paths with LUT luminescence scanners has proved
highly effective.
riety of media. They are invisible to the
human eye but light up as soon as
they are excited by high-wavelength
light. LUT luminescence scanners both
stimulate luminophores and detect
them. The vehicle reliably follows the
detected light on the basis of digital
signals transmitted to the control sys-
tem.
Sensor solution for transport
systems with heavy loads
The leading manufacturer of transform-
ers uses so-called air-cushion trans-
port systems in its production, inspec-
tion and dispatch areas, with loads
that at times exceed 500 tonnes. De-
pending on the size and type of trans-
formers, different transport destina-
tions must occasionally be reached via
differing routes. Shorter journeys
across the works grounds are also an
everyday occurrence. The use of fluo-
rescent guidance paths together with
luminescence scanners provides trans-
port systems with the maximum possi-
ble degree of freedom, and thus maxi-
mum applicability. Thus guidance paths
can be individually set up in the inspec-
tion area, for example. If narrow areas
must be approached, or the vehicle re-
quires exact positioning, this is
achieved with millimetre accuracy
thanks to the devices precise detec-
tion of the guidance path.
Other sectors also face situations
similar to those found during internal
works transportation in transformer
construction. These include furnace
and tank construction; the production
of modules for commissioning shelves;
rolling stock construction and the pro-
duction of diesel and ships engines;
the production and assembly of air-
craft; or the transport of large-scale
tools and machines for metal process-
ing.
The LUT for detecting guidance paths
the flexible and cost-effective solution.
Suitable for free-moving industrial trucks with changing destinations: the LUT lu-
minescence scanner
SICK insight 2/2004
Identification with hand-held and bar code scanners at Swedish recycling works 19 Applications
A clean solution for a clean environment
Stationary and mobile bar code readers
control recycling process
>> The works a joint venture between
Danish and Swedish companies went
into operation in March 2004. It is de-
signed for enormous recycling volumes
an estimated annual volume of 6,500
trucks loaded with cans and bottles.
Whereby cartons with counted
amounts of cans and PET bottles, and
sacks with uncounted contents from
gastronomic sources must be identi-
fied, explains Claes Johansson, Man-
aging Director of the company Styrlog-
ic, which solved the control and identi-
fication tasks in the project. Ultima-
tely, every customer wants to get their
deposits back.
Stationary scanners for special
containers
A special disposable carton, suitable
for Europallets, has been developed in
order to permit consistent automatic
handling inside and outside the factory.
A counted number of aluminium cans
and PET bottles are delivered within
them from the trade. Each carton is
Every year, 250 million PET bottles and 850 million aluminium cans are
prepared for recycling at Returpacks new recycling works in Norr-
kping, Sweden. CLV 450 stationary bar code readers and IT 3870
data-radio scanners identify the incoming consolidated packages in or-
der to ensure smooth processing of the financial deposit on the goods.
identified by stationary CLV 450 scan-
ners, with inductive encoders, checked
for its content (aluminium or plastic)
and then pushed onto the appropriate
conveyor belt to the next process step.
The great strength of the CLV 450,
says Claes Johansson, is that the de-
vices can also reliably read poor-quality
bar codes, because not every carton is
in a good condition when it arrives at
the works from the dealers.
Mobile solution for the uncounted
material for recycling
Returpack receives cans and PET bot-
tles from gastronomy and other
sources in plastic sacks, for which no
individual automated counting can take
place. These sacks are distributed to
15 manned stations at the factory.
Each sack is identified online with the
help of IT 3870 hand-held scanners be-
fore its contents are emptied into large
bins for counting and further transport.
Whats practical about the mobile
scanners argues Claes Johansson,
is that they offer great freedom of
movement after all, the area covered
by data radio is about 730 m
2
. Then
there is the reading distance of about
0.5 m, which makes it possible to iden-
tify the sacks ergonomically.
By the way
In addition to the scanners mentioned
above, a large number of WL 250 pho-
toelectric switches are installed along
the edges of the conveyor system.
insightLINK
You can find obtain further product
www.returpack.se
Recycling countless PET bottles and aluminium cans at the new recycling works in
Sweden
The CLV 450
bar-code scanner
The IT 3870
hand-held scanner
SICK insight 2/2004
Egg labelling with a variety of SICK sensors 20 Applications
Cracking the egg positioning problem
SICK sensors control
automatic egg labelling
EU law stipulates that all class A* eggs must be labelled with a special
identification code: a twelve-character producer code. So this is now
required in Poland, a new EU member state, as the company Intrex
has recognised. Those at Intrex have also recognised that SICK
sensors crack the problem of detecting the position of eggs in the
labelling system.
>> The code on the premium goods
should look like an extension of the
egg shell. This places two demands on
the automatic coding system: the egg
must be detected before printing, and
must be transported at the right speed
during printing.
R-egg-ular information
Egg detection by light or more pre-
cisely with the help of WLL 170 photo-
electric fibre-optic switches or VTE 18
cylindrical photoelectric switches. The
labelling system is thus reliably in-
formed that there is again something
there for labelling.
L-egg-ibility assured
The DRS 60 encoder co-ordinates the
speed of egg rotation with the printing
speed of the labelling system, thus
achieving a cleanly applied and clearly
legible print result.
Simple adaptation to new
b-egg-innings
Both the photoelectric switches and
the encoders are fit for any southward
enlargement of the EU. The ranges of
the WLL 170 and the VTE 18 can be
adapted; the DRS 60 can be ordered
Ex-Works with a variety of pulse num-
bers for differing rotation speeds. Thus
if Australia should ever join the EU, the
labelling of premium ostrich eggs, in
line with their new l-egg-islation, would
actually not be any problem at all ...
insightLINK
www.intrex.pl
* Eggs are divided into quality classes A
and B. Retailers, however, only offer class
A eggs. Class B eggs are second-quality
eggs. They can only be delivered to spe-
cially approved food companies or the non-
food industry.
New labelling obligation in the EU
An important code for maintaining food quality: where is my
breakfast egg from?
From January 2004 no one egg is the same as another. Each egg must show
where it originated and how the laying hen lives. A uniform code composed of
numbers and letters informs consumers about the eggs country of origin,
whether it was laid by a hen living outdoors, only on the ground, or in cages,
and in which hen-house it was laid.
Decoding the code
The first two numbers show the type of living con-
ditions under which the egg was laid. 0 is organ-
ic production, 1 is for living outdoors, 2 is for liv-
ing on the ground, 3 means that the hen lives in
a cage. The letters are abbreviations for the coun-
try of origin.
Each egg receives a special ID code in line with EU legislation
SICK insight 2/2004
2-D reading devices check medical products 21 Applications
insightLINK
INFO 210
www.ethicon.com
Checking 2-D batch numbers with the ICR 850 data matrix reader
Seamless identification of sutures
>> Ethicon, a 100% subsidiary of the
US Johnson & Johnson Group, employs
about 2,100 personnel. Every year, in
addition to 150 million surgical nee-
dles, they also produce 130 m. metres
of surgical sutures on the modern pro-
duction plant thats three times the
length of the Equator. Safety aspects,
quality requirements, and the tracking
of every production batch necessitate
100% checking of the sutures during
the packaging process on the foil lines.
Batch numbers in data
matrix code
During packing, the suture material
is laid in a cavity a type of shell.
Before the wrapper with the product in-
formation is attached, ICR 850 units
read the data matrix code on the prod-
uct. The coding contains part of the
batch number that is now compared
with the current order code. If the two
codes match, the wrapper with the
product information is attached. This
check ensures that any product mix-up
on the packing line is detected in good
time and reliably prevents use of the
wrong wrapper.
Matchcode, Profibus,
visualisation
The ICR 850 is not just a reliable solu-
tion here, but also a particularly user-
friendly one. For example, at the start
of a packing order the appropriate or-
der matchcode is automatically taught-
in at the code reader the ICR 850
is thus promptly ready for operation
with maximum flexibility. The devices
are connected to the machine PLC via
CDM 420 fieldbus gateways with
Profibus. The use of this proven func-
tional module ensures smooth data ex-
change right from the start. During
operation, a wide variety of ICR 850
read and process information is dis-
played on an industrial PC. Teach-in,
matchcodes, read codes, no reads,
error messages and numerous evalua-
tions can be read by the machine
operator in situ.
The ICR 850 the seamless identifi-
cation solution that is not just for sur-
gical suture material.
ICR 850 data matrix readers at medical product manufacturer Ethicon,
in Norderstedt, ensure that the wrappers match the products and that
there are no product mix-ups.
The ICR 850 2-D reader checks whether the product and wrappers match
Use of numerous magnetic encoders in the pipe-straightening machine
Pipes pass through roller segments
SICK insight 2/2004
Pipe-straightening machines with absolute encoders in England 22 Applications
Magnetic pick-up technology guarantees maximum reliability
The ATM 60 absolute encoder: the robust
solution for a harsh environment
Bronx Taylor/Wilson, English producers of pipe straightening machines,
insist on the ATM 60. Several hundred devices have been installed in re-
cent years, and none of them have been harmed by the harsh operating
conditions.
straight it is necessary to process
them further typical requirements are
a straightness of just 1 mm deviation
per 1,500 mm or even 3,000 mm to
achieve these tolerances the pipe
straightening machines from Bronx Tay-
lor/Wilson are used. Pipe diameters of
between 15 mm and 600 mm can be
processed on them with insertion
speeds of up to 3.3 m/s. The pipes
pass through several roller segments
whose pressure straightens the pipe.
The task of the ATM 60 is to regulate
the height of the rollers and their angle
relative to the pipe. The encoders mul-
titurn property is achieved by using
several reducing gears with magnets
mounted upon them. This enables the
absolute position of the rollers to
be detected as the drive mechanism
moving the rollers turns through multi-
ple rotations.
Global encoder
The highly robust nature of the ATM 60
is ideal for machines that are installed
worldwide they prevent unnecessary
complaints and service work. They re-
liably withstand the impacts and vibra-
tions, that go hand-in-hand with this
process, for years 24 hours a day,
seven days a week, year in and year
out, says John Dunn. Moreover, the
device also speaks a variety of lan-
guages: the communication protocols
for Interbus, Profibus DP, CanOpen, De-
viceNet and SSI allow the standardised
transfer of digital data to the worlds
most important fieldbus systems for
factory automation.
The ATM 60 is the robust rotary meas-
urement system for linear travels, an-
gles, positions and pipes.
insightLINK
INFO 211
www.btwcorp.com
>> Optical encoders have many posi-
tive features, but are relatively sensi-
tive to vibrations, shocks and impacts
as a result of their glass code discs.
Magnetic encoders, such as the
ATM 60, are sensors whose permanent
magnetic elements scan a magnetic
scale, and are considerably more
robust due to their principle of opera-
tion. This was decisive for us,
because each machine we manufac-
ture is equipped with numerous
encoders, says John Dunn, MD of
Bronx Taylor/Wilson, a company active
worldwide.
Regulating heights and angles
It is not possible to manufacture weld-
ed or seamless pipes to tight toler-
ances. If pipes need to be particularly
SICK insight 2/2004
Automatic parking system with laser scanners at the Mvenpick Hotel in Berlin 23 Applications
The facade of Berlins Mvenpick Hotel
Laser scanners prevent damage during parking and retrieval
insightLINK
You can find obtain further product infor-
mation on the Internet at:
www.woehr.de and
www.moevenpick-hotels.com
Automatic car park at Berlins Mvenpick Hotel
LMS 200 laser measurement systems de-
tect projecting car parts
>> Berlins Mvenpick Hotel is located
in the completely built-up area of a for-
mer administration building. Technical
reasons made it impossible to build a
conventional underground car park. On
the other hand, however, the hotel
wanted to be able to offer the maxi-
mum number of beds while allowing ho-
tel guests easy access to their vehi-
cles. Whr found the solution in the in-
ner courtyard or rather below it.
No loss of space through
road access or paths
According to calculations, the space
below the inner courtyard was suffi-
cient for the necessary 22 parking
spaces but only if there were no road
Car park system producer Whr has constructed an automatic car park
for hotel guests below the inner courtyard of Berlins Mvenpick Hotel.
LMS 200 laser measurement systems ensure that projecting vehicle
parts are detected during automatic parking and retrieval to prevent
damage.
access or paths. For this reason the
project was implemented with Whrs
automatic Flurparker 570 (corridor
parker) parking system. It offers
space-saving parking with vehicles be-
ing put on pallets and pushed into the
parking level lengthways or laterally, de-
pending on demand. A vertical convey-
or joins the parking level to the sur-
face.
Safety for vehicles, ease-of-use
for hotel guests
Hotel guests see nothing of the work-
ing behind the Flurparker 570. They
use a parking chip to request an empty
pallet, park the vehicle on it and off it
goes into the depths of the car park. When the vehicle is removed there is
no damage resulting from projecting
parts because LMS 200 laser scan-
ners checked the vehicle contour be-
fore it was accepted by the vertical con-
veyor.
Hotel guests are provided with a
message in clear text if the vehicle is
incorrectly positioned on the pallet, or
an aerial, a wing mirror or a bulky load
exceeds the pallet dimensions. But it is
not just the dialogue with the parking
system that is user-friendly, but the
system itself: on collection, integrated
rotary equipment automatically makes
the vehicle available in the correct di-
rection for driving off!
Berlin is also worth a visit for
its parking technology thanks to the
Flurparker 570 and the LMS units
it employs.
SICK insight 2/2004
Mattress production Swedish shelving system with miniature photoelectric switches 24 Applications
Mini-sensor feeds the feeders
WL 2S handles
auto-filling shelves
>> Whether milk, yoghurt, curd cheese
or fruit juices its just plain annoying
when the shelf is almost empty and
one gets cold fingers from having to
reach right into the back of the fridge to
get an article out. Then some cus-
tomers would prefer to take a better po-
sitioned product from further forward.
But now an economy of scarcity at
the refrigerators is a thing of the past
with the new generation of self-filling
shelves.
Small, light and easy to install
The Swedish conveyor company Easy-
Link AB has developed the new
shelves. Particular emphasis was
placed on a space-saving design, a low
weight, and simple installation in the
refrigerated shelves. The WL 2S mini-
photoelectric switches exhibit the
same preferences. This through-beam
photoelectric switch offers a range of
1,000 mm sufficient for the width of
the shelves. The housings, produced
using extrusion technology, are ultra-
light (only 20 g) as well as ultra-small,
though they detect objects of almost
any size. And they have an enclosure
rating of IP 67 so the sensor has no
problems when the shelves are
cleaned. The WL 2S has its hands full
in the shelves during opening times.
The light beam of the WL 2S is inter-
rupted as soon as a hand reaches out
to remove a package from the shelf. A
roller shelf floor, powered by com-
pressed air, then moves the next pack-
age to the front row after waiting about
5 seconds.
Better presentation of goods,
less time needed
The shelves not only autonomously re-
fill spaces with goods, they also full-
fill the expectations placed upon them
regarding product presentation and
time-savings. Cautious estimates by re-
tailers reckon that about 15 minutes of
Off the shelf, onto the shelf with the auto-filling shelf system from
Easy-Link AB, WL 2S mini-photoelectric switches detect each removal
of goods and immediately initiate the filling process.
Self-filling shelf system
refilling time is saved per day and
shelf. When adjusted for one month,
and with an average total of 16 auto-fill-
ing shelves per store, this adds up to
almost 100 hours.
WL 2S the sturdy solution for activat-
ing the feed process for the feeders.
insightLINK
www.easylink.se
Dream machine
solves nightmare
DT 500 laying
it on the line
for mattresses
>> Small or large pores in foam,
mattress cores in all colours, scan-
ning distances of between 500 mm
and 1,600 mm, and reproducible accu-
racy of just a few millimetres the
DT 500 achieves, with dreamlike relia-
bility, what is a nightmare for other po-
sition sensors.
Eurofoam, in Kremsmnster in Aus-
tria, uses the DT 500 on a machine for
gluing and then stacking foam mat-
tresses. The foam itself has the most
varied of properties, depending on how
a customer wants to make their beds
later. Sensors used in the past caused
considerable problems with inaccurate
mattress positioning in the machine.
The DT 500 does better.
Comfortable positioning
easily achieved
The DT 500 is a distance scanner with
a particularly long range and high accu-
racy. It generates a measurement
value every 250 ms, and transmits it
via a 420 mA analogue output or a se-
rial RS-422 measurement data inter-
face. For mattress positioning this
means: comfortable positioning easily
achieved. First, a mattress surface is
glued onto the mattress core on one
side. Then the machine turns the core.
The DT 500 now ensures that the ro-
tated mattress is correctly positioned
and centred so that the mattress sur-
face can be attached to the other side.
The finished mattresses are then put in
the mattress warehouse tidily
stacked with the help of more position
detection with the DT 500.
www.eurofoam.at and www.euro-foam.com
Further product information on page 39
N
E
W
S
SICK insight 2/2004
GPSG Germanys new device and product safety legislation 25 Standards
In force since 1 May 2004
Device and product safety legislation
(GPSG) clears up uncertainties
insightLINK
Further details on the GPSG are
available at:
www.gpsg.info
or on the home page of the Federal
Ministry for Economics and Employment:
www.bmwa.bund.de or
www.bmwi.de.
Information on the GPSG (device and product safety legislation)
What is the GPSG?
Germanys new Gerte- und Produktsicherheitsgesetz (GPSG) device and
product safety legislation combines the Gertesicherheitsgesetz (device safe-
ty legislation) and the Produktsicherheitsgesetz (product safety legislation),
discards oft-criticised multiple regulation, and implements the EU Product
Safety Directive of 2001 in national law. Business, authorities and, above all,
consumers should profit from the new arrangement. The justification for the
legal text states that: In the context of deregulation and de-bureaucratisa-
tion, the new GPSG is intended to create comprehensive legislation guaran-
teeing health and safety regarding the marketing of technical products.
Much has been included from the old laws, some central aspects are new.
EU legislation: EU Product Safety Directive 2001/95/EG
National law until 30 April 2004:
National law since 1 May 2004:
Device and product safety legislation (GPSG)
Requirement: implementation in national law
Device safety legislation (GSG) Product safety legislation (PSG)
In force since 1 May 2004: Germanys device and product safety legislation
Germanys new Gerte- und Pro-
duktsicherheitsgesetz (GPSG) de-
vice and product safety legislation
came into force on 1 May 2004. It
combines the safety legislation for
products, that was previously con-
tained in the Gertesicherheitsge-
setz (device safety legislation) and
the Produktsicherheitsgesetz
(product safety legislation), and si-
multaneously incorporates the
EUs Product Safety Directive
2001/95/EG in national law.
>> The new GPSG is umbrella legis-
lation incorporating the EU Low Voltage
Directive, the EU Machine Directive and
the EU ATEX Directive, among others; it
is also a catch-all regulation in case
special regulations, such as building
legislation or laws on electromagnetic
compatibility, fail to cover individual
points.
Important changes
The most obvious change affects
the term device that has been re-
placed by the generic term product
which distinguishes between techni-
cal equipment and consumer prod-
ucts. Further modifications affect,
among other things, its range of appli-
cability (which now also includes used
devices or exhibits); the introduction of
traceability for all consumer products;
self-accusation; and CE-designation.
Regarding technical equipment, the
new approach in 4 Clause 1 of the
GPSG has created an evidentiary privi-
lege for manufacturers over the author-
ities increasing security for products
that have been manufactured in com-
pliance with a harmonised standard.
Dr. Werner Jansen (left) spoke to Dirk S. Heyden from SICK insight
SICK insight 2/2004
In conversation with Dr. Werner Jansen, Manager of the BGFEs Prevention Department (Training) 26 Interview
A visit to the Trade Association for Precision Mechanics and Electrical Engineering
Safety at work involves technology,
knowledge and the right attitude
SICK insight: What are the tasks of the
BGFE?
Dr. Jansen: The Trade Associations
have been around since 1885, when
Bismarcks social legislation was intro-
duced. Trade Associations have been
part of the social network since then,
though with some special aspects that
still apply today. Thus companies that
are considered to be in the precision
mechanics and electronics sectors au-
tomatically become members of the
BGFE when they are founded. And they
pay 100% of the contribution, not 50%
as is the case for national pension or
unemployment insurance, for example.
The BGFE uses this money to carry out
its tasks: compensation payments in
cases of industrial illnesses and acci-
dents at work; medical, professional
and social rehabilitation; accident pre-
vention in companies in the form of in-
spections by technical supervisory
staff; providing safety advice on plants
in operation and new product develop-
ments; as well as the implementation
of comprehensive preventive meas-
ures. The BGFE is now responsible for
almost 100,000 member firms with
about 2.2 million insured personnel.
SICK insight: Training is a fundamental
part of your preventative work. Who are
your courses intended for?
Dr. Jansen: A short historical excursion
would help answer this question. Peo-
ple were already thinking about preven-
tion in the 20s. But they were given a
decisive boost in the late 50s and ear-
ly 60s when strong economic growth
unfortunately led to a sharp increase in
accidents at work. And the safety at
work legislation introduced in 1974
created an enormous need for training.
The BGFE soon recognised that safety
was more than just technology. Sen-
sors and barriers alone do not make
machines safe whats needed is a
lively belief in safety in the form of atti-
tude, behaviour, organisation and lead-
ership. This is why the Safety at Work
Centre here at the Berghof in Bad
Mnstereifel, which was opened in
1962, was deliberately set up as a
training centre at that time the first of
its type in Germany. The express aim of
this organisation was not merely to
pass on technical knowledge, but to
highlight and propagate safety-oriented
behaviour and safer organisation.
These ideas are best put over in the
factories, by training multipliers
throughout the hierarchy to create safe-
ty specialists who are also prepared to
make use of this material and take re-
sponsibility. And it is precisely these
people for whom the courses are in-
tended: persons on a variety of levels
with a range of different functions who
are capable of raising safety levels in
the factory.
SICK insight: With about 100,000
member firms you must have quite
a lot to do
Dr. Jansen: Without doubt. BGFE train-
ing centres in other words, the
Berghof and the other meeting places
and academies in Linowsee, Dresden
and Oberaichen near Stuttgart organ-
ise about 1,000 seminars, workshops
and such like every year, attended by
approximately 16,000 participants.
Last year we welcomed our 250,000th
participant to the Berghof. Though it
must be noted that it is mainly the larg-
er companies that send employees to
the BGFE, while participants from the
85,000 small and medium-sized com-
panies are clearly under-represented.
This may have something to do with the
amount of work that potential partici-
pants face, though it is certainly not
because of the costs involved: the
seminars are free-of-charge and in-
Whether switches or safety fencing, light curtains or laser scanners
components alone do not make machines safer. Specialist knowledge
and the right attitude towards safety are just as important. Getting this
interrelationship across is one of the tasks of the Berufsgenossenschaft
der Feinmechanik und Elektrotechnik (BGFE), the German Trade Asso-
ciation for Precision Mechanics and Electrical Engineering. SICK insight
spoke with Dr. Werner Jansen, Manager of the BGFEs Prevention
Department (Training).
SICK insight 2/2004
27 Interview
clude board and lodging, i.e. the costs
are covered by the membership fees.
And the BGFE also pays for the travel-
ling costs.
SICK insight: 1,000 seminars, more
than 16,000 participants this all re-
quires a lot of organisation. But how do
you organise the trainers and spe-
cialists necessary for the wide range of
topics studied they dont grow on the
trees in front of the Berghof, do they?
Dr. Jansen: Youre right there even
with a lot of shaking weve never har-
vested any. To be serious our pool of
about 350 trainers comes from many
sources. First of all, the BGFE has a to-
tal of 20 full-time teachers distributed
among the various training sites. Then
there are also about 80 technical su-
pervisory staff who make regular visits
to the works and are very well aware of
the real situation in practice. Lawyers
from the main administration in
Cologne and some of the BGFEs local
administrations explain topics that in-
volve the legal situation and the conse-
quences of safety at work regulations.
But most of our work is achieved with
external experts from other Trade As-
sociations, from universities, from offi-
cial factory inspection authorities and
particularly from companies. SICK also
offers a seminar that has been suc-
cessfully run by your Mr Grnemann for
many years now.
SICK insight: How significant for the
BGFE is co-operation with the industry?
Dr. Jansen: Co-operation with the in-
dustry not only ensures that our teach-
ing content is heavily practice-related,
but is also important for the BGFE be-
cause our specialists are kept up-to-
date in technological terms by the early
consideration of new product develop-
ments. This is particularly important
because safety technology is increas-
ingly becoming more software-oriented.
Electronics is increasingly taking over
safety functions whose examination
and assessment requires correspon-
ding specialist knowledge. One can see
at a glance whether a protective door is
open or not but whether a particular
software activates measure X in case Y
requires a more intensive inspection.
Only well-founded specialist knowledge
is of any assistance when there are al-
so safety-relevant, complex communi-
cation structures in machines and
plants.
SICK insight: What status do the new
media have for the BGFEs work?
Dr. Jansen: When I look back over my
more than twenty years with the BGFE I
can see that we have developed from a
regulatory body to a modern service-
provider not least as a result of the
new media which we actively exploit.
This starts with the intensive use of
our Seminar Database on the Internet.
Well over half our participants register
for courses online. Information of al-
most any type can be downloaded at
the click of a mouse. A newsletter for
subscribers is in development and will
hopefully be available soon. Twelve
times a year we offer the Topic of the
month on our home page and thus
achieve greater topicality. And, of
course, new media have created ad-
vances in the seminars themselves.
The latest computer and presentation
technologies ensure that our trainers
really do get their knowledge across.
SICK insight: One last question: Is the
co-operative approach of the BGFE still
in keeping with the times and fit for the
future?
Dr. Jansen: One only has to look
around at the economic landscape to
see that not every change is beneficial.
In my opinion, this would also be the
case if, as is often brought up in con-
versation, the Trade Associations were
privatised. The solidarity principle
would be replaced by a kind of efficien-
cy principle. I dont have anything at all
against efficiency, quite the opposite in
fact. But safety cannot be reduced to a
money matter, i.e. seminars must still
be offered even if they do not seem to
add up commercially at first glance. Or
what would happen to the small Trade
Associations or those that are in finan-
cial difficulties as a result of the eco-
nomic situation in their sector, e.g. in
building or mining? How would the soli-
darity adjustment currently in use be
handled then? I think that the consider-
ations that have so far taken place are
half-baked because ultimately they fail
to ensure the safety of those we insure
at the workplace precisely because
safe machines cannot be achieved with
technology alone, and the passing on
of safety competence in a variety of
forms is still vital.
SICK insight: At least one thing is cer-
tain, Dr. Jansen: the idyllic location of
your Berghof training centre. Thank
you very much for this conversation.
insightLINK
Further Information on the Internet at:
www.bgfe.de
The 2003 Annual Report is available. It
offers detailed information on the work
of the Berufsgenossenschaft der Fein-
mechanik und Elektrotechnik (the Ger-
man Trade Association for Precision Me-
chanics and Electrical Engineering). The
report provides up-to-date statistics on
accidents, companies and insured mem-
bers. It shows how contributions are de-
veloping and provides information on
compensation, prevention, treatment and
professional assistance. The Annual Re-
port is automatically sent in printed form
to companies with more than 21 insured
members. The Annual Report can be
downloaded from the Internet as a .PDF
version in the Statistics section.
The Berghof , the Bad Mnstereifel
house for safety at work
Co-operation with the industry [...]

is also important for the BGFE be-
cause our specialists are kept up-to-
date in technological terms by the
early consideration of new product
developments.
+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+
SICK insight 2/2004
28 Products
Fewer cables, lower costs: with sensor connection boxes
Ready-made simplification of field wiring
The costs of wiring sensors and actuators in machine
and plant construction represent a not inconsider-
able component in terms of time and money. SICK of-
fers sensor connection boxes for direct field use to
provide customers with simple installation in com-
pact, robust and proven module technology.
>> These connection boxes allow optimum adaptation of
your wiring to the particular machine and plant periphery.
Robust and versatile
The sensor connection boxes are characterised, among oth-
er things, by their high enclosure rating of IP 67, compact de-
signs with cast plastic housings, and high levels of immunity
to impacts and vibrations, as well as withstanding chemical
and electrical loads. Interference-free operation is ensured
by high-quality, gilt-edged contacts; threaded metal connec-
tions; and halogen-free PUR connection cables. SICK offers a
wide variety of these sensor connection boxes to adapt to the
machine and plant periphery. According to the application,
SICK offers 4-plug or 8-plug M12 boxes with 2 signals per
slot. The connection of these boxes can be carried out via di-
rectly connected halogen-free PUR cables in 5 m and 10 m
lengths, or can be achieved using an M23 central plug. The
sensors and actuators can be connected with tried-and-test-
ed M12/M8 connection cables from SICKs range of connec-
tion systems, available with lengths of 0.6 m and 2 m.
Use in wet areas in the food industry
SICK also offers all the advantages of proven connection
technology for wet areas in the food industry. Connection
boxes specially designed for this environment are available
in high-quality V4A stainless steel with an enclosure rating of
IP 69K. The cables between the connection box and the sen-
sors have been adapted appropriately.
SICK sensor connection boxes practical connection sol-
utions for installation and maintenance.
With its own GSD file
The MLG light grid the new Profibus bus stop
SICK is presenting the new MLG Profibus light grid
for the first time at SPS/IPC/DRIVES. Its special fea-
ture? The bus node is entirely accommodated within
the sensor housing.
>> Doing without the otherwise usual external gateway
makes the cost of driving the Profibus particularly reason-
able, as the integrated bus connection saves about 200.
Rapidly ready for action
Users need not wait long for departure on the MLG
Profibus. The universal GSD file ensures speedy system
settings. The MLG Profibus has its
own PNO number for logging-in the new
bus traffic at the machine control
system. The corresponding GSD file,
that allows the PLC to interpret the
sensors signals, can be downloaded
at www.profibus.com. All in all, the
MLG Profibus is thus ready for action
with just a few mouse-clicks. When
required, all configuration parameters
can be transmitted to a new light grid
via Profibus.
Object detection by means of parallel beams
The MLG light grid is the right automation solution whenever
single-beam sensors do not offer the desired reliability. The
number of beams and their separation from one another, i.e.
the resolution of the MLG, can be assigned task-specifically
as can the range of the system. Typical areas of use are
height measurement, the detection of lying parts or objects
that fall through the light grid, monitoring web slack, or the
detection of holes and cracks.
Those seeking a professional detection and data transmis-
sion solution would do well to choose the MLG Profibus.
S
P
O
T
L
I
G
H
T
+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++
SICK insight 2/2004
29 Products
Magnetic cylinder sensor with ATEX approval
T-slot talent MZT 6
defies explosion potential
Ignitable gases or non-conductive dusts in the oper-
ating environment are just the right environment for
the new MZT 6 with ATEX approval.
>> Right from the start, the MZT 6 proved itself as the mag-
netic cylinder sensor for detecting the position of pistons in
pneumatic cylinders. The reasons: very user-friendly, im-
mune to vibrations, and with high switching accuracy. And
from now on secure fixing and reliable function (to sum-
marise the experience of many users of the T-slot talent) is
also possible in the Ex-Zone.
Give ground
is what many standard devices have had to do, as they do
not conform to the ATEX directive. In almost all cylinder T-
slots their place is increasingly being taken by the MZT 6
ATEX. It is approved for Ex-Zone 22, Category 3D/3G, among
others. The sensor is not just gaining ground, but often of-
fers users better and more reliable switching behaviour than
before. This has been made possible by a specially adapted
mounting technology, whereby the sensor is first inserted
from above saving time. Then the MZT 6 is pressed onto
the bottom of the pneumatic cylinder slot over its entire
length during fixing. Standard tools are sufficient to carry
out rapid and firm screwing of the slotted head or Allen
screw into the metal cylinder liner and the sensor cannot
be ripped out.
Excellent against potential explosions the new MZT 6 ATEX.
INFO 212
Growth capacity for capacitive sensors
CM family has no succession worries
SICK has extended its family of capacitive sensors
with further sensor variants. The CM 30 is now avail-
able in a 2-wire design for an operating voltage of
250 V AC.
>> Increased switching distances of up to 25 mm and op-
tions for flush or non-flush installation characterise capaci-
tive sensors from SICK the new CM 30 AC too. Moreover,
all capacitive sensors share a special highlight: their high
level of electromagnetic compatibility. This reliably prevents
spurious switching caused by, for example, electrostatically
charged granulate in bulk material silos, mobile telephones
and radio devices, or from interfering voltages brought about
by magnetic valves, relays or frequency converters.
CM 18 PTFE: a tough guy with fine discrimination
Capacitive sensors are mainly used in applications for which
optoelectronic sensors are unsuitable because of the high
risk of contamination, for example. Now the CM 18 PTFE
goes one step further: the use of PTFE (Polytetrafluoroethyl-
ene, also known as Teflon) for the housing and the M18
threaded connections allows the sensor to check the filling
levels of aggressive media, e.g. hydrochloric acid, sulphuric
acid, phosphoric acid, a variety of alkalis, and numerous
solvents. The same applies for object detection in
environments in which these materials can be present
as gases, steams or vapours. It is also suitable wherever
plants require frequent cleaning with chemicals or at high
temperatures. INFO 213
See page 17 for an application report.
S
P
O
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L
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H
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SICK insight 2/2004
The UE 440 and UE 470 safety controllers 30 Products
UE 440/470 safety controllers
Flexible, compact and reliable
>> While safety PLC and open fieldbus
systems are becoming increasingly
dominant in larger, complex production
sites, simple applications are still best
solved with safety relays. The UE 440
safety controller the device for com-
plex protective applications, and the
UE 470 the variant specifically de-
signed for presses and rotary attach-
ments, with integrated single-break,
double-break and protective functions
are positioned precisely between the
two. Among other features, they offer
15 single-channel inputs, of which six
can be connected as two-channel in-
puts. There are also two safe connec-
tions (Cat. 4, SIL 3) for electro-sensi-
Freely programmable Intelliface UE 440/470 safety controllers are the
right choice for smaller to medium-sized machines with significant safe-
ty requirements. They fill the technological gap between safety relays
that require complicated wiring and the safety PLC, whose cost-benefit
ratio is unfavourable in this machine segment.
tive protective equipment from SICK
with internal device interfaces. Eight
output pairs, of which two are safe out-
put pairs, allow individual control of
downstream plant components.
The compact alternative
UE 440/470 interfaces are charac-
terised by low engineering and initial
costs per input and output, lower wiring
costs, and optimum user-friendliness
during operation, troubleshooting or
when making modifications. The con-
trol systems, accommodated in com-
pact housings, also convince with their
customer-specific parameterisation
and Category 4 compliance with
EN 954-1 and SIL 3 according to
EN 61508. In combination with electro-
sensitive protective equipment from
SICK, UE 440/470 interfaces not only
cover a wide range of safety functions
such as Emergency Stop, Restart, or
the monitoring of protective doors
there are also interesting expanded
functions for users.
Intelligent configuration memory
Pre-configured ready-to-use C 4000
light curtains often contain a lot of ex-
pertise in the form of parameterisation
or operating-mode-specific settings
such as blanked protective field areas.
UE 440/470 interfaces also ensure
that these are not lost if a sensor is re-
placed. Of course, they autonomously
detect the new light curtains and auto-
matically configure it with the data of
the original device retained in the con-
figuration memory.
Thus UE 440/470 interfaces are
the safe choice whenever flexibility and
relay technology wiring costs are limit-
ing factors, and use of a safety PLC
would be unwarranted.
insightLINK
INFO 214
Protecting hazardous areas and access with the UE 440
When greater safety is required:
the UE 440 safety controller
SICK insight 2/2004
The W 190L series of laser photoelectric switches 31 Products
New W 190L series of laser photoelectric switches
Specialists for standard
and special applications
Externally uniform, but internally with differing laser technology adapted
for meeting application requirements this is the new W 190L. The
Standard series of this sensor family is designed for uncritical appli-
cations. The W 190L High Grade series is intended for demanding appli-
cations and provides maximum accuracy and resolution.
Numerous features in common
As distinctive as the interiors of the individual W 190L sensors can be, they
are all similar on the outside. All sensors have a red-light laser in Protection
Class 2. As a result, the sensors can be rapidly and accurately aligned on tar-
get objects. The rotatable M8 plug or the 2 m cable are just as much device
standards as the yellow and green LED display, providing practical assistance
during commissioning and operation. The uniform compact plastic housing
made of ABS allows use of the devices even under difficult conditions.
>> All the sensors have a red-light
laser in Protection Class 2, so they can
be rapidly and accurately aligned on
the target object.
For standard use
The W 190L Standard series is a com-
plete family of photoelectric switches
consisting of through-beam and reflex
photoelectric switches as well as prox-
imity switches with adjustable back-
ground suppression. They are reliable,
user-friendly and economical sensors,
whose basic features and functions are
designed for solving conventional appli-
cations.
High Grade: individually optimised
for demanding applications
Specialisation is trumps with the
W 190 Laser High Grade series. Thus,
the CMOS technology of the WTB 190TL
scanner offers a very high resolution.
This permits reliable detection of ob-
jects with highly reflective surfaces,
such as foils. With appropriate pro-
gramming, the scanner can operate
with a choice of background or fore-
ground suppression. The WLG 190T
glass photoelectric switch is designed
for the reliable detection of transparent
objects. Whether glass bottles or flat
objects, such as discs; whether thin-
walled PET plastics or transparent foils
the WLG 190T makes even the al-
most invisible visible. Both sensors of-
fer teach-in programming at the touch
of a button or externally via the control
cable. This allows simple definition of
scanning distances and ranges. Menu
navigation takes place on an easily vis-
ible numerical display via which, for ex-
ample, the type of switching can be
programmed and, if necessary, a time
delay activated.
insightLINK
INFO 215
The W 190L series consists of Standard and High-grade laser sensors for demand-
ing applications
SICK insight 2/2004
The programmable IVC-2D smart camera 32 Products
>> Vision solutions for factory au-
tomation: the introduction of the
IVC-2D marks a breakthrough in high-
tech image-processing technology for
factory automation. This camera com-
bines the latest technology with a high-
ly flexible and powerful library of image
evaluation programs. Quality inspec-
tions on assembly lines, robot guid-
ance, or checking labels on packaging
are just a few of the examples of the
wide variety of application possibilities
of the IVC-2D in industrial environ-
ments.
A tool for experts
The IVC-2D offers image-processing
users a wide range of possibilities.
These include approximately 100 soft-
ware tools from the program library,
with which the most varied of two-di-
With its integration of the Swedish image-processing experts IVP last
year, SICK has taken a further step in expanding its leading techno-
logical position in the area of factory automation. The first result of
this combination of competence in sensor technology and specialist
know-how in image processing is the new 2-D IVC-2D Industrial Vision
Camera, which was presented to interested users at the international
VISION trade fair in Stuttgart in October.
mensional tasks can be solved.
Shapes, geometries, sizes or designs
users can make very detailed adjust-
ments of the camera via the graphic
programming interface to meet the re-
quirements of their object detection.
The solution is exclusively oriented on
the function of the machine without
any compromises and thus without im-
pairing its performance potential. Dif-
insightLINK
INFO 216
Excellent co-operation the latest joint
development with the new SICK IVP
logo: the programmable IVC-2D
smart camera
The smart-
camera IVC-2D
Setting its sights on the future
SICK IVP the new brand in
image processing
fering pixel resolutions, a shutter for re-
ducing the effect of ambient light, in-
dustrial housing and connection
technology, and immunity to impacts
and vibrations guarantee the smart
camera a high level of availability in in-
dustrial environments.
Fieldbus-enabled with
Fast Ethernet
In addition to three freely programma-
ble switching outputs, the IVC-2D offers
a Fast Ethernet connection for rapid
and uncomplicated construction of a
communication network for transferring
data and parameters to the machine
control system. This also removes any
communication restrictions on its use.
SICK IVP: from vision sensors for
standard applications and optimally
programmable solutions to complex
camera systems it is needs-oriented
image processing that counts.
SICK insight 2/2004
The IN 4000 inductive safety system 33 Products
Sensor can be connected directly to safe PLC
The IN 4000 safety system
switches on metal
Friction-free, immune to vibrations, easy to install and unaffected by dirt
the new inductive IN 4000 safety system fulfils all the requirements
for the reliable monitoring of position or protective gates in harsh indus-
trial environments. A further highlight: the sensor of the IN 4000 can al-
so be connected directly to a safe PLC.
>> The basic version of the IN 4000
consists of an inductive sensor in a cu-
bic housing for switching distances of
10 to 15 mm, and a relay evaluation
unit. The entire system, as well as
each of the two individual components,
is certified for Category 4 in compli-
ance with EN 954-1, making individual
safety solutions possible.
The direct solution
If the control system of the machine or
plant to be protected is based on a
safe PLC, the IN 4000 sensor can be
operated directly. This is possible be-
cause the sensors input and output
signals are designed to correspond to
EN 61131-2 and are thus compatible
with the I/O signals of a safe PLC. Con-
trol Category 4 according to EN 954-1
is maintained even if the maximum
number of 10 sensors is connected in
series.
The relay solution
If there is no safe PLC available, the
sensor can be connected to the
IN 4000 evaluation unit with relay out-
puts. Here, too, connection of up to ten
sensors is possible leading to con-
siderable cost savings, particularly in
the case of complex machines or
plants. Three safety-relevant N.O. con-
tacts, two N.C. contacts, and integrat-
ed external device monitoring also
allow flexible integration in the particu-
lar machine controller.
Monitoring the switching area
prevents tampering
The sensors inductive operating princi-
ple means that no separately coded ac-
tuator is required, i.e. the sensor
detects the presence or absence of
metal directly. In order to meet the re-
quirement to prevent simple tamper-
ing, the switching area of the sensor is
monitored in terms of both time and
space. Unauthorised alterations are
detected and lead to the machine be-
ing safely switched off.
The design of the IN 4000 inductive
safety system thus offers completely
new approaches to the safe monitoring
of position and protective gates on ma-
chines and plants.
The basis version of the IN 4000: relay
evaluation unit and inductive sensor
insightLINK
INFO 217
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SICK insight 2/2004
New contrast scanners The IT 3810 hand-held scanner 34 Products
Good and reasonably priced
The IT 3810 hand-held
scanner: bar codes in focus
The IT 3810 hand-held scanner has been designed as a good, reasonably
priced solution for reading bar codes on documents and low-volume
goods. Its reading performance and simple operation is good, its high re-
liability and low cost make it reasonably priced, too.
>> As a basic model lacking no techno-
logical necessities, the IT 3810 rounds
out the successful IT 3800 series, of
which more than 1,000,000 have been
sold. The linear image-capture module
generates a clear scanning line on the
bar code and reads it at the usual
counter distance of between about
100 mm and 150 mm. Thanks to menu
options and quick-start instructions,
the IT 3810 is easily and quickly pre-
pared for operation. A variety of inter-
faces, including a keyboard wedge,
RS-232 or USB permit connection to
mobile terminals as well as stationary
computer systems.
Robust and user-friendly
Typical areas of use for the IT 3810 are
fixed and mobile workplaces, at which
the bar codes on documents, packag-
ing or storage spaces (as in invento-
ries) require detection. The robust and
shockproof device design ensures ex-
traordinary availability; the ergonomic
handle, low weight and simple target-
ing of the bar codes provide a high lev-
el of user-friendliness.
Deal yourself a good hand with the
bar-code reading advantages of the
IT 3810.
insightLINK
INFO 219
Poster for hand-held scanners provides overview
Have you got a good grasp of scanning?
With or without cable? Radio: yes or no? Bar code or 2-D? Range? Wall-mount-
ed receptacle or belt attachment? USB, RS-232 or both? Who can keep a
grasp on the scanning possibilities? Become a scanner-grasper with
SICKs new hand-held scanner poster.
Theoretically, SICKs hand-held scanner family and accessories offer well over
200 potential configurations. Request the scanner poster and any confusion
will be brought to an end with a practised grasp of scanners you will imme-
diately be able to identify your mobile bar-code or 2-D reader.
To receive your poster use the attached card under: INFO 220
Know the devices scan with the right one!
The IT 3810 hand-held scanner
The KT 3 Laser compact
contrast scanner
Highly reliable
detection of small
objects
>> The new KT 3 Laser is intended
to be a contrast to other scanners.
Maximum scanning distances and
minimum light spot both features of
the new KT 3 Laser allow no con-
trasts to escape detection, whether
cracks in glass, grooves in metal,
or printed marks.
Moreover the sensor, in its minia-
ture housing, is easily installed even if
space is limited.
A real giant in performance
In terms of device properties, the
dwarf in SICKs family of contrast scan-
ners is actually a giant. 20 to 60 mm
range with a light spot of only 2 mm
2
at
a scanning distance of 40 mm, large
detection reserves with changing ob-
ject distances, switching frequencies
of 1.5 kHz, and an enclosure rating of
IP 67 are features that ensure high de-
tection reliability in a wide variety of ap-
plications. Then there is the rapid com-
missioning of the KT 3L resulting from
static teach-in on the mark and the
background a process that can be
carried out either on the control panel
of the device or via the control cable. If
the target object is highly reflective, au-
tomatic adaptation of the switching
threshold guarantees reliable detec-
tion.
Thus the KT 3L is dazzlingly pre-
pared for e.g. the detection of cracks
in glass and narrow grooves on metal-
lic surfaces, as well as the detection
and precise positioning of small marks
and labels. INFO 218
SICK insight 2/2004
NEW: The DKS 40 incremental encoder Ultrasonic sensors 35 Products
Predestined for monitoring the rotation of
rollers, cylinders and axles
The DKS 40 incremental
encoder the compact and
robust cost-cutter
>> Given its application and price seg-
ment, the DKS 40 offers unaccus-
tomed quality. Its housing consists of
solid die-cast zinc and is also extreme-
ly compact with a diameter of 50 mm
and a height of 42 mm. The user thus
saves on valuable installation space.
The DKS 40 is extremely robust
against impacts and vibrations as a re-
sult of using the highly successful mini-
disc technology. Whether in a tooling,
textile, packaging or timber processing
machine conditions can be tough and
space limited.
The DKS 40 is available with
a face-mount flange and 8 mm solid
shaft. The device offers all common
line numbers up to 1,024 per revolu-
tion. There is a choice of electrical
interface between Open Collector,
TTL/RS-422 and HTL/push-pull. The
connection cable is positioned in such
a way that it is possible to lay the cable
downin a radial or axial direction with-
out any excessive bending. With this
flexibility, the DKS 40 sets a new stan-
dard in its class.
Robust, compact, reasonably priced,
flexible and rapidly available for use
the new star from SICK-STEGMANN can
be seen at SPS/IPC/DRIVES.
insightLINK
INFO 221
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Users are increasingly demanding encoders for standard applications,
such as monitoring the rotation of rollers, cylinders and other axles, in a
robust but nevertheless reasonably priced design. The new DKS 40 was
specially developed for these applications. It is not only the compact de-
sign and robustness that attracts attention, but also the fact that
its extremely attractive price makes it a genuine cost-cutter.
New ultrasonic sensors
UM 18 when
space is limited
>> SICK presents the new UM 18 ul-
trasonic sensor, specially designed for
applications with limited space. The
device, in robust M18 fine-thread
housings, is available in two variants
Standard and High End.
The detection of transparent ob-
jects (e.g. PET bottles) or checking
liquid levels in test tubes are just two
of the many applications for the new
UM 18. Both device variants offer an
operating scanning distance of be-
tween 30 mm and 250 mm, as well as
teach-in and switching threshold pro-
gramming via the control cable.
The Standard UM 18 is best suited
for those for whom a single switching
output is sufficient. The High End
version is available for those who
require more.
More functions and additional
switching reliability
Externally, the UM 18 High End is dis-
tinguished by the two function LEDs
and the two switching outputs. Inter-
nally, an integrated temperature com-
pensation system ensures that the
sensors detection accuracy and relia-
bility remain constant despite changes
in ambient temperature during opera-
tion. The possibility of background
teach-in is a real highlight. Critical ob-
jects can thus be detected with partic-
ular reliability, as it is not their often un-
defined sonic reflectivity but the inter-
ruption of the taught-in background
sound reflections that leads to a
response from the UM 18.
The UM 18 ultrasonic sensor
reliable switching made easy. INFO 222
SICK insight 2/2004
The new V 4000 Press Brake Category 4 camera sensor 36 Products
Reliable image processing on press brakes
The V 4000 Press Brake optimises
safety and processes
>> Conventional systems for safe-
guarding the hazardous closing move-
ment on sinking brake presses consist
of simple optoelectronic sensors and
receivers and are mounted on the top
clamping bar and thus move with it.
While they detect any hazardous reach-
ing into the protective field, they have
serious disadvantages for machine
productivity.
The V 4000 Press Brake offers
visionary use
The new V 4000 Press Brake corre-
sponds to Category 4 in compliance
with EN 954-1 and SIL 3 according to
EN 61508 and thus offers maximum
safety. Machine vision, i.e. image pro-
The new V 4000 Press Brake Category 4 camera sensor offers both
maximum safety at work and maximum optimisation of folding process-
es. This has been made possible by programming a safety field whose
evaluation can do more than just monitor a light path.
cessing, is the technological approach
upon which this electro-sensitive pro-
tective equipment is based. A two-di-
mensional safety field, co-ordinated
with the particular bending process, is
active during the downward motion of
the die. The height of this field de-
creases continuously as the bending
die, on which the V 4000 Press Brake
is installed, approaches the die plate.
This offers a variety of advantages:
thick sheet metal, bent metal shapes,
and thin plate with side walls are sub-
ject to differing protection modes ac-
cording to the various bending tasks:
Standard for simple one-dimensional
bending, Box for bending multi-di-
mensional objects such as boxes, and
Limit stop to take into account limit
stops tight on the object to be bent.
The system is exceptionally easy to in-
tegrate into the press constructors
machine control system. In this way
the safety equipment can be switched
to the optimum protective mode via se-
lection of the bending program. The
machine can thus activate the different
protection modes appropriate for the
bending techniques, one after another
and as often as required, for the same
object, e.g. first Standard, then
Box for a high box side, and finally
Limit stop for the low part of a side.
Now possible: folding without an
intermediate break
The features and opportunities of the
V 4000 Press Brake provide a very im-
portant advantage for the actual bend-
ing process. Unlike with conventional
systems, the downward movement of
the press bar must no longer be
SICK insight 2/2004
The KT 5 contrast scanner (with) display 37 Products
Bar display for easier use
The KT 5 contrast scanner dis-
play: a straight back for com-
fortable use
>> Teach-in and tuning a maximum of
two steps to get the contrast scanner
ready for use. First, the bar display of
the KT 5 Display supports the user dur-
ing teach-in, when the sensor is taught
the mark and its background, whereby
the sensor activates the optimum
transmission colour of the three-colour
LED according to the contrast. If, in in-
dividual cases, even more accurate
fine adjustment is necessary, the dis-
play permits pixel-precise fine adjust-
ment of the current signal level via a
tuning button.
Its all a question of adjustment
So users can now check the current
signal level in combination with the cur-
rent switching threshold, as well as as-
sessing detection accuracy and, if
necessary, carry out a manual adapta-
tion of the switching threshold. Thus if,
for example, the appearance of a label
Those who desire maximum ease of use from their contrast scanners
should select the new KT 5 Display. Why? The new bar display on the
back of the sensor housing now makes teach-in and fine adjustment par-
ticularly easy.
changes (leading to altered grey values
of marks, and the background or reflec-
tivity), the KT 5 Display can now be eas-
ily re-adjusted during operation.
Performance features that
re-define the device standard
The new KT 5 Display has several per-
formance features upon which users
place particular value. In addition to
the three-colour LED technology and
the proven 2-point teach-in, these in-
clude a switching frequency of 10 kHz
and automatic adaptation of switching
thresholds with highly reflective materi-
als. Individual alignment and attach-
ment possibilities cover a wide variety
of mounting situations and ensure both
the electrical and mechanical compati-
bility of the KT 5 Standard.
A winner without drawbacks the KT 5
Display with the new informative back.
INFO 224
Bildtext
insightLINK
Weitere Infos erhalten Sie mit der
Karte am Ende des Magazins unter:
INFO 200
oder im Internet unter:
www.sick.de/insight
insightLINK
INFO 223
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stopped just before folding, with a new
approach then being made using a foot
switch. The savings in cycle time that
this brings about increase machine ca-
pacity and thus economic
efficiency.
Setting new standards in practice
The intelligent image processing of the
V 4000 Press Brake also sets new
standards regarding commissioning
and availability. Vibrations typical for
presses do not trigger any system re-
sponse because the entire camera
field, within which the safety-monitored
area is programmed, is intelligently
evaluated. The monitored area of the
safe camera sensor tracks even small
changes in alignment. This immunity to
any misalignment also makes adjust-
ment during first commissioning, and
after a change of tools, simpler and
quicker than with other passenger
systems.
The very simple integration in exist-
ing control systems is also remarkable,
as the V 4000 Press Brake operates
with the signals that are anyway used
on press brakes.
The V 4000 Press Brake press pro-
tection that offer users and integrators
a real technological lead.
Maximum optimisation of bending
processes and maximum operating
safety with the V 4000 Press Brake
camera sensor
The bar display informs the user about the detection reliability of the taught-in contrast
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Automatic counting of persons at
airports, shopping malls or stadiums
LD PeCo enables more
efficient safety strategies
With 11 or 16 beams in a com-
pact housing
The ELG 1 short
range the rea-
sonably priced au-
tomation light grid
>> Simple installation and robustness
during operation characterise SICKs
automation light grid. With a range of
up to 3 m, the ELG 1 is the ideal solu-
tion, e.g. for regulating throughput,
checking and positioning pallets, de-
tecting objects on overhead conveyors,
or counting parts.
Those who know how difficult it is
to create ones own light grid from
large numbers of individual sensors
appreciate the advantages of the new
ELG short range. No more misalign-
ment and there is no longer a mess of
cables between the sensors and the
control system the ELG 1 eliminates
many disadvantages that are almost
impossible to avoid with multi-beam
detection solutions involving individual
sensors.
Optical synchronisation, optimum
object detection
ELG 1 options are avail-
able with a monitoring
height of 150 mm with
16 light beams, or a
monitoring height of
100 mm with 11 light
beams. Senders and
receivers are optically
synchronised thus
there is no need for the
otherwise necessary
cable. A detection field
with beam separations
of 10 mm is generated
between the sender
and the receiver hous-
ings. This fine resolu-
tion allows even small
parts to be detected.
Furthermore, it is even
possible to detect flat
objects with the help of
cross-beam evaluation.
The ELG 1 its
better to install a single
device than improvise
with lots of sensors.
INFO 225
LD PeCo is a new type of long-range system for counting persons and de-
termining the direction in which they are moving. Whether children or
adults, individuals or entire groups the non-contact measurement sys-
tem reliably detects how many people there are, where they are, and in
what direction they are moving.
>> The system is particularly suitable
for counting people in large buildings,
e.g. at airports, shopping centres or
stadiums, as it detects the direction of
movement and can monitor path
widths of up to 26 m. In this way the
LD PeCo can, among other things, de-
termine the best place for advertising,
control air conditioning, or provide im-
portant information for security and
rescue measures in an emergency.
Detection by means of invisible
light curtains
The LD PeCo is an actively scanning,
highly precise laser measurement sys-
tem, whose scanner emits two invisi-
ble, fan-shaped, parallel light pulses
and measures the time until reception
of their reflections. Regardless of the
size and geometry of a space, room or
passage, LD PeCo can be adapted to
take any spatial structure into account,
e.g. supporting pillars or electronic
goods security portals. The time-of-
flight of the transmitted light pulses
changes as soon as someone walks
through the light curtains, and the per-
son is counted. When several people,
even of different sizes, cross the moni-
tored area, they are also reliably de-
tected and counted. Simultaneously,
the LD PeCo detects which of the two
light curtains is interrupted first and
calculates the direction the persons
are moving in. This quantity and direc-
tional information can be transmitted
to, for example, the central building
control system via RS-232, RS-422 or
two digital switching outputs.
SICK insight 2/2004
The ELG 1 light grid The LD People Counter laser measurement system 38 Products
The LD PeCo provides reliable results even in dense crowds
insightLINK
Can be installed almost anywhere
The maintenance-free LD PeCo offers
almost no restrictions regarding instal-
lation. The system can be installed out-
side the aisles or beyond any possible
access, thus protecting it against dam-
age or tampering. People can be reli-
ably counted, even in high arcades in
shopping malls, or in arrival and depar-
ture halls at airports, thanks to a
mounting height of up to 15 m. Unlike
cameras, the LD PeCo operates inde-
pendently of the light conditions and is
effectively protected against strong
light or targeted dazzling.
The LD PeCo the detection solution
that meets numerous requirements in
building management.
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SICK insight 2/2004
DT 500/DS 500 distance sensors 39 Products
>> Numerous users are not distancing
themselves from the DT 500 and
DS 500 distance scanners on the
contrary. Since it was initially intro-
duced at the Hanover Industrial Trade
Fair 2004 the devices have enjoyed
ever-increasing popularity.
This is particularly the case in ap-
plications such as collision prevention
for cranes, distancing for transported
objects, or measuring the heights of
stacks. The sensors have proved them-
selves everywhere as a result of their
high accuracy even with pitch-black
surfaces.
Analogue or digital a choice but
no dilemma
While the DS 500 has two switching
outputs that can be displayed, the
DT 500 offers a choice between a
420 mA analogue output and a serial
RS-422 measurement data interface.
The start and end of the measurement
range is freely programmable via the
control and display field thus the
DT 500 can be ideally adapted to the
particular task involved.
3 mm greater inaccuracy
is not possible
The range of 18 m on a black back-
ground with an accuracy of 3 mm pos-
sible as a result of the minimised tem-
perature drift of just 0.05 mm/K
leaves nothing to be desired in terms of
detection accuracy. At the same time
(the devices provide a measurement
value every 250 ms), they also exhibit
extremely precise background suppres-
sion even if the background material
has a light surface. During develop-
ment, however, care was not only taken
to ensure precision but also user-friend-
liness: an integrated display allows sim-
ple setting of measurement ranges and
switching thresholds, as well as dis-
playing the current system function.
Better by a long chalk this is the
view of users convinced by the perform-
ance of the new DT 500 and DS 500
distance sensors.
Even suitable for black surfaces DT 500 and DS 500 distance scanners
The LD PeCo
Black is beautiful!
DT 500/DS 500 distance
scanners offer long range
and great accuracy
Tastweite und Genauigkeit
insightLINK
INFO 226
For further reading
see page 24
Dream machine solves nightmare
DT 500 laying it on the line
for mattresses.
SICK insight 2/2004
The LD PDS building security laser measurement system 40 Products
Recommended by da Vinci, Tizian and Drer
and prevents vandalism
>> In many cases laser measurement
technology, such as the LD PDS, has
proved an economical and technical al-
ternative for monitoring buildings, as
well as a sensible supplement to CCTV.
Reliable detection and precise
camera guidance
Independent of the lighting conditions
in an area, and effectively protected
against strong light impingement or de-
liberate dazzling, the LD PDS laser
measurement system offers maximum
detection reliability. The active scanner
The LD PDS is a new, non-contact building security laser measurement
system for horizontal and vertical 360 all-round monitoring. The Pro-
tection and Detection System (PDS) offers versatility and detection re-
liability. It is thus ideally suited for security functions in building
management. Famous paintings are already protected by the LD PDS.
of the measurement system transmits
an invisible fan-shaped light pulse and
measures the time until reception of its
reflection. The time-of-flight of the
transmitted light pulse changes as
soon as someone reaches into or en-
ters the protective field and triggers
an alarm signal. As the system not on-
ly detects persons as such, but can al-
so determine their position in an area,
observation cameras can also be ex-
tremely accurately aimed and focused
on the basis of the information sup-
plied by the LD PDS.
Maximum flexibility thanks
to dual DSP
In addition to a first digital signal
processor (DSP) for controlling the
measurement system, every LD PDS
has a second DSP that carries out a
programmable application-specific con-
version of the measurement values ob-
tained, and transmits them via RS-232,
RS-422 or two digital switching out-
puts. As a result, any security techni-
cian, system integrator or user of the
measurement system can adapt the
monitored area appropriately. If this
changes, e.g. as a result of putting up
new walls or buildings, or exchanging
guarded objects of different sizes, this
is also easily taken into account via
software in the device. Thus the laser
measurement systems allow continued
flexible use of spaces or wall areas.
Light veils protect
Louvre works
About 30 LD PDS are in use at the
Louvre in Paris, one of Europes oldest
and most prestigious museums. As a
result of their designs, the devices
could be integrated into the walls of
the exhibition rooms and protected
against sabotage and interference.
The veil of light generated by the de-
vice does not impair visitors views of
works by Leonardo da Vinci, Raphael,
Rembrandt, Tizian, Drer and other
great masters.
The LD PDS
insightLINK
SICK insight 2/2004
The CVS 1 Color Vision Sensor 41 Products
>> The CVS 1 Color Vision Sensor
checks whether the amount, or number
of pixels, of the colour tone in its field
of view matches at least the minimum
taught-in in principle it therefore
functions like a colour scanner with a
very large light spot and very long op-
erating distance.
Industrial design in photoelectric
switch format
The CVS 1 is used for colour detection
in industrial environments. For this rea-
son, during development emphasis
was placed upon: simple teach-in pro-
gramming, direct display of the image
captured by the CVS 1 Color Vision
Sensor, typical cycle times of just
10 ms, and the storage and immediate
retrieval of up to 16 different colour
tone inspections.
What is special about all these fea-
tures is that they have been achieved
within the CVS 1 camera sensor itself
(only about the size of a photoelectric
switch) without any supplementary
external control and evaluation unit.
There is a separate monitor and control
panel that can be connected to the
camera sensor for use in mounting lo-
cations where its own display cannot
be seen.
Great performance low price
The CVS 1 offers highly versatile use
from monitoring the browning of meat-
balls, and checking the presence of
bottle tops and lids, to detecting logos
and checking labels in packaging ma-
chines. Here, for example, labels with
defective designs can be detected al-
most impossible with point-based sen-
sor detection. The CVS 1 also detects
colour in applications such as checking
the completeness of crates or carrier
systems, checking the presence of en-
closed instructions, differentiating be-
tween objects on the basis of colour,
and checking the filling levels of trans-
parent containers. Given all these ad-
vantages, one can hardly believe the
price of the CVS 1 the device is the
only one in its performance class avail-
able for less than 1,000!
Whether price or performance the
CVS is a fantastic solution from any
point of view.
The intelligent small-scale CVS 1 Color Vision Sensor: a photoelectric switch for
detecting colour in industrial environements
insightLINK
INFO 227
Large-format colour detection with the CVS 1 Color Vision Sensor
Suitable for meatballs, bottle tops
and packaging
A large detection field, integrated illumination, long operating distances,
a colour monitor for simple operation, a teach-in button and extremely
short evaluation times. A single device, the CVS 1, offers all these fea-
tures normally requiring expensive camera and computer equipment.
SICK insight 2/2004
Standardised sensor teach-in Bluetooth 42 Know- how
Maximum simplicity for users
SICK supports standardised teach-in
>> Intuitive operation without a manu-
al, simple and rapid commissioning,
prevention of unintentional triggering,
and clear visual indication of device
states on the sensor or in response to
remote querying this is how users
want to commission and operate their
optoelectronic and ultrasonic sensors.
So the leading suppliers of standard
sensors are working towards the goal
of formulating uniform teach-in philoso-
phies for customers and producers,
and deriving shared features from
them.
Uniform features
Participants in the workgroup have dis-
cussed uniform sensor features based
on the requirements of customers and
the solutions already implemented indi-
vidually by producers. Among other
things, this affects the use of buttons;
operating modes and their visualisa-
tion by means of LEDs; automatic ac-
ceptance of teach-in values; indication
In partnership with other producers, SICK is working on the rapid imple-
mentation of a producer-independent standard teach-in process in the
Standardisation of sensor teach-in processes workgroup in the Ger-
man Trade Association for Electronic Components and Systems (ZVEI).
of error states; and time locks in the
teach-in process intended to prevent
unintentional operation. Icons have al-
so been defined for uniformly labelling
teach-in buttons for:
p single-value teach-in: only set on one
object, and
p two-value teach-in: setting takes
place on one object and one back-
ground.
Draft standard handed in to
CENELEC*
A draft for standardising the teach-in
process of standard sensors has been
presented to CENELEC for European
standardisation as an appendix to
EN 60947-5-2: the IEC 60947-5-2
Annex G Draft. Parallel to this, SICK
has integrated the latest generation of
optoelectronic switching circuits (so-
called opto-ASICs), that are in com-
plete conformity with the agreed draft
standard, in its latest optical sensors
for automation, including the WT 9-2,
WT 14-2 and WT 18-3, among others.
All producers a single goal:
straight forward teach-in without com-
plicated operating instructions.
www.zvei.org and www.stafuco.org
* CENELEC is the European Electrotechnical
Standardisation Committee
The DME 5000 distance measuring device: teach-in by mobile phone
Parameterisation and diagnosis via Bluetooth
>> Replacement of the serial in-
terfaces of sensors such as the
DME 5000 laser distance measuring
device is particularly attractive. With
the help of a Bluetooth-enabled laptop,
service technicians can communicate
with the sensor on the high bay stacker
from a distance, without having to en-
ter a blocked aisle of shelving. This is
considerably simpler and more com-
fortable than via cable. And it is also
secure, as Bluetooth not only encodes
the radio signal, but also changes its
transmission frequency up to 1,600
times per second.
Greater mobility and comfort
drive the standard
Cable-free connections, mobility of end-
devices, and online communication
over short and medium ranges are the
reasons why Bluetooth is well on the
way towards becoming the standard in
the cable-free IT environment. Numer-
ous end-devices are already equipped
with this radio interface.
So its hardly surprising that the
DME 5000 with the Bluetooth interface
attracts great interest whenever it is
presented.
insightLINK
Comprehensive information on Blue-
tooth is available in six languages at
www.bluetooth.com the official
Bluetooth web site.
Away with the cables this trend is becoming increasingly common
among modern automation components. Whether parameterisation or
diagnosis cable-free data transmission via Bluetooth simplifies work in
situ, e.g. in high-bay warehouses.
Teach-in button labels
Single-value teach-in
without background/
target differentiation
Two-value teach-in
Optional
Target Background
SICK insight 2/2004
Autoworld in Brussels, Belgium 43 Museum
>> Several hundred cars can be seen
lovingly restored and looked after.
Horse-drawn vehicles are just as much
a part of the museum as are the first
real cars and their successors: state
carriages, luxury limousines, convert-
ibles, coups as well as buses and
trucks. Motorcycles are a further area
of interest.
A variety of collections embedded
in their time
Several private contributors have lent
their collections to the museum over
the decades. The Mahy Collection
shows extraordinary and prestigious
vehicles, the Thiry Marcel Collection
concentrates on two-wheeled vehicles,
while buses and transport vehicles of
One of Europes most interesting automobile museums is accommodat-
ed in the Palais du Cinquantenaire: the Brussels Autoworld. It tells of
times long past, while also stimulating a critical consideration of the car
in todays social environment.
all types are to be seen in the Gallery
Pierre dIeteren. There is also a replica
of the 1902 Motor Show, and a depart-
ment for the history of car design.
Looking at the exhibits conjures up in
ones minds eye the history of the last
century. The Belle poque of the 20s,
two world wars, the limousine era and
the revolutions of the 50s and 60s, as
well as the last three decades during
which the car finally developed into a
commodity for the masses.
Goods for the masses = good for
the masses?
In addition to its purely expositional
aims, the Brussels Autoworld also fol-
lows technical and social education
aims. Children and young adults are of-
fered a variety of visitor programmes
that, in addition to the automobile as
technology, also consider how the car
has influenced the appearance of the
world, the development of societies,
and the attitudes and ways of life of
mankind and families.
Whether the car, as a good for the
masses was, and is, always good for
the masses the visitor must come to
their own conclusion. Whatever the
case, the Brussels Autoworld provides
a richness of stimuli here.
100 years of automotive history at the Autoworld Museum in Brussels
insightLINK
You can obtain further information
about the Brussels Autoworld
on the Internet at:
www.autoworld.be
A vehicular
journeythrough time
Turkish subsidiary for south-east Europe
SICK founds S.I.C.K.
>> As of now, S.I.C.K. (Sensrler ve
Ileri Cihazler Kontrol Sanayi Ticaret)
A.S. has exclusive rights to sell the en-
tire range of products in Turkey, and will
later also distribute them in a variety of
neighbouring countries.
10-year history of success
Onur Mhendislik was founded in
1994. While just six staff were em-
ployed during the first two years, meet-
ing all the needs of sensor sales in
As part of its strategy of expanding its market position in south-east Eu-
rope, SICK has integrated its former Turkish sales representative in
Istanbul, Onur Mhendislik, into its worldwide sales network as a
new subsidiary.
Turkey, Onur achieved continuous
growth during the following years de-
spite the difficult economic conditions.
A total of 22 personnel are now em-
ployed by the new SICK subsidiary, up-
on whose specialist knowledge
numerous customers and users rely
including major press producers, auto-
motive suppliers and logistical compa-
nies that use sensors, safety systems
and bar-code readers.
SICK insight 2/2004
Company founded in Turkey Results of the safety co-operation 44 SICK Tour
Safety co-operation: Omron + Rockwell + SICK
DeviceNet Safety on the march
>> SICK sees DeviceNet Safety as a
technology on a par with Profisafe and
AS-Interface Safety at Work, and has
deliberately integrated a lot of expert-
ise in the development of products.
The UE 4470 is one of the first exam-
ples of this.
For consistent machine safe-
guarding concepts
Any combination of safety sensors and
actuators can be integrated locally and
decentrally in DeviceNet Safety net-
works with the UE 4470 Safety Con-
troller. Status, diagnostic and error
messages can be detected and
processed in situ or via the network. In-
tegrated and certified basic and appli-
cation function blocks (such as
automatic reset, enabling switches or
two-hand control units) permit the solu-
tion of simple and more complex safety
tasks, allowing the realisation of con-
sistent machine protection concepts,
In October 2002 the companies Rockwell Automation, Omron and SICK
presented the Open DeviceNet Vendor Association (ODVA), the safety co-
operation they had founded. The aim of this collaboration was and remains
the development of hardware and software components that use De-
viceNet Safety, the safety extension of DeviceNet, as their protocol. The
UE 4470 Safety Controller is one of the first results.
such as those relevant for packaging
machines or machine tools, robot cells
and conveyor systems.
Equal partners with differing
emphases
With Rockwell Automation, Omron and
SICK, three partners that are leaders
in their market segments with leading
market positions in the USA, Asia and
Europe, have united in a safety co-op-
eration. Each company contributes
specific expertise: Rockwell Automa-
tion and Omron provide control system,
programming and network technolo-
gies, while SICK provides expertise in
safety applications and technology.
Flexible safety automation with De-
viceNet Safety SICK actively supports
the dialogue on distributed logic in
networks. INFO 228
www.odva.org key words: CIP Safety
The UE 4450 safe bus node
and the UE 4470 safety con-
troller (right)
10 years SICK Hong Kong
>> Danny Chan, the current Managing
Director, and three other employees,
were the original team at SICK Hong
Kong in 1994. The company developed
as dynamically as the market: after a
first office in Guangzhou, a branch was
opened in the metropolis itself one
year later. With further offices in Bei-
jing and Shanghai, SICK China now has
a presence in the most important ar-
eas of the nation. The company pro-
vides support to all the key industries
in China: automobile construction and
the electronics industry, steel works,
machine tool manufacturers, the print-
ing and packaging industries, food and
drinks producers, as well as compa-
nies involved in material handling.
Congratulations for the last ten
years and all the best for the new
decade.
SICK insight 2/2004
Finding products in the eCatalog Hong Kong celebrates tenth anniversary 45 SICK Tour
In September 2004, almost 60 staff celebrated the founding of SICK
Hong Kong ten years ago. The company formed the core of the SICK Op-
tic-Electronic Co. Ltd., Guangzhou China which came into being in 2003.
Hong Kong at a glance:
Official name: Hong Kong Special Administrative Region of the Peo-
ples Republic of China, since 01.07.1997
Area: 1,092 km
2
about the size of Martinique c.f. China
with 9,597,995 km
2
= almost as large as the USA or
approx. 27 times the size of Germany
Population: approx. 7.3 m. about as many people as in all
Switzerland estimated total population of China is
almost 1.3 bn.
Population density: 6,771 persons per km
2
c.f. 387 on Martinique
Exchange rate: 1 Hong Kong dollar (HKD) = ca. 0.10 EUR; 1 EUR =
9.66 HKD (in October 2004)
Sources: Homepage Spiegel / Lnderlexikon
The Team of SICK Hong Kong
The Product Finder offers you the
opportunity to enter parameters to se-
lect the products that potentially meet
your needs. You can narrow down the
search results as desired and therefore
influence the number of products se-
lected. You can thus rapidly and com-
prehensibly obtain information on our
products.
You can obtain detailed product da-
ta such as the data sheet, connection
diagrams, accessories, etc. by clicking
within your search results.
To the product via the
Application Finder
The Application Finder guides you from
the application to the product. By se-
lecting the task, sector and products
used one rapidly reaches an appropri-
ate application description and links
that take you to the products used in
the application. Thus your search al-
ways results in a solution. And you can
find mounting sets, plugs, lenses, etc.
in the Accessory Finder.
Please note: As a result of the enor-
mous range of products not all products
are available in the Finder pages during
the transition period.
SICK Product Finder eCatalog on the Internet
ecatalog.sick.com Find sensors online
>> Find dont
seek. Click
and stay up-to-
date. Its never
been easier
with SICKs Prod-
uct Finder eCatalog.
A complete range of automation sen-
sors; industrial safety systems; and
trail-blazing material flow, identification
and handling systems the Product
Finder eCatalog invites online research
for SICK products (currently in three lan-
guages).
SICK insight 2/2004
P6 SICK Rundschau Eat that frog by Brian Tracy 46 Book Corner
>> When I picked up this book I
thought: Well, it looks funny enough,
the frog on the cover, looking at me in
that way with its big froggy eyes but
Im supposed to eat that? No thanks!!!
OK, even I quickly grasped that it
was just a bit of imagery for something
uncomfortable, something that I really
dont want to do, which I may even find
disgusting. And there are a few things
that spring to mind which I would take
the trouble to think of 1,000 excuses
to keep putting off. But what effects
does that have on my life? Either pri-
vate or professional.
So lets see what tips and tricks
Brian Tracy can offer me to conquer my
weaker self.
Right at the start he impresses up-
on us the importance of not starting
the day with the easier tasks, as we hu-
mans are wont to do. So the first job is
to clearly define what the biggest frog
is. Its helpful to plan the day properly.
A range of rules and various lists are
very helpful here.
It is also very important to consider
the repercussions of doing or not doing
something. This can become a key fac-
tor in the long-term perspective of life.
Whereby one also determines the next
frog what more could one want?
Eat that Frog
21 great ways to stop procrastinating
and get more done in less time
The 21 steps to success build upon
one another logically and are compre-
hensibly structured with key words and
sub-headings. Many of the steps also
offer exercises that help me put the
theory into practice.
Summary: A very stimulating book
that I would recommend. It made me
think about my long-term aims in life
and about how I can achieve them
most effectively, if I really want to.
Book Corner by
Ingrid Rathfelder, Editor
SICK insight e-mail newsletter
Eat that frog is available from Berrett
Publishers, Inc., ISBN 1-57675-198-8
Another significant tip: set priorities
and never start a B, C, or D task before
the A task has been completed.
Concentration on key areas, such
as planning, organisation, job place-
ments, delegation, inspection, meas-
urement and reporting, is the next ma-
jor factor, particularly in management.
In this context it is important to contin-
uously improve oneself. Here Tracy rec-
ommends, among other things, keep-
ing the working environment clean and
tidy. Oh dear, looking at my desk is so
awfully depressing!
How well I succeed in taking my
special talents into account, what can
prove to be important impediments,
how I can motivate myself to take ac-
tion, how I can put pressure on myself,
when matters are critical, what the
Salami Tactic or Swiss Cheese
Method are, and much else besides,
are covered in the remaining third of
the book.
A well organised summary at the end
provides assistance in again clarifying
that eating the biggest frog in the morn-
ing is both satisfying and motivating,
and that I will then find the other tasks
much easier to deal with.
The rule is that you should
never do a B task
when there is an A task
left undone
Rule: Long-term thinking
improves short-term
decision making
The key to the success of this
method of working in specific
time segments is for you to plan
your day in advance and specifi-
cally schedule a fixed time period
for a particular activity or task
insightLINK
Weitere Infos erhalten Sie mit der
Karte am Ende des Magazins unter:
INFO 121
insightSERVICE
Trade fair dates Imprint Contacts 47 Info
Central Sales, Germany
SICK AG
Schiess-Strae 56
40549 Dsseldorf
Germany
Phone +49 211 53 01-0
Fax +49 211 53 01-100
e-mail vzdinfo@sick.de
Company Headquarters
SICK AG
Sebastian-Kneipp-Str. 1
79183 Waldkirch
Germany
Phone +49 7681 202-0
Fax +49 7681 202-38 63
e-mail info@sick.de
Trade fair dates Germany
Trade fair Location Date 2004/2005
SPS/IPC/DRIVES Nuremberg 23.11.25.11.2004
i+e Freiburg 27.01.29.01.2005
LogiMAT Stuttgart 01.02.03.02.2005
HANNOVER MESSE Hanover 11.04.15.04.2005
SEMICON Europa Munich 12.04.14.04.2005
interpack Dsseldorf 21.04.27.04.2005
Trade fair dates Europe
Elektro Vakbeurs Hardenberg, NL 07.12.09.12.2004
elec Paris, F 09.12.13.12.2004
DRIVES AND CONTROL Danzig, PL 09.02.11.02.2005
AIDC Papendal, NL 08.03.09.03.2005
CFIA Rennes, F 08.03.10.03.2005
MOCON s-Hertogenbosch, NL 30.03.31.03.2005
AUTOMATICON Warsaw, PL 05.04.08.04 2005
Swiss Sensor Market Zurich, CH 07.06.09.06.2005
VISION SOLUTIONS Nijmegen, NL 15.06.16.06.2005
SAWO Posen, PL 20.06.23.06.2005
ELEKTROTECHNIEK Utrecht, NL 26.09.30.09.2005
Trade fair dates worldwide
PRO MAT Chicago, Illinois, USA 10.01.13.01.2005
METALFORM Rosemont, Illinois, USA 20.03.23.03.2005
FIE Anhembi, So Paulo, BR 25.04.29.04.2005
Subsidiaries
Australia
Phone +61 3 9497 4100
+1800 3 3480 2 toll free
sales@sick.com.au
Austria
Phone +43 22 36 62 28 8-0
office@sick.at
Belgium/Luxembourg
Phone +32 2 466 55 66
info@sick.be
Brazil
Phone +55 11 5091 4900
sac@sick.com.br
China
Phone +85 2 2763 6966
ghk@sick.com.hk
Czech Republic
Phone +420 2 57 91 18 50
sick@sick.cz
Denmark
Phone +45 45 82 64 00
sick@sick.dk
Finland
Phone +358 9-25 15 800
sick@sick.fi
France
Phone +33 1 64 62 35 00
info@sick.fr
Great Britain
Phone +44 17 27-83 11 21
info@sick.co.uk
Italy
Phone +39 02 27 40 93 19
ced@sick.it
Japan
Phone +81 3 3358 1341
info@sick.jp
Korea
Phone +82 2 786 6321/4
kang@sickkorea.net
Netherlands
Phone +31 30 229 25 44
info@sick.nl
Norway
Phone +47 67 81 50 00
austefjord@sick.no
Poland
Phone +48 22 837 40 50
info@sick.pl
Singapore
Phone +65 6744 3732
admin@sicksgp.com.sg
Spain
Phone +34 93 4 80 31 00
info@sick.es
Sweden
Phone +46 8-680 64 50
info@sick.se
Switzerland
Phone +41 41 619 29 39
contact@sick.ch
Taiwan
Phone +886 2 2365 6292
sickgrc@ms6.hinet.net
Turkey
Phone +90 216 388 95 90 pbx
info@sick.com.tr
USA
Phone +1 (952) 941 6780
info@sickusa.com
More representatives and sales
offices in all major industrial
nations at www.sick.com
Imprint
Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com
Phone +49 7681 202-0 Fax +49 7681 202-3863 info@sick.de
Co-ordination: Anette Hippach Customer Magazine Project Manager, SICK AG
Anette.Hippach@sick.de
Specialist editors: TOP MEDIA Dirk S. Heyden 69469 Weinheim
info@topmedia-weinheim.de
Conception/layout: johnson][braun Direktwerbung 76133 Karlsruhe
jb@johnsonbraun.de
Translator: Richard Dennis 79194 Grundelfingen richarddennis@t-online.de
Printing: Druckerei Furtwngler 79211 Denzlingen info@druckerei-furtwaengler.de
Pictures: SICK AG, Getty Images, Autoworld Brussels, BGFE, Roland Krieg Fotodesign
Individual contributions may be reproduced after prior consent. Please contact us at:
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