Industrial communication and device integration in our customer magazine SICKinsight

Industrial communication and device integration in our customer magazine SICKinsight
www.sick.com
S i c k ’ s
C u s t o m e r
M ag a z i n e
2_2011
>Perfectly
networked
Industrial communication & device integration
Pages 32 to 35
Getting progress on the road
Solution competence by SICK
PROFINET IO at VW
Trends of the automotive industry in
the industry focus automotive
Pages 4 to 11
Industry focus electronics & solar ­presents application know-how
Pages 12 to 19
Interview on the topic of systems
and networks
Page 20
: IndustryFocusAutomotive. ..................... 4
Safety laser scanners increase availability............. 6
Identification of windshields for trucks...................... 7
New tasks for DT50 distance sensors..................... 8
Flexible use of robots in body assembly.................. 9
Automatic “cherry-picking” on production lines....10
RFID – continuously and flexibly identifying..........11
: IndustryFocusElectronics&Solar.....12
Diameter control at the panel milling cutter.........14
High-power lasers in electronics production.........16
Combined solution for solar producers.................17
Solar panels follow the path of the sun.................18
: Views & Voices
PROFINET IO delivers excellent performance.......20
: Applications
Finding the right pallet with IQ...............................22
Pallet and magazine centering at KHS..................23
Light grids enable optimum use of ­cargo space.....24
Sensor with light array increases efficiency..........25
Hybrid solution for baggage identification............26
Qantas automates self check-in............................27
Continuous controlling of conveyor belts..............28
Emission measurement proven in practice..........29
Protection of hazardous area.................................30
More flexibility: modular safety concept................31
: Technology
Replacement of analog sensor technology...........32
EFI without fieldbus interface................................33
One ­platform, three auto ID technologies.............34
Digital evolution for electrical drive technology....35
: Know-how
Transparency: photoelectric sensor solutions.......36
: Products
Print marks yield to pattern....................................37
Reliable detection: foil-wrapped units...................38
Part inspection using infrared light........................38
The new dimension in code reading......................39
Encoder programming without PC...............................40
OLM200 linear measurement sensor.........................40
Monitoring oxygen in industrial environments........41
Ethernet encoders improve availability.................41
Photoelectric sensors as installation geniuses.....42
Portfolio of fiber-optic cables extended.................42
Keeping distances, avoiding collisions..................43
Level measurement with guided microwave.........44
Volume measurement with VMS520.......................45
Perfect sensor integration made easy...................45
Sensors for trouble-free handling of pallets..........46
Differentiating humans and material reliably ......46
IDM160: robust hand-held scanner......................47
: Service & Support
Legal security when retrofitting..............................48
Complete service for Brazil’s Nº 1..........................49
: Editorial
Technological openness
Dear Readers,
For six decades, sensor technology has been
not one but the business of SICK. Markets,
technologies, and demands are changing
­continuously – and we are changing along with
them. This constitutes the key to our success.
Our innovative products are reliable and offer solutions for applications
becoming increasingly more complex. The great breadth and depth of
our product range opens up to users in all regions of the world complete
solutions from a single source, solutions that our experts on location
­develop together with you and that they will continue to service as well.
However, our sensors can do more than that, for they are open to all system worlds prevailing in automation. Many approaches to a solution call
for simple, application-compatible integration of the sensors into these
automation worlds. Consequently, we are pursuing platform strategies in
the areas of connectivity and network technology as well as in the field
of software modules that permit our customers the most ­cost-effective
integration. In order for you to learn more about this variability of interfaces and the integration capability of our products, we have chosen for
this issue of SICKinsight the main technological emphasis of “industrial
communication and device integration.”
In our industry focus on automotive, too, you will find examples of how
smooth communication between the sensor and the plant can work in
automobile production. In particular, solutions for automation systems
with quite specific technological problems and application requirements,
such as integrated solutions from the body shop to final assembly in
terms of bodywork identification, pose a great challenge – our industry
experts managed to provide such a solution. As a result, our customers
rely on our broad experience in many other industries as well, such as
the electronics and solar industry. Just how we can meet the specific
performance requirements in this context constitutes the topic of the industry focus on electronics & solar.
Visit us at the productronica in Munich or at the SPS/IPC/DRIVES ­in
Nuremberg and experience trade fair highlights such as the ­HIPERFACE
DSL® digital interface. Take the opportunity to talk to our industry
­experts about the competitive advantages you can work out together
with us. Talk to them about how you benefit today and in the future,
too, from solutions adapted to specific uses that stand out due to their
­efficiency, openness, sustainability, and security of investment.
We are already looking forward to seeing you!
Yours sincerely,
: SICK Tour........................................................50
: SICKinsight[plus]
100th anniversary: Hamburg’s Old Elbe Tunnel .........52
Markus Paschmann | Executive Board Member Factory Automation
: Info. ....................................................................53
2
02 2011
: News
Winner in the category of “Competitiveness in Electrical Components”
Award by SIEMENS for
SICK Vertriebs-GmbH
Six companies were nominated by
SIEMENS this year to the presentation of prizes for “Our stars for Mobility
Infrastructure Logistics 2011” – and
the winner was SICK Vertriebs-GmbH.
SPS/IPC/DRIVES 2011 in Nuremberg
SICK presents new
­products and solutions
This year, too, SICK will once again be
represented at Europe’s leading trade
fair for electric automation, the SPS/
IPC/DRIVES taking place from 22 to
24 November 2011 in Nuremberg.
>> Following the motto of “strong in innovation and leading in technology,” both
new technologies and many innovative
product highlights will await you there.
Moreover, join us in looking forward
to the 100th Tour Stop of our Solutions
Tour. The exhibition stand, covering 625
square meters (6725 sq. ft.), will feature
the entire range of products from SICK.
However, the focus is not on introducing
single products but rather on presenting
solutions for our customer industries.
Visit us at the fair:
SPS/IPC/DRIVES 2011 in Nuremberg
from 22 to 24 November 2011
>> As a subsidiary of the SICK Group,
SICK Vertriebs-GmbH headquartered in
Düsseldorf is responsible for the entire
sales of products and services in the factory and logistics automation segment
across all of Germany. The recognition by
SIEMENS acknowledges the superb cooperation and outstanding performance
of the sales company and its employees.
Christian-Marius Wegner, Siemens AG;
Günther Tinnesz and Heinz Nelle, SICK
Vertriebs-GmbH, as well as Dr. Stefan
Keh, Siemens AG (from left to right)
Hall 7A – Stand 340 www.mesago.de/sps
An annual overview of all trade fairs
with SICK is available on page 53
Smart PDF available at www.sickinsight.com
“SICK Solutions Tour” on the home stretch
Tour Stop 100 coming into view
>> One hundred challenges at the customer’s operation. One hundred sensor solutions around the world. One
hundred times application competence in all industries. The web page
www.sick-solutions-tour.com presents
an impressive collection of customer
references that underscore the versatile
means of applying sensor technology
from SICK. At the end of November, just
in time for the SPS/IPC/DRIVES 2011 in
Nuremberg, we will present the 100th application. At that point, the Solutions Tour
will have reached the finish line, but we
will continue to keep you informed with
real solutions at www.sick.com. To all
of those who have supported us in this
campaign and who will continue to do so
with their good name and their logo, we
would like to say: Thank you!
www.sick-solutions-tour.com
3
: IndustryFocusAutomotive
>Automotive
Individual mobility increases
Demands on the
­automotive industry
Since the automobile was invented in Germany 125 years ago,
it has stood for individual mobility. Today, this trend remains unbroken, as mounting numbers of people worldwide wish to drive
a car, something revealed by the numbers of registrations. Thus,
last year global demand for passenger cars reached the second
highest level of all times, with 59.4 million first registrations reported. For the year 2011, analysts even anticipate 65 million first
registrations; in five years, the numbers are expected to ­exceed
the 90-million mark. This has consequences for production.
>> Thanks to innovative entrepreneurs,
resourceful engineers, highly qualified
employees, and the latest manufacturing technology, the German automotive
industry has captured a top position for
many years in terms of quality, design,
safety, and engine efficiency. In order to
maintain this standing in the years ahead,
the model policy and production, too,
need to change fundamentally, according to the latest “Automotive Landscape
2025” study by Roland Berger Strategy
Consultants. The authors point to five
driving forces that will change worldwide
automobile production fundamentally in
the next fifteen years: geopolitical changes, the demographic transition, the demand for sustainability regarding production and the product itself, as well as new
behavioral patterns among people, and
the influences of new technologies.
The repercussions on car production
and automotive suppliers can be felt
clearly even today: Thus, the aim is to
4
adapt the car better all the time to individual needs, which requires constantly
enhanced flexibility in manufacturing
as well as efficiency and productivity of
plants. An increasing number of carmakers are manufacturing mass products
in batch size 1. This represents a great
opportunity for plant and machine builders or sensor producers such as SICK
to provide for a high degree of automation of the production and assembly lines
with innovative technology. As it is, one
can still improve on a wealth of potential for rationalization and automate processes considered unsuitable for automation even a few years ago.
Sensors from SICK are precise and reliable in guaranteeing quality in manufacturing as well as protecting humans and
machines. SICK’s automotive specialists
offer the appropriate support worldwide,
ensuring that even tomorrow the car will
continue to be the mainstream and, at the
same time, an expression of ­individuality.
02 2011
: IndustryFocusAutomotive
Recognizing trends in time
Getting progress on the road
For the third time in succession, SICK’s Automotive Team hosted
the Automotive Days at SICK’s customer center in Waldkirch. At
the 2011 event, the center of attention was car production in an international setting as well as its flexible and efficient ­organization.
>> With 28 lectures, including 16 by experts from the industry, well over 80 participants from automotive enterprises,
component suppliers, machine builders,
and equipment suppliers obtained an
overview of new challenges and technological trends in car manufacturing. In
his keynote speech, Dr. Ralph Wiechers,
Chief Economist of the VDMA (German
Engineering Federation) industry association spread confidence, saying that production in nearly all German sectors of
industry has once again reached the precrisis level. In this context, the growth
engines are China and India. As Thomas Stähler, responsible at SICK for the
worldwide automotive business, confirmed, SICK was also intensifying its commitment in the BRIC countries (Brazil,
Russia, India, and China). Therefore, he
stated, the company was setting up an
international Key Account Management
with regional subdivision and a strong
presence in the countries mentioned.
“Thus, our customers benefit from the
long-standing industry and application
experience of our experts on location.”
The
subsequent
presentations
showed where the industry is facing
problems: The lectures discussed safety
topics resulting from the Machinery Directive and explained new possibilities of
sensor-based robot assembly processes.
An important topic that ran through the
event like a thread was quality assurance. Examples of solutions in this respect are provided by industrial image
processing, which one can use to monitor handling processes automatically
and check for presence, quality, and safe
position of components. Another trend
arises from RFID technology in logistics.
It helps to monitor and continuously document material provision or production
and assembly runs. Flexible production
is supported by networking of all components via PROFINET. Sabrina Hein from
the Institute for Automation & Industrial
IT at the FH Cologne demonstrated this
in her lecture on the commissioning
of an assembly line at Volkswagen in
Mexico. Overall, it was a very informative and successful event, as all participants declared unanimously. “We will
come again,” was the positive echo of
all participants. “We are already looking
forward to the fourth 2012 ­Automotive
Days in Waldkirch.”
Participants in SICK’s 2011 Automotive Days got an overview of challenges and
trends in the automotive industry
Visit us at the fair:
SPS/IPC/DRIVES
from 22 to 24 November 2011
Hall 7A – Stand 340
5
: IndustryFocusAutomotive
Hazardous area protection
For the new BMW 1 series
Safety laser scanners with PROFINET
IO increase availability
When protecting hazardous areas of robot work cells and assembly lines in car body construction, the S3000 safety laser scanners from SICK with integrated PROFINET IO interface are the
preferred choice.
>> Safety laser scanners of the S3000
product family from SICK are established
as a standard at BMW, being used at the
worldwide locations. In terms of body construction technology, all of the robot and
drive systems both in Regensburg and in
Munich are equipped with ­PROFINET and
at these locations alone, about 9,000
PROFINET devices are integrated into the
network in each plant. Therefore, it appeared obvious to work with PROFINET IO
in the area of sensor technology as well
and, from now on, to use the new S3000
safety laser scanners from SICK with integrated PROFINET IO interface.
What benefit does BMW derive from
integrating safety laser scanners in
PROFINET IO?
In Regensburg, a large number of laser
scanners are used in body construction,
among other things as point-of-operation
guarding in welding robot cells. The utility aspects that BMW derives from direct
integration of the S3000 PROFINET IO
safety laser scanners into the production
network are diverse. To begin with, one
can mention complete and continuous
integration of the field devices. There is
no longer any need for switching modules and sub-distributors, as the S3000
PROFINET IO feature two integrated RJ45
ports with switching functionality. Anoth-
6
er benefit is the significantly reduced cabling effort. The entire data transmission
takes place via one medium within the
same physical network. In plant operation, the safety laser scanners with PROFINET interface support BMW’s central
plant operation concept in an optimum
way. Since configuration is possible from
a central operating computer, the entire commissioning proceeds faster and
easier.
For the availability and productivity
of the plants, it is of crucial importance
that in case of diagnosis, maintenance
and malfunction, one can communicate
directly with the sensor in the field. Since
all of the sensors’ status data can be
retrieved via the central automation system, remote diagnosis is possible at any
time. PROFINET integration of the safety
laser scanners from SICK also allows integrating the sensors into arrangements
for preventive maintenance. Finally, the
safety laser scanner is protected from
manipulations. For this purpose, the sensor transmits its safety configuration ID
(SCID) to the host computer by means of
a check sum, which makes it possible to
recognize and trace any modification of
the field device that was not authorized.
There is no need to buy any of these
benefits at excess cost – on the contrary.
If one compares the cost for additional
Roland Kolb, SICK Vertriebs-GmbH;
Christian Protzek, BMW, and Alexander
Meyer, SICK AG (from left to right)
hardware, mechanical and electrical installation, commissioning, testing, diagnosis, and retrofitting the robot work cell
in the case of a classic installation of a
safety laser scanner with the cost of an
S3000 PROFINET installation, the result
may be significant savings potentials.
PROFINET IO has the right
of way at BMW
The sum total of benefits has made the
S3000 PROFINET IO a standard worldwide in body construction at BMW. The
installation for the new BMW 1 series in
Regensburg gave the go-ahead.
Further product information:
www.mysick.com/applications
More about the customer:
www.bmw.com
02 2011
Windshield identification
: IndustryFocusAutomotive
Clear view for LECTOR®620
Identification of windshields for trucks
The cycle times are high in commercial vehicle production. ­Every
day, up to 470 trucks are leaving the assembly shop at the world’s
largest truck assembly plant in Wörth, Germany. Every three minutes, one vehicle rolls off the line, a total of up to 70,000 different variations and six different production series last year. ­­
The ­LECTOR®620 image-based code reader is in the midst of
things at the windshield assembly.
>> Assembling the windshield is the last
step of finishing work for the driver’s cab.
In order to insert the proper windshield
Steve Schlicker from Daimler and
Dieter Häge, SICK Vertriebs-GmbH
into the right truck, each windshield
has, printed on the lower left edge, a
­Data Matrix code that is read by the
­LECTOR®620 image-based code reader
with integrated red and blue lighting.
However, due to ­the transparency of the
windshield, there is no sufficient contrast
between the code and the background.
To obtain a stable and process-reliable
reading, the technicians from Daimler
and SICK thought up a special solution:
Behind the windshield and thus behind
the code, they installed a white plastic
surface. Now the ­LECTOR®620 “looks”
from above through the windshield onto
the white background, and the cells of
the Data Matrix code printed in black
provide it with superb contrast for the
read-out. In the course of assembly, this
set-up is used twice: once when feeding
the windshields on the conveyor belt and
shortly before the gluing process in the
final installation position.
Integration of LECTOR®620 into the
plant control takes place via PROFINET,
which transmits both the “start reading” command and the reading results
by means of the CDM425 connection
module. For optimum connection of the
­LECTOR®620 to the Simatic S7 controller, SICK provided a specific function
block that facilitates integration of the
sensor into the PROFINET environment,
thus reducing commissioning effort.
In this application, Daimler was supplied with a complete solution, starting
with code detection all the way to data
transfer in the plant control.
Further product information:
www.mysick.com/applications
More about the customer:
www.daimler.com
7
: IndustryFocusAutomotive
Robot guidance & process monitoring
New tasks for DT50 distance sensors
Flexibility that Ford in Cologne requires
For a custom-designed car to work perfectly as well, up to 7,000
components must be put together. Completely pre-assembled or
delivered as separate components, they are welded, glued, and
bolted together into subassemblies in body manufacture. At Ford
in Cologne, distance sensors of the Dx50 product family make
sure things run smoothly.
>> The distance sensors are generalists. For instance, in automated conveyor systems, they ensure the proper
distance of the load carriers from each
other, preventing rear-ending. Put on a
robot arm, they prevent collisions of the
delicate grippers with material inserted
improperly. In addition, they measure the
distances between the gripper and the
work piece, triggering an alarm when the
values fall below a certain level. In this
connection, the laser is switched on only
when the robot moves toward the gripping position, thus preventing the laser
light from impairing the worker.
The DT50 distance sensors feature
ranges of up to 10 meters (11 yds.) as
well as excellent resolution, which allows
installing them into robot work and processing cells even outside of the actual
safety zone. Here, the compact sensors
8
check for presence of borings and openings or the insertion of bolts and sheet
metal components into manual pick-andplace stations, e.g. rotary tables.
Combined with safety light curtains,
the distance sensors also monitor the
automatic feeding and removal of material in the work cells. As muting sensors,
they enable the safety devices of the
robot work cells from above for material transport, thus automatically and
reliably differentiating every component
conveyed in from humans.
Now the distance sensors at Ford
in Cologne have opened up a new application field: “level measurement”
at a pick-and-place station. Here, a robot picks A-pillars from a transport car
and inserts them into a holding fixture.
The transport car contains two stacks
with eleven A-pillars each. Depending
on the stack height, the robot must be
moved in the proper gripping position
every time. Previously, 22 inductive sensors attached to the side of the station
completed this task. Now only two DT50
distance sensors monitor the filling level
from above and transmit the measured
analog value, or rather the height, to
the controller. This saves the wiring of
20 sensors and accompanying PLC inputs, facilitates integration into the PLC
program, and increases reliability due to
fewer components installed. “In this application, the DT50 did an excellent job,”
says Uwe Radke, Maintenance Specialist
in the body assembly shop at Ford in Cologne. “Because of the high-quality LCD
display, the sensors are easy to operate;
the version featuring an analog output
gives us the flexibility of PLC programming that we need. And the robust metal
housing is perfectly suited to our tough
requirements.”
Further product information:
www.mysick.com/applications
More about the customer:
www.ford.com
02 2011
Gripping arm positioning on pick-and-place stations
: IndustryFocusAutomotive
Flexible use of robots in body assembly
Simply seeing better
Pick-and-place stations in automotive body assembly are still
loaded by hand. Difficulties related to using a robot are caused
by fast cycle times, the complex geometry of the sheet metal
components, and the high accuracy of placement. Where robots
are in use nevertheless, the sheet metal components are either
supplied in special racks or singulated mechanically, or the robots are equipped with elaborate 3D measurement technology.
SICK now demonstrates that things can be easier using IVC-2D
smart ­cameras.
>> Door skins, hoods, and other large
components are delivered in packs of
70 to the pick-and-place stations, where
they are inserted separately into the robot work cell. However, usually only the
first sheet metal pieces are well positioned on the rack, since in the course of
picking action, they are shifting slightly.
Whereas a worker can correct this with a
minor movement of the hand, the robot
requires constant, accurately defined
picking positions throughout. One can
solve this issue by means of elaborate
rack designs, which necessitates greater
logistics effort and considerably higher
costs. Alternatively, one can determine
the position of the sheet metal pieces
using complex image-processing systems. In this context, however, conventional image-processing systems quickly
reach their limits in spatial resolution.
Now SICK has cooperated with a
system integrator for robot work cells, in
developing a simpler and more accurate
system solution: PLM (Part Locator for
Manufacturing). It consists of an IVC-2D
smart camera and two different lighting
designs – LED area lighting and a laser
Without an additional PC, the system
­solution PLM communicates via Ethernet interface directly with the robot
cross projector. In an initial step, the robot travels to a defined measuring position and projects a pre-set laser cross on
to the metal sheet. Based on its geometrical displacement in space, the ­IVC-2D
smart camera calculates a correction
frame, transmitting the data to the robot
via Ethernet interface. The robot subsequently aligns the gripper parallel to the
metal sheet, correcting its distance and
starting the pattern recognition for gripper positioning. In doing so, it adjusts
to the individual features of the sheet
metal components. Following the picking
of the sheet metal part, the process repeats until the rack is emptied.
The clever combination of laser triangulation and pattern matching is capable of detecting geometrical features
reliably, independent of fluctuations in
contrast and ambient light interference.
This method permits fast cycle times
between 200 and 300 milliseconds per
image frame and positioning at a level of
accuracy less than 1 mm. The integrated
intelligence of the IVC-2D smart camera
allows teaching-in new objects as well. In
the setting-up mode, the user-friendly operating software supports fast teach-in.
Further product information:
www.mysick.com/applications
9
: IndustryFocusAutomotive
Robot guidance in supplying assembly lines
Automatic “cherry-picking” on production lines
Sharp eyes for the robot
Cars have been rolling off the assembly line at the Chinese car
manufacturer Chery Automobile in Anhui province since 1999;
last year alone, output numbered 700,000 vehicles. The enterprise is one of the largest Chinese manufacturers and, at a share
of 40 percent, the leading car exporter in the emergent Asian
country.
>> According to its own information,
Chery Automobile intends to combine
innovative technology from international
suppliers with its own developments to
gain better international renown and to
realize its vision of an independent international brand. In order to utilize fully the
production capacity of currently 900,000
vehicles and engines, the company is undertaking a concerted effort to automate
its production environment.
One example is the automatic removal of engine blocks and their singulation
on a conveyor belt. The unfinished diecast aluminum housings are delivered
on pallets in batches of 30 units each
from the Chery powertrain foundry. Until now, workers had lifted these parts,
weighing up to 20 kilograms, on to the
conveyor system. For reasons of occupational safety and the harsh working
conditions, Chery decided to replace
in the future the manual order picking
with robots. The challenge related to this
­automation is the fact that the cast parts
do not have a fixed position on the pallet. They are located on top of or beside
each other, tipped over, or shifted, which
means the robot never encounters the
same position for picking.
SICK now provided it with eyes that
allow it to see flawlessly even in the third
dimension and under dusty and low-contrast ambient conditions. To this end, the
robot’s arm was fitted with a 3D camera
IVC-3D that scans the engine block and
transmits the coordinates to the robot
system. The robot aligns accordingly and
grips the items. Due to its high measuring precision featuring integrated evaluation, the IVC-3D smart camera provides
for smooth order picking at high speed.
Up to 5,000 profiles per minute are evaluated, with the results sent without the
detour of an additional PC directly to the
robot as a gripping coordinate.
In close cooperation with Chery’s
production engineer and Jake Jin from
SICK’s Chinese automotive team, an
easy-to-integrate solution has taking
shape that facilitates work and makes
processes more efficient. Now only the
pallet needs to be deposited using a forklift; the robot takes care of the rest. This
approach integrates machine assembling automatically into ­component logistics and optimizes the overall ­process.
Seeing through the IVC-3D smart camera from SICK, the robot packs the
cast parts from the pallet (photo on the
right) onto the conveyor belt (photo on
the left)
Further product information:
www.mysick.com/applications
More about the customer:
www.cheryinternational.com
10
02 2011
Bodywork identification
: IndustryFocusAutomotive
Body identification in the automotive industry
Identifying continuously
and flexibly with RFID
The more individually vehicles are equipped, the more information car manufacturers must gather, process, and evaluate even
during production. Current developments in RFID technology
open up new potentials for controlling complex processes and
their ­traceability.
>> Only once every one and a half years,
big car manufacturers build an identical
car. This is hardly surprising, considering
the combinations of several hundred different paint jobs, interior fittings, engine
types, and accessories. However, this
great variety also poses difficulties: For
example, one must know at any time and
place which car is currently under construction. Therefore, it is important even
while assembling the underbody to apply
an unambiguous marking that allows reliable identification of the developing car at
all subsequent stations, all the way to final
assembly and outward transfer. The task
is not easy, as the labels for identification
necessary to this end must be read reliably at every production step; they must
even withstand temperatures of 200 °C
(392 °F) common in the painting line.
Until now, different identification
technologies were available for this pur-
pose, none of which, however, could be
used universally and across all processing systems, since bar and Data Matrix
codes are no longer visible after painting. Alternatives such as perforated
sheet metal, etc. are elaborate and expensive. 1D/2D or active RFID systems
are attached to the skid in the body
assembly shop and the paint shop and
changed over to a different skid for final
assembly. This involves the risk of confusions. Moreover, the closed circulation of
transponders causes high maintenance
and handling costs.
A great improvement results from
marking the automotive body with a body
ID on an RFID transponder label from the
very beginning. Specifically for this purpose, SICK has developed a cost-effective, temperature-resistant, and dimensionally stable ISO/IEC-18000-6-compatible UHF RFID label. It is attached in such
Ideal for applications in automotive
­manufacturing: the RFU630 RFID
reader
a way as to remain fixed on the vehicle
during the ongoing production process.
It survives the painting process, one can
read and write on it, and it makes confusions impossible. The accompanying
RFU630 RFID reader utilizes UHF technology and provides ideal reading and
writing properties, specifically for applications in car manufacturing. Reading and
writing on the transponders takes just a
few milliseconds, which makes it possible
to achieve very good reading quality with
high scanning rates. Use of the accompanying IDpro-compliant interface allows integrating the solution easily into industrial
network environments. In this connection, the spectrum extends from ­Ethernet
(TCP/IP), PROFINET IO to EtherNet/
IP and all the way to PROFIBUS DP and
­DeviceNet as well as RS-232/422/485.
Further product information:
www.mysick.com/products
11
: IndustryFocusElectronics & Solar
>Electronics
Sensor technology for demanding automation
Solution competence
from SICK for the electronics and solar industry
Automated manufacturing processes for solar cells and electronics components require reliable and highly available sensors –
and the right application expertise. What SICK has to offer in this
respect cannot only be seen at the industry’s key trade fairs, but
is also summarized in the new Electronics & Solar Industry Guide.
>> Beyond that, SICK also takes into
account the importance of this industry
from an organizational perspective: by
means of the Electronics & Solar International Industry team. Within the SICK
Group, it focuses industry competence
and takes care of customers operating nationally and internationally in a
network together with Product Management, Sales, and Service. The exchange
within the team concerning applications
and the relevant manufacturing and sensor technologies ensures technically and
economically efficient customer solutions.
The industry experts from the Electronics & Solar team at SICK are well positioned
and networked worldwide
12
02 2011
: IndustryFocusElectronics & Solar
& Solar
Accomplishing more with
­intelligent sensor technology
New edition of the
Electronics & Solar
Industry Guide
SICK at the key trade fair of the solar industry
Broad solution portfolio
presented
With its sensor technology, SICK offers customers a large ­number
of suitable solutions for the photovoltaics and solar industry as
well as the electronics industry.
>> At the solar industry’s key trade fair,
the 26th European Photovoltaic Solar
Energy Conference and Exhibition (26th
EU PVSEC) in Hamburg, last September
SICK was represented for the fifth time
already, once again presenting this year
a great variety of solutions for the photovoltaics and solar industry. The focus of
attention was on sensors for detecting,
measuring, identifying, and positioning,
as well as for machine protection in ­solar
and flat glass production. Highlights resulting in many international contacts
and interesting specialist talks included
the W4-3 miniature photoelectric sensor,
Data Matrix identification on solar wafers
and thin-film modules/glass substrates
with the LECTOR®620 image-based code
reader, and wafer edge control using the
Inspector vision sensor. Accordingly, the
exhibition stand attracted numerous visitors. All of those not able to attend personally have an opportunity here to take
a virtual tour of our exhibition stand on
the Internet: www.sick.com/pvsec
Sensor solutions related to printed
circuit board production and electronics assembly will be the focus of SICK’s
trade fair presence at the productronica
in ­Munich. At the world’s key trade fair
for innovative electronics manufacturing,
taking place from 15 to 18 November
2011, the Electronics & Solar International Industry team is in on the ­action
with a 50-square-meter (540 sq. ft.)
stand and the latest sensor ­technologies.
Visit us at the fair:
productronica 2011
from 15 to 18 November 2011
Hall A2 – Stand 355
>> The new enlarged edition of the Electronics & Solar Industry Guide from SICK
shows solutions along the entire manufacturing process in the electronics,
semiconductor, and solar industries. The
size of the chapter on solar energy has increased substantially due to the addition
of new sections concerning wafer production, thin-film technology, and glass handling. All representations of applications
in the catalog are 3D-supported. The new
product pages inform readers about the
essential features of the sensors presented. The Industry Guide is available in German, English, Chinese, and Japanese.
Sensor technology from SICK:
solution competence in focus
SICK’s overall portfolio offers a large
number of innovative sensor solutions for
the electronics and solar industry from
a single source. Examples to mention
­include opto-electronic, electromagnetic,
as well as ultrasonic sensors in handling
systems and solutions for identifying solar cell boxes, solar modules, or ­individual
solar cells. The spectrum also includes
vision sensors, smart and 3D cameras,
as well as vision systems for inspection
tasks of varying complexity. Beyond that,
electromechanical or electro-sensitive
protective equipment provides for the optimum combination of safety, availability,
and ergonomics on both semi-automated
processing
stations
and fully automatic
­robot work cells.
The new Industry
Guide presents products and solutions
for the electronics
and solar industry
13
: IndustryFocusElectronics & Solar
Diameter control & hazardous point protection
Fork sensor delivers desired accuracy
Diameter control at the panel mill
Perfectly integrated into the machine design, the V300 Work Station Extended camera system secures the access opening in
the area of a rotary table to protect the operator
Is the right cutter loaded? To what extent has its wear limit been
reached? In the panel separation (depaneling) systems of ASYS,
a manufacturer of electronics and solar plants, WFL5 laser fork
sensors provide these important process data. At the same time,
V300 Work Station Extended safety camera systems protect operators from hazards.
>> Utmost accuracy is essential when
detecting the milling cutters, as the rotating tools have a diameter of only 1.5
to 3 mm.
ASYS – plant technology for
electronics and solar
The ASYS Group of companies, whose
corporate headquarters are located in
14
Dornstadt near Ulm, is a globally operating technology company with more than
800 employees. In the market segment
covering the solar industry, ASYS holds
a leading market position worldwide,
supplying highly developed metallization
lines in the back-end area and innovative
platform solutions in the front-end area
of solar cell manufacturing. Developed
for the electronics industry, the group
of companies develops, manufactures,
and markets high-quality and technically
innovative machines and plants in the
areas of handling, marking, depaneling, final assembly, testing, and screen
­printing.
Depaneling by mini milling cutters
The depaneling solutions of the ADS (automated depaneling systems) family of
plants are semi-automatic and fully-automatic panel separation systems for singulating multiple printed circuit boards.
Small milling tools measuring only a few
millimeters in diameter cut out the individual circuits. Depending on the batch,
the machine operator loads milling cut-
02 2011
: IndustryFocusElectronics & Solar
spots, since once can accurately adjust
the area to be detected to the predetermined geometry using the reflective
strip.” Simple integration is complemented by first-rate operating ergonomics at
the workstation.
ling cutter
ters with varying diameter. In order to
avoid operator errors, i.e. insertion of the
incorrect milling cutter into the spindle,
and to detect critical tool wear during
the milling process automatically and in
time, ASYS has equipped the depaneling
systems with diameter control.
Laser fork sensor works
precisely and fast
“After various tests we decided in favor of
the WFL5 laser fork sensor from SICK,”
says Armin Haug, Application Technician
at ASYS. “This sensor features extremely
fast signal processing as well as a very
precisely focused light beam, which allows detecting even small differences in
diameter very accurately.” The WFL5 detects the rotating milling cutter, despite
its segmented cutting edges that look
like teeth, as an “enveloping” whole. After changing the tool, one can thus check
the correct mounting in the spindle, the
correct mounting height, and the correct
diameter prior to the start of processing.
During the separation process, the milling cutter is checked for wear regularly.
For this purpose, it is moved through the
fork of the sensor at approx. 400 mm/
min to measure the current diameter
with high accuracy. In this way, ASYS ensures highly available and high-quality
depaneling with its ADS facilities.
Monitoring hazardous points
with safety camera system
In front of the milling cutter’s operating
area, there is the access area of the machine, where the panels are located on
a rotary table. In order to avoid accident
risks for the operator due to rotary motions, this hazardous point is protected
by a V300 Work Station Extended safety
camera system. “The sensor has the
great advantage that it can be integrated
perfectly and discreetly into the machine
design,” says Armin Haug. “In addition,
there are neither overlaps nor blind
Long-standing and proven cooperation
ASYS and SICK have been technological
partners for many years when it comes
to efficiently automating processes for
production plants in the electronics and
solar industry. Continually, they work out
solutions that offer end users advantages with respect to performance, quality,
and safety of manufacturing and transfer
processes. Another example worth mentioning is µ-precise monitoring of gripper
fingers using displacement sensors of
the OD2 product family from SICK.
WFL5, V300 Work Station Extended,
and OD2 – three different sensors that
represent the diverse application solutions from SICK in the electronics environment.
Further product information:
www.mysick.com/applications
More about the customer:
www.asys.de
After the changing of the tool, the WFL5 laser fork sensor checks the correct mounting in the spindle, the correct mounting
height, and – even during ongoing operation – the correct diameter of the milling cutter. For this purpose, it is moved through
the fork of the sensor at approx. 400 mm/min
15
: IndustryFocusElectronics & Solar
Safe laser system controlling
High-powered lasers create safety challenges
Safe use of a high-power laser in
­electronics production
Laser is the technology of creating “coherent” light and using
the attributes of that highly focused light to shape materials. Because light is comprised of subatomic-sized photons, it is the
best solution for fabricating very small, or “nano” structures,
such as those required in electronics, semiconductor, and solar
wafer ­production.
>> Laser has become an established
process tool in these industries. Laser is
fast and very accurate when compared
to mechanical processes for the same
tasks. But, the properties that make
laser an effective, highly-focused light
energy can also make it a safety hazard
to operators. As a result, regulations in
most industries restrict how lasers are
used and provide guidelines to maintain
safety.
Has a grip on
the laser: the
Flexi Soft
safety
controller
16
A leading U.S. supplier of innovative
laser-based manufacturing solutions for
the micro technology industry frequently
uses power lasers (Class 4) in its equipment. The laser is used for cutting, trimming, ablating or etching electronic components. When using a laser, care must
be taken to meet the relevant safety requirements.
Creating a safe solution using
­applicable standards
Class 4 is the highest class of laser radiation. Radiation in this class is very
dangerous, and viewing the diffuse reflection may be harmful.
Laser light is highly regulated due
to potential human safety hazards in its
application. In the U.S., the relevant industry standard for laser/LED safety is
ANSI Z136. The standard addresses the
proper selection, application and use of
light-emitting devices with the potential
to create a safety hazard. In 2001, the
standard governing the safety of laser
products in Europe (EN) and internationally (IEC) was substantially revised
and the classification system was overhauled.
ISO/IEC, ANSI and OSHA require a
safety interlock system on machines that
uses Class 4 lasers along with specific
monitoring requirements. The customer
is using the Flexi Soft safety controller
and SICK interlock switches, emergency
stop switches and safety light curtains,
which meet the applicable standards for
safety-rated control of a laser system.
Flexi Soft is a modular solution that the
customer can expand and use on multiple types and sizes of laser cutting and
trimming machines. Optional gateway
communications for remote monitoring
and trouble-shooting of machine and
safety process are also available. The
solution monitors laser status (on/off)
and disables access to the laser trim
area when enabled and “on.” It also allows the e-Stop of laser and monitor
door status (open/closed). In addition,
it eliminates problems experienced with
interlock “bounce.”
SICK has the solutions to make laser
processing systems/machines safe. The
Flexi Soft controller can be adapted to
any type of laser processing system and
can be configured to protect as many or
as few points as required. It also has inherent monitoring and communications
capability so that the safety system and
the machine itself can be remotely monitored for performance. This improves
uptime and provides productivity benefits to the machine owner. SICK and
laser processing make a powerful combination for improved production of very
small components.
Further product information:
www.mysick.com/applications
02 2011
Bar code identification & checking for presence
: IndustryFocusElectronics & Solar
Combined solution for solar producers
Identification and checking for
­completeness in one
With the help of bar code scanners from SICK, a manufacturer
of conveyor systems from Taiwan has implemented a solution for
simultaneous identification and checking for completeness of
­wafer boxes at a producer of solar wafers.
CLV650-6000
>> In the packaging and transporting
process, 100 wafers at a time are packaged into a box labeled on top with a
Code128 bar code. In the next step, 10
boxes each are packaged into a carton
bearing a Code39 bar code. The task
for the manufacturer of the conveyor
system was identifying the boxes, recognizing shortages, and detecting the
markings of the carton.
No code, no box
CLV650 bar code scanners are used to
identify the boxes. They are installed
above the level of the conveyor system.
Their special sorting function allows
reliable detection of missing codes –
and thus missing boxes – while the bar
codes on all boxes present are read at
the same time. Simultaneously, the carton with the boxes is identified by another bar code scanner from SICK installed
at the side of the conveyor system.
Inner box
with bar code
Outer box
Stop point
CLV431-1010
In this way, the solar producer knows
which boxes are found in which carton
and which of the cartons are not complete.
Further product information:
www.mysick.com/applications
Identifying boxes present, reporting missing boxes – with a single scan,
the CLV650 solves two tasks at once
>> Product information CLV650
The CLV650 bar code scanner features a reading field of 200 mm to­ 1,600 mm with real-time auto focus
and integrated distance measurement,
which guarantees top reading reliability even in case of high plant throughput and the most diverse object sizes.
Ethernet on board and integrated web
server functionality for scanner diagno-
sis are just as much part of the scope
of features as the proven two-stage
fieldbus integration concept with separate connection box. The parameter
cloning option ensures minimum times
for replacing devices – either via cloning module or via micro SD card. Added
to this are the SMART decoding algorithms that have been refined further.
17
: IndustryFocusElectronics & Solar
Solar tracking
Encoders from SICK optimize energy yield
Solar panels follow the path of the sun
When equipping solar parks, the Italian EAR Group Company relies
on encoders and inductive proximity sensors from SICK. The main
reasons are precision, ruggedness, and ­“guaranteed” ­quality.
>> EAR Group is a major supplier of turnkey photovoltaic systems in Italy. The plant
which the company has ­constructed in the
Italian town of ­Cerbera on an area covering 30,000 m² (approx. 35,850 sq. yds.)
consists of 93 solar fields with 33 solar
panels each. ­DC-AC inverters convert the
direct current ­generated into alternating
current on ­location. The overall output of
the facility is 700 kWp.
More efficiency through
tracking of p
­ anels
EAR Group has designed the panels in
such a way that they follow the sun’s
path automatically. This approach results in a substantially higher energy
18
yield than using rigid panels. The repositioning motion is controlled by so-called
trackers that change the alignment of
the photovoltaic collectors at varying
minute intervals. Two motors are operating in the trackers: One aligns the panel
to the position of the sun, the so-called
tilt; the other provides for extremely precise tracking of the panels during the
day corresponding to the path of the
sun. Each of these current deviations of
a solar panel in relation to the alignment
due south is called azimuth. At –90° the
solar cells are aligned toward the east
in the morning; they are supposed to
be at +90° in the evening after sunset.
This tracking of panels allows the sun to
hit the solar cells vertically at any given
time. This approach results in the optimum energy yield, which may be at up
to 40 percent higher than that of firmly
installed panels.
Both tracker motors are equipped
with DFS60 incremental encoders featuring through hollow shafts. To achieve
mechanical integration for tilt tracking, it
was necessary to mount the encoder directly on a motor-driven rotating mechanism and to convert the rotating motion
by means of a linear guideway into linear travel for the solar field. The azimuth
tracking is controlled by an encoder installed in a separate casing on the concrete foundation of the solar field.
Encoder technology, also convincing
in harsh operating conditions
“We decided to opt for this sensor from
SICK because it features very high reso-
02 2011
: IndustryFocusElectronics & Solar
»All in all, however, it is not just the
sensors that are convincing, but also
the technical support«
Inductive proximity sensors
signal overtravel
Both at EAR Group and the parent company, Siem Impianti, SICK is known as
a reliable partner leading in technology
and oriented towards solutions. “Therefore, we are also using other sensors
from the portfolio, e.g. inductive sensors of the IME product family that detect overtravel,” says Gianluca Narducci,
who is also Technical Manager at Siem
Impianti, where he uses, among others,
safety light curtains and photoelectric
sensors from SICK as well.
The inductive proximity sensors limit
the travel of the trackers and are mounted in such a way that both in the summer
and in the winter, one can get the most
out of the solar radiation. The sensors
are positioned for tracking motions up
to 240°. In the summer, 240° are necessary to follow the sun – in the winter
120° are sufficient. The inductive proximity sensors allow using the optimum
tracking paths, while at the same time
detecting possible overtravel beyond the
end position.
The panels are aligning automatically
toward the sun. They work with motors
that are equipped with encoders from
SICK for azimuth tracking.
lution and permits precise tracking of
the panels,” says Gianluca Narducci,
Technical Director of EAR Group. “What
convinced us beyond that was its ruggedness in outdoor use and its compact,
easy-to-integrate design. Moreover, to
us, SICK as a brand name stands for
guaranteed quality.” Indeed, features
such as the metal code disk, dual shaft
bearings, high enclosure rating, and the
water-resistant cable outlet make the
DFS60 a sensor solution that guarantees maximum availability in all kinds
of weather and temperatures between
–30 °C and +100 °C (86 °F to 212 °F).
SICK convinces with
support and a
­ vailability
“All in all, however, it is not just the sensors that are convincing, but also the
technical support as well as the fact that
the sensors are available worldwide in
case one requires replacement,” says
Gianlucca Narducci. He offers praise
for the assistance and 24/7 availability
of Carlo Sportiello from Sales at SICK
Italy, as well as the support by the technical product specialists from SICK. This
­applies not only to this project: For many
years now, the quality of products, the
support in projects, and the high delivery
reliability have helped establish a close
partnership between the ­companies.
Further product information:
www.mysick.com/applications
More about the customer:
www.eargroup.it
>> Product information
DFS60 incremental encoders
The high-resolution DFS60 family
of incremental encoders with high
enclosure rating and water-resistant
cable outlet withstands all kinds of
weather.
Inductive proximity sensors
of the IME product family
The inductive proximity sensors of
the IME product family enable use
of optimum tracking paths both in
summer and in winter.
19
: Views & Voices
Systems and networks in automotive manufacturing
Connectivity @SICK
PROFINET IO proves its worth in practice
In conversation: Ulrich Lichtblau,
­Electrical Planning at Volkswagen
­Commercial Vehicles in Hanover
drives, robots, process devices, and control units into the network.
SICKinsight: What advantages do you
see in using PROFINET IO?
Ulrich Lichtblau: For the first time, we
are able here to integrate the safety technology as well and to use the configuration and diagnostic services throughout
by means of integrated tools. Something
quite essential to us is the possibility to
employ polymer optical fibers continuously all the way to the components.
SICKinsight: What advantages does the
use of OWG (optical waveguide) tech­
nology yield?
Flexible production and automation are catchwords describing
the challenges currently faced by German car manufacturers.
PROFINET IO with integrated personal safety plays an important
role in this context. SICKinsight spoke with Ulrich Lichtblau, Electrical Planning at Volkswagen Nutzfahrzeuge (Volkswagen Commercial Vehicles) in Hanover, who is responsible for systems and
networks in production.
SICKinsight: As a car manufacturer,
which areas of use do you see for PROFINET IO?
Ulrich Lichtblau: PROFINET IO is used
across the board in all manufacturing
segments such as the stamping facility,
body construction, painting, and assembly at the Hanover location. Thus, we are
consistently integrating all automation
components, such as complex sensors,
20
Ulrich Lichtblau: So far, we have fared
very well in building up OWG. These networks feature higher plant availability,
better EMC – important in the field of
welding – as well as the means of integrated performance diagnosis. Equipped
with warning thresholds, this set-up provides us with the possibility of quality
assessments regarding the automation
network in ongoing operation.
>> Information: S3000 PROFINET IO-OF Professional
The S3000 PROFINET IO-OF Professional (optical fiber) is based on the proven
technology of the S3000 safety laser scanner. All variants featuring safe PROFIsafe for PROFINET communication have performance characteristics such as a
protective field with a range of 7 m and 8 programmable protective fields. Polymer
optical fibers (POF) for wavelengths of 650 nm are used for connecting to the integrated optical fiber interface. This increases electromagnetic compatibility (EMC)
and results in better plant availability.
02 2011
: Views & Voices
advantage of PROFINET the possibility of
remote maintenance, for servicing all the
way to the individual components listed
above. In this way, we reach higher availability of the plant as a whole.
SICKinsight: What is your take on the
use of the S3000 safety laser scanner
from SICK?
>> Brief information on Volkswagen Commercial Vehicles
Within the Volkswagen Group, the Volkswagen Nutzfahrzeuge (Volkswagen Commercial Vehicles – VWCV) brand is responsible worldwide for development, production, and sales of light commercial vehicles, multi-purpose vehicles, and recreational vehicles. The range of models extends from the lightweight Caddy urban delivery
van, to the T5, the Crafter cargo van, and all the way to Volkswagen’s new Amarok
pickup. The highly variable T5 series, the fifth-generation Volkswagen van, is built in
all of its different versions – the Transporter, Caravelle, Multivan, and California – at
the main plant in Hanover. In addition to the T5, the location also manufactures the
painted bodywork of the Porsche Panamera. Starting in mid-2012, the site will also
see production of the European contingent of VW’s Amarok pickup, which up to now
rolled off the assembly line exclusively at the Argentinean Pacheco location.
Ulrich Lichtblau: For us, it is an important element within the integrated automation system, representative of the
area of safety-capable components with
PROFIsafe. The S3000 is used mainly in
the new body construction and the assembly shop. In this context, the PROFINET IO interface is advantageous. Even
at the planning and commissioning stages, we have less I/O to plan, wire, and
test. We can parameterize the device
outside of the work cell. This allows optimizing the safety scanner more quickly,
something particularly important during
conversions and extensions. After all,
this makes us more flexible when producing different new models.
SICKinsight: Mr. Lichtblau, many thanks
for this informative interview.
Further information about
Volkswagen Nutzfahrzeuge:
www.volkswagencommercial-vehicles.com
www.volkswagen.com
SICKinsight: Could you please give us
an example to explain this in detail?
Ulrich Lichtblau: Here at the Hanover
site, the existing infrastructure, such
as, e.g., the power networks, remain in
place even in the course of conversions
for other vehicle types. Our facilities are
supplied both by the TN-C networks (general network) and TN-S networks (welding network). By using OWG, we achieve
better decoupling. We regard as a further
Optical fiber technology
in use – the S3000 PROFINET IO-OF
Professional
21
: Applications
Differentiation of pallets
Finding the right pallet with IQ
IQ40 inductive sensor sorts wooden
and plastic pallets
Some things are as simple as they are ingenious. Sometimes
one just has to think “around the corner.” In the case at hand,
the Swiss wholesaler and retailer Migros Aare wished to distinguish between plastic pallets and wooden pallets. The idea: Use
a reasonably priced inductive proximity sensor. It detects the
nails in the boards of the wooden pallet. They interfere with the
field and switch the points. Not without reason, the IQ40 series
from SICK is used in this operation.
>> Since 1925, Switzerland’s largest retailer, the Migros Cooperative, has been
the bridge between producers and consumers. Today, about 780 suppliers deliver goods to Migros, supplying the 700
branch stores with about 330,000 different articles on a daily basis. Thus, every
day approx. 7.6 million load devices such
as plastic packaging units, Euro pallets,
etc. move back and forth between goods
suppliers, distribution centers, and stores.
Wooden pallets reach limits
In the warehouse of the largest regional
cooperative, Migros Aare in Schönbühl,
every day sees shipment of 4,500 to
5,500 pallets with diverse articles to the
branch stores. In many applications, pal-
lets made of wood are reaching their
limits due to their susceptibility to breakage and distortion. In addition, they have
the negative property of absorbing water,
which can make them weigh up to 40 kg
(approx. 88 lbs). Plastic pallets are lighter,
more hygienic, and they can be fitted optionally with two to six steel pipes for reinforcement. For this reason, Migros is testing plastic pallets made by the Swiss Utz
Company for suitability in everyday use.
This poses new challenges for warehouse
management, as the plastic and wooden
pallets must now be stored and entered
separately.
High demands on sensor technology
“We wished to separate the plastic pal-
lets automatically and reliably from the
wooden pallets,” says Anton Loosli, Manager Maintenance Delta. The demands­ on
the sensor technology were relatively high.
The ambient conditions are extremely
harsh while installation options are very
limited. Optical sensors were usable only
to some extent and more susceptible to
malfunctions.
Thinking “around the corner”
For separation, IQ40 inductive proximity
sensors wired differently and featuring a
sensing range of 35 mm are installed between the transport rollers of a conveyor
belt. They recognize whether nails are
present in the bottom of the pallets. If
this is the case, the sensor actuates the
transverse conveyor and sorts them out.
The compact, rectangular proximity sensor has increased sensing ranges and an
active sensor surface that can be aligned
in five directions. Using the M12, 4-pin device plug, one can install the sensor very
quickly and replace it easily. “We are satisfied with this extremely cost-effective solution. It goes to show that ‘thinking around
the corner’ pays off.”
IQ40 inductive proximity sensor
in use between the transport rollers
of a conveyor belt
Further product information:
www.mysick.com/applications
More about the customer:
www.migros.ch
www.utzgroup.com
22
02 2011
Centering of pallets and magazines
: Applications
Adil Kuscu, Design Engineer Mechanics
at KHS in Worms, and Bernd Brockhoff,
Key Account Manager, SICK VertriebsGmbH Düsseldorf
Pallet and magazine centering in palletizers
Easy to install, precise,
and detecting reliably
KHS, a worldwide leader in system solutions for filling and packaging in the beverage industry, relies on the MPS magnetic cylinder sensor from SICK for precise and process-reliable centering of
pallets and storage magazines.
>> With annual sales of nearly one billion euros, more than 5,500 employees
worldwide, and over 6,000 complete facilities for the beverage industry installed
on all continents, KHS ranks among the
top addresses when it comes to innovative and high-quality filling and packaging solutions. “At the plant in Worms, we
are responsible for palletizing systems
as well as packaging and unpacking
solutions, i.e. for essential segments of
dry-component technology within the
KHS Group,” says Adil Kuscu, Design
Engineer Mechanics at KHS in Worms.
This also includes the palletizer systems
of KHS’ Innopal series for refillable and
non-refillable containers. “These are
highly flexible, two-pillar palletizers,” ex-
plains Hans-Werner Holzer, the Product
Manager in charge at KHS in Worms,
adding: “Depending on the model, they
are suitable for processing non-refillable containers, such as cartons, trays,
shrink-packaging units, unit packages,
bags, as well as refillable containers.
Thus, they cover all of the loading tasks
both of the beverage industry and in the
food and non-food market.”
Process reliability for flexible
palletizing sequences
In terms of design technology, flexible layout of the palletizers requires automatic
centering processes for different formats
of containers and inserted liners. This ensures that the pallets can be loaded level
after level in the optimum way and without projections at positioning cycle times
of six seconds and that the inserted liners can be placed with a perfect fit. KHS
achieves this format-specific centering in
a series of machines by employing two
pneumatic cylinders each per travel direction. Due to tolerances in piston movement, it became apparent that the reed
contacts used did not always detect the
switching points in a process-reliable way.
With the MPS, SICK managed to offer a
sensor alternative that is reliable, easy to
integrate, and – for KHS and the final customer alike – economical. “An additional
element is that in practical operation the
MPS proves to be particularly process-reliable because it continuously delivers accurate measuring values, thus detecting
dependably all switching points that we
require for the different crate and magazine formats,” says Adil Kuscu.
MPS: analog distance measurement for
vertical travel from 32 up to 256 mm
The MPS magnetic cylinder sensors cover measuring ranges from 32 mm to 256
mm in 32-mm increments – with minimized blind zones. The construction of
the IP67 Housing is designed in such a
way that it allows fast drop-in installation
from the top into all common T-slots and
quick fastening with two screws. Polling
of pistons occurs very rapidly and with
high resolution. “With the help of the
MPS, the pneumatic cylinders achieve a
superb level of accuracy when centering
crates and positioning the inserted liner
magazines,” confirms Adil Kuscu.
Further product information:
www.mysick.com/applications
More about the customer:
www.khs.com
23
: Applications
Height control for pallet and container stacking
Height control on pallets and packaging units at Geberit
Light grids enable optimum use of ­cargo space
About 500 pallets containing sanitary articles leave Geberit’s production site in Rapperswil every day. In order to achieve the best
possible utilization of cargo capacities in the trucks, the packaging units are automatically stacked prior to loading. Height control
takes place using automation light grids from SICK.
>> Geberit AG ranks among the quality
and market leaders in the field of sanitation engineering. The product range
includes sanitary systems such as flushing cisterns and inner fittings, faucets
and flushing systems, waste fittings
and traps, showers and toilets, as well
as pipe systems for domestic drainage
and water supply. In part, the components are produced at the new production site in Rapperswil-Jona, where they
are also made available for shipment by
truck to a Geberit plant in Germany. In
order to optimize shipment efficiently in
terms of logistics and in an ecologically
sustainable way, Geberit commissioned
the plant manufacturer Graber AG in
Fahrwangen with building a pallet conveying and stacking facility. Its task is to
stack pallets and packaging units and
to make them available at the shipping
ramp in a way that achieves the best possible utilization of truck transport capacity. “In terms of automation technology,
the plant is firmly in the hands of SICK,”
says Fabian Gfellner from Indumont, the
implementing partner company. “The devices used are safety light curtains, photoelectric sensors, and bar code scanners from SICK. We managed to solve
height control by means of two automation light grids, which enabled us to obtain the entire sensor technology except
for the scale from a single source.”
Precise height measurement through
single-beam evaluation
The pallet and stacking facility connects
production with the new logistics system
for truck loading. Indumont designed
and merged all required plant components – scales, sensors, as well as the
control, conveyor and lifting systems.
Special focus was on the most precise
24
height detection of the stacks possible.
Two automation light grids are in use for
this purpose. The high-resolution HLG is
employed to detect the wooden pallet. “It
has exactly the right height to detect the
clearance of the pallet. This is not possible using a single photoelectric sensor, because it would look through the
pallets,” says Fabian Gfellner. The MLG
automation light grid detects whether
the object in question is a normal pallet or a pallet with mesh or how high the
loading height is. “The MLG was very
easy to align and commission,” Fabian
Gfellner recalls. “The decisive aspect for
the task at hand is the option of singlebeam evaluation offered by the MLG. In
this way, one can detect the height of the
respective packaging unit almost down to
the millimeter.”
Since what takes place at the stacking stations is not limited to height detection but also includes weighing the pallets
and identifying them by means of their bar
codes, the values known for each stack of
pallets are their weight, the content of the
individual packaging units, as well as the
overall height and weight. When it comes
to loading, this information constitutes
the basis for utilizing the transport capacity of the trucks in the best possible way.
In terms of the sustainability that Geberit practices in all of its business segments, this logistics solution supports the
high environmental standards to which
the enterprise has committed itself.
Further product information:
www.mysick.com/applications
More about the customer:
www.geberit.com
www.indumont.ch
www.graber.ch
Two automation light grids that complement each other: the HLG detects wooden
pallets (photo on the right), the MLG detects the load height (photo on the left)
02 2011
Detection of lamellae
: Applications
ante-holz GmbH: competence in sawing, planing,
and glulam wood technology
Sensor with light array increases efficiency in production ­processes
SICK’s new WL27-3 Reflex Array photoelectric sensor, featuring
a light array 50 mm in height, increases productivity in material
transport. In this way, ante-holz GmbH managed to enhance efficiency and thus plant availability when transporting wood on
­conveyor systems.
>> Headquartered in BromskirchenSomplar, ante-holz GmbH looks back on
a more than 80-year tradition in sawmill
operations and in dealing with the wood
products associated with it. The core activities focus on the area of sawn timber,
laminated wood, framework construction,
garden or outdoor wood, and energy.
The company offers all dimensions of
laminated (glulam) wood, solid structural
timber (KVH®), as well as sawn timber. At
the framework construction center, roof
timbering and wooden frame constructions are manufactured tailor-made. The
outdoor segment extends from, for instance, the carport to outdoor furniture,
and toys, all the way to fences. Finally, the
production of pellets completes the product program. The manufacture of such a
large variety of wood products as well as
delivery on schedule requires smooth processes in production and logistics.
WL27-3 Reflex Array photoelectric
sensor increases efficiency in transporting lamellae for laminated wood
In a preliminary stage of laminated wood
production, the lamellae or boards are
transported from the galvanizing plant
to the storeroom by a roller conveyor. Afterwards, the lamellae are stacked in the
roller conveyor and conveyed to the next
processing step. In the transfer unit, collisions and delays occur repeatedly because it is activated prematurely, even
though the lamella possibly has not been
completely placed in the transfer unit yet.
The reason is the previous use of a photoelectric proximity sensor featuring a pointshaped light spot. The lamellae with small
height start swinging, causing the switching signal of the photoelectric proximity
sensor to interrupt because the lamella
is located briefly outside or, respectively,
above the light spot. The solution is the
WL27-3 Reflex Array photoelectric sensor.
Using the light array measuring 50 mm
in height, it is capable of reliably detecting even a lamella swinging on the roller
conveyor. The sensor’s switching signal is
not interrupted. This method significantly
increases productivity, particularly in fully
automatic operation.
WL27-3 Reflex Array,
the cost-effective solution
The WL27-3 Reflex Array photoelectric
sensor thus replaces several separate
With the light array 50 mm in height, the
WL27-3 Reflex Array photoelectric sensor from SICK reliably detects even swinging lamellae on the roller conveyor
photoelectric retro-reflective sensors.
The light array is generated by the combination of the PinPoint LED and a special
lens system. The novel contamination
compensation enhances the availability
of the photoelectric sensor above average. This means that the cleaning intervals for the external lens surfaces are extended significantly, thus reducing costs
overall.
Further product information:
www.mysick.com/applications
More about the customer:
www.ante-holz.de/en
25
: Applications
Baggage identification
Hybrid solution for baggage identification
Bar code + RFID: the formula for
100-percent read reliability
No search and handling costs for lost or delayed baggage – Helsinki-Vantaa International Airport benefits from the use of the
ALIS400 Hybrid code reading system from SICK. The combination of bar code and RFID technology helps achieve read rates of
100 percent.
>> Improved reliability in sorting and
conveying transfer baggage increases
satisfaction among passengers, airlines,
and the airport operator.
Baggage handling without “stopover”
At 13 million passengers a year, HelsinkiVantaa International Airport is the largest
airport in Finland and the fourth largest
in northern Europe. Due to its geographical location, it serves many airlines as a
hub for long-haul flights between Europe,
North America, and Asia. In 2009, the
state-owned airport operator, Finavia
Corporation, extended the terminal facilities. One focus was on smooth handling
of transfer baggage that possibly may not
be transferred in time or at all because of
unreadable luggage labels, which means
it must take an unscheduled stopover. In
order to evaluate the benefit of the hybrid technology, which is a combination
26
of bar code and RFID, for the optimization of transfer processes, Finavia decided to test the identification of transfer baggage from Hong Kong, which is
tagged there exclusively with bar code
RFID labels. The goal was reliable handling of the transfer baggage between
the terminals and the new Baggage Logistics Center.
No read figures in a nosedive
Finavia opted in favor of the ALIS400
Hybrid – the code reading system with
integrated bar code and RFID reading
technology. Developed completely by
SICK, it was integrated by the Danish
Crisplant Company. Within the tunnel,
a homogenous and consistent reading
field is generated, shielded against any
cross interference form outside. It allows
reliable identification and localization of
the RFID tag on the piece of luggage. The
Bar code and RFID technology from
SICK optimizes baggage identification at
Helsinki-Vantaa International Airport
bar code portal, the second component
of the system, detects the luggage label
in any position and orientation. When a
piece of baggage from Hong Kong passes the tunnel, both the bar code and the
RFID tags are being read. In the baggage
handling facility in Helsinki, the ALIS400
Hybrid makes possible a 100-percent
read rate for the transfer baggage from
Hong Kong, with the number of non-identifiable baggage in a nosedive.
Further product information:
www.mysick.com/applications
More about the customer:
www.helsinki-vantaa.fi
www.finavia.fi
www.crisplant.com
02 2011
Automated baggage check-in
: Applications
For more leisure time before the flight
Qantas automates self check-in using
technologies from SICK
ICM Airport Technics Australia, together with SICK Australia, has
developed fully automated stations for Qantas Airlines for self
check-in of air travel baggage. In an integrated network from a
single source, RFID and bar code reading devices, automation
light grids, and laser measurement sensors ensure maximum reliability and optimum ease of use.
>> Going shopping instead of lining up
– that is the option Qantas offers its passengers by operating the new bag drop
systems. ICM and SICK were able to provide the Australian airline with the appropriate complete solution – and doing so
very quickly at that. Within a mere three
months after the start of the project, the
first prototype was presented and tested
successfully in December 2009. Perth
Airport began operating the first bag
drop system in May 2010. Sydney, Melbourne, Brisbane, Canberra, and Adelaide followed suit.
Success due to close cooperation
Meeting the tight schedule became feasible through close cooperation by ICM,
Qantas, SICK Australia, and the specialists of SICK AG in Waldkirch. The specia-
list expertise of those involved as well as
specific tests and optimizations of the
system designs led to the solution eventually realized. It consists of complete
bag drop stations integrating the entire
sensor and control technology, which
could be installed and commissioned as
a module. One further advantage of this
design: The software parameters had to
be configured only once – for the first
station. After that, three mouse clicks
sufficed to copy them to the additional
systems.
Checking in baggage without stress
In the new world of Qantas frequent flyer
passengers, there is now only one piece
of paper left: the boarding stub when
boarding the plane, which in­cludes the
seat number. The bag tag that is tradi-
tionally attached to the baggage prior
to check-in has been replaced with a
permanent RFID Q-tag and the boarding pass has been integrated into the
frequent­ flyer card.
From there, it’s only a few steps to
the bag drop station, which weighs the
piece of baggage upon receiving it. Following this, the RFID or bar code reading
devices identify the bag tag. The automation light grid detects the dimensions
of the baggage. During automated conveyance, laser measurement sensors
ensure smooth transfer of the baggage
from the passenger to the conveyor sys­
tem. The entire process of self check-in
and bag drop takes only a fraction of the
time commonly required at the check-in
counter, avoids stress, and affords air
passengers more time prior to boarding.
Further product information:
www.mysick.com/applications
More about the customer:
www.qantas.com
www.icm-airtec.com
27
: Applications
Process monitoring in candy production
Continuous and trouble-free controlling of conveyor belts
Candy production without downtimes
Machine downtimes in candy production entail not only reduced
output but also problems concerning processing steps upstream.
In order to avoid both, SOLLICH, a manufacturer of special machines for candy production, relies on WTB12-3 photoelectric
proximity sensors from SICK.
>> In the course of its more than 80-year
company history, SOLLICH KG in Bad Salzuflen has become an innovation leader
in machines and plants for candy production through numerous patents and
process-related further developments.
Meanwhile the enterprise is a market
leader for candy bar machines as well
as candy molders, coating plants, and
chocolate tempering machines. And that
applies worldwide: The export quota is at
80 percent.
Process reliability means
utmost production availability
Monitoring the correct running of the
conveyor belts, e.g. in cooling channels,
chocolate coating plants, candy bar
and chocolate molders, or machines for
sprinkling, decorating, or refining, is an
important and – in terms of sensor technology – a demanding task. Contingent
on processing or environmental conditions, the belts may easily wander to the
left or right. This has to be detected early
on in order to move the belt’s barrel controllers appropriately, thus preventing
damage and a stop of production. Using the WTB12-3 photoelectric proximity
sensor from SICK, SOLLICH “bars” such
malfunctions.
Making the sensor available
quickly as a special version
The WTB12-3 is a high-performance
photoelectric proximity sensor with background suppression, particularly suited
for use in machines related to candy and
food production. Independent of material, color, and surface structure of the
conveyor belts, high detection reliability
is guaranteed in continuous operation.
In addition, the innovative chip technology ensures that interfering optical reflections from the surroundings are detected
and blanked dependably. The decisive
point for SOLLICH, however, was not
only sensor performance but also SICK’s
quick reaction when it came to making
the sensor available at short notice in
a special version that featured a timing
element and modified switching current.
Established in the food sector,
available worldwide
SICK has established itself as a sensor
supplier in the food-producing and foodpackaging industry and is recommended
by many manufacturers and end customers. For SOLLICH as a company exporting worldwide, these references, coupled
with rapid worldwide availability of the
new sensor version, were important service and safety arguments in favor of the
WTB12-3 that went beyond sensor performance. Direct quote from SOLLICH: “The
sum of all benefits speaks for SICK.”
The WTB12-3 photoelectric proximity
sensor from SICK monitors correct running of the conveyor belts
Further product information:
www.mysick.com/applications
More about the customer:
www.sollich.com
28
02 2011
: Applications
Emission measurement in marine engines
Emission measurement proven in practice
The Love Boat emits clean air
Marine vessel exhaust has to correspond to rigid exhaust regulations. As one of the first companies, Norwegian Cruise Lines has
tackled the issue of air pollution by installing an emission monitoring system on the Norwegian Epic. Customers can profit from
SICK’s experience with diesel power plants for the emission measurement of marine engines. The MCS100E HW analyzing system
is the solution.
>> As in all combustion processes, high
concentrations of sulfur dioxide and nitrogen oxides are emitted into the atmosphere during operation; for marine vessels, the high concentrations are caused
by the use of cheap fuel, often extremely
high in sulfur. To minimize the pollution of
the environment, very strict emission limits have to be observed. As initiated by the
International Maritime Organization (IMO),
the exhaust allowed for ­SO2and NOX will
be gradually reduced. The exhaust must
have the same concentrations as those of
a low-polluting fuel. Motor producers try to
reduce nitric oxide emissions by modifying
the motors. The NOx limits required after
2016 however can only be met by using
waste gas cleaning systems.
It makes sense to accurately monitor emissions so that only the allowed
amount of emissions is emitted into
the atmosphere. Therefore the released
amount depends on the accuracy and
reliability of measurement.
Approved and low-maintenance measurement technique is in demand
The MCS100E HW analyzing system accomplishes exactly this: It measures SO2
and NOx precisely and reliably and can
even be upgraded for the measurement
of further gas components. From the
sampling unit to the cuvette, all ducts
having contact with measuring gas are
heated over the dew point and thus protected against corrosion. Additionally, the
system offers two further advantages:
the measurement of water to enable calculations at standard conditions and the
check of CO limits to optimize the combustion process. The MCS100E HW – a
reliable system with low life cycle costs.
In future, only vessels able to observe
the limits will be allowed to pass into
emission-controlled areas, such as the
North and Baltic Seas and along the
US coasts. Therefore, the ships have to
depend on reliable, low-maintenance
analyzing systems, because while on
the ocean and during short stays in harbors, service technicians are not easily
accessible. Here, the MCS100E HW also
scores highly with its approved all-round
experience in emission measurement.
On board as well: the MCS100E HW
analyzing system from SICK
Further product information:
www.mysick.com/applications
More about the customer:
www.ncl.eu
29
: Applications
Protection of hazardous areas for bar-processing centers
Safety camera system for customer-friendly protection of hazardous area
Safety and improved operating
­ergonomics for bar-processing centers
Now elumatec GmbH can offer its customers even more ergonomic and efficient machines for processing sectional bars. This
is made possible by the V300 Work Station Extended safety camera system from SICK.
>> By supplying efficient, flexible, and reliable machines and processing centers
for sectional bars made of aluminum,
plastic, steel, and stainless steel, elumatec GmbH in Mühlacker has gained
international renown. The final products
comprised of the processed profiles include, among others, window, door, and
façade building, soccer goals, ships’
masts, superstructures for marquees, or
housings for sensors and cylinders. For
this purpose, the bar-processing centers,
e.g. of the SBZ131 series, are capable
of drilling and milling sections measuring
several meters fully automatically from
up to five directions. “The machines work
most efficiently in reciprocal operation,”
explains René Begoihn from Electronics
Development at elumatec. “To this end,
the machine, operated by one person,
has two stations to which the tool head
moves alternately. At the point where the
head is not working at the moment, it is
possible to insert raw sections and to remove processed sections.”
No impediment through
safety t­ echnology
Access to the entire machine is monitored by two M4000 multiple light beam
safety devices from SICK – one system
each per operating side. To ensure that
within the protective field the operator
neither comes too close to the travel of
the tool head with the machine running
nor is able to change from one side to
the other, elumatec has used a mechanical guard until now.
“An increasing number of customers demanded from us an alternative
to the mechanical protective device in
the middle of the machine, because it
makes operation, particularly in case of
long sections, far more difficult,” says
Thorsten­ Gienger from Mechanics Design
at elumatec­. Previous approaches to a solution failed: Horizontal light grids turned
out to be tripping hazards, pressure mats
broke down within a short time due to
fallen chips stamped into the mats, and
single-beam photoelectric safety switches
proved too susceptible to misalignment.
Station Extended: „Two bolts, one connection cable, and teaching-in of the protective field without elaborate, precise
alignment to the reflective strip – we
never had it this easy with an electrosensitive protective device.” Moreover,
elumatec’s customers are enthusiastic
as well, since the machine’s new safety
design permits significantly more ergonomic and productive bar processing.
Rolf Kribl, SICK Vertriebs-GmbH;
René Begoihn, elumatec GmbH;
Wolfram Tanner, SICK AG,
and Thorsten Gienger, elumatec GmbH
(from left to right)
Ergonomic and efficient bar processing due to safety camera system
“With the V300 Work Station Extended,
we now have a solution that avoids these
disadvantages,” says René Begoihn.
“The sensor is not affected even by the
sometimes harsh operating environment with the risk of spray from drilling
oil as well as chips falling through the
monitoring field.” For the reflective strip,
elumatec has found a clever because
obvious solution: “We simply attached it
to the rear side of the M4000 housing
columns,” says Thorsten Gienger. Both
he and his colleague, René Begoihn,
were thrilled by the simple installation
and commissioning of the V300 Work
Bar-processing machine
from elumatec
Further product information:
www.mysick.com/applications
More about the customer:
www.elumatec.com
30
02 2011
Modular safety concept for production of furniture panels
: Applications
Plant operation, section by section
Flexible production using a modular
safety concept
At the Belgian Unilin Company’s Ooigem plant, the use of the
Flexi Soft safety controller from SICK has substantially reduced
changeover times through use of a flexible safety concept.
>> Thanks to Flexi Soft, the furniture
panel production lines can be quickly
modified to manufacture a different
product, thereby making them operate
more economically.
Protection in sections
Unilin, headquartered in the Belgian
town of Wielsbeke, is one of the leading manufacturers of laminate floors,
engineered wood, self-supporting and
insulating roofing elements, as well as
insulation boards made of polyisocyanurate. At the Ooigem plant, chipboards
and medium density fiberboards are processed into decorative furniture panels
in multiple process steps. The stations
for positioning the boards and decor paper, for pressing, laminating, and cutting
paper edges, for sawing to size, for stacking and transporting the materials away
are monitored by protective fences with
access doors as well as electro-sensitive
protective equipment. Emergency stop
and enabling switches complement the
plant’s safety monitoring. However, previous plant operations still had potential for more efficiency, as during each
batch change – on average after approx.
100 press events – the entire production
line had to be shut down completely for
changeover. With the help of the Flexi
Soft safety controller, it was possible to
make this rigid and time-consuming design more flexible by dividing the facility into eight different sections. This approach now allows for the changing of
individual plant sections over to the next
batch while other sections of the production line are still running.
Safety solution, tailored perfectly
It was possible to tailor the new safety
and operating concept based on the
Flexi Soft safety controller perfectly to
the requirements at Unilin. Three Flexi
Soft CPUs are integrated into a Flexi
Link network where they process approx. 250 inputs and 100 outputs via
the pluggable I/O modules. In terms
of safety logic, the plant is divided into
eight sections, which are monitored independently of each other by the Flexi
Soft – and which accordingly are flexibly
accessible for changeover work. In addition to the new safety controller, the
facility was also equipped with several
operating panels, which serve to visualize the state of the safety system as well
as allow for visualization of diagnostic
information such as errors and their
cause. This improves the plant’s availability and efficiency even further.
Future-proof IT integration
Communication between the plant’s PLC
and Flexi Soft is done via Ethernet; data
exchange between the control level and
the operating panels takes place via
PROFIBUS. In this way, the diagnostic
functions of Flexi Soft were integrated
into the visualization.
Implementation without
specific ­expert knowledge
Unilin’s own employees implemented the
new safety concept largely by themselves.
After receiving training from SICK, they
were able to establish data exchange
from the safety controllers to the existing PLCs and to program them independently. A helpful feature was the Flexi Soft
Designer software from SICK with which
Unilin used to carry out the programming
and which can be downloaded online free
of charge. Now it serves to manage and
operate the safety system as well as adjust the safety controller accordingly in
case of subsequent changes.
Further product information:
www.mysick.com/applications
More about the customer:
www.unilin.com
31
: Technology
Industrial communication & device integration
Replacement of analog sensor technology in sight
Opto-ASICs for the first time with digital signal processing
Maximum performance and interference immunity, more operating and communication convenience – the new Opto-ASIC with
digital signal processing is another milestone in photoelectric sensor technology made by SICK.
>> With the latest, fourth generation of
sensor ASICs from SICK, for the first time
the methods of digital signal processing
are making their arrival in the world of opto-electronic sensors. As compared to the
previous chip technologies, ruggedness
and performance in terms of, e.g., sensing range and sensing distance, as well
as interference immunity, operation, or
sensor communications, were extended
considerably. These features – but also
the reduction of components and miniaturization accompanying the latest ASIC
technology – result in a significant improvement of the price/performance ratio
of through-beam photoelectric and photoelectric retro-reflective sensors as well as
energetic sensors that will be equipped
with the new Opto-ASICs in the future.
Sensor functionalities
improved markedly
The new Opto-ASIC from SICK is a
12.5 mm² high-voltage ASIC in 0.35 µm
CMOS technology. Innovative features
include, among others, the integrated
electronics for a switching power supply, active reverse polarity protection, as
well as separately feasible parameterization of the output wiring, the switching
32
threshold, the hysteresis, or of contamination control. Finally, the Opto-ASIC offers an integrated IO-Link driver stage. In
this way, the range of communicationcapable sensors from SICK is extended
significantly. Because of communication
with the plant control system, the new
sensors featuring this technology provide the user with more availability, e.g.
through remote parameterization, early
contamination control signaling, or specific status polling.
Digital instead of analog: more
accurate adjustment, minimized tolerances, and stable switching points
The decisive innovation of the new OptoASIC is integration of digital algorithms
for signal processing. Among other
things, they enable better adjustability of
the sensors as well as the highest possible stability of switching points once set.
The feature responsible for this is the digital, linearized adjustment characteristic
of the ASIC. With respect to energetic
sensors in particular, it permits very sensitive setting across the entire sen­sing
distance. In addition, tolerances, drift
behavior, and dependence in case of
temperature fluctuations are minimized.
Chip technology from SICK: The new
Opto-ASICs make the sensors capable
of communicating
Interference pulses dampened
by a factor of up to 1000
The use of filters with finite pulse response constitutes the crucial technological edge in the context of digital signal
02 2011
: Technology
processing. Based on a patented evaluation method, these FIR filters are able
to dampen undesired signal portions on
the sensor’s measuring signal by a factor of up to 1000. The advantage of this
technology becomes apparent, for instance, in the presence of energy-saving
lamps in the sensor’s field of view. Sensors without interference suppression
exhibit massive faulty switching in the
area of the switching point. Sensors with
simple interference suppression must
reduce their sensitivity – which, however,
causes the set switching point to shift.
This may result in the actual scanning
object not being detected at the desired
position. By means of the FIR technology, these disadvantages are avoided
reliably: The interference signal of the
energy-saving lamp is filtered out without
influencing the sensor’s own signal. The
set switching point remains stable – the
object to be scanned is detected at the
desired point.
Open for smartphone and other ways
of signal transmission
With the integrated IO-Link driver stage,
the new Opto-ASIC offers communication solutions with automation systems
that are easy and economical to implement. Even migration capability toward
wireless solutions was taken into consideration. This approach makes allowance
for the trend toward remote operation
of sensors without signal cabling. Bluetooth, for instance, provides transmission ranges of up to 20 m – and thus in
principle, the possibility of parameterizing sensors or of retrieving operating and
diagnostic data via smartphone.
Committed to the technological edge
The new Opto-ASIC from SICK incorporates 20 years of experience in developing ASICs. It raises the “sensor as an
overall system” to the next performance
level, forming the basis for new and advanced families of photoelectric sensors.
In this way, the chip further consolidates
SICK’s innovative edge in opto-electronic
sensors – particularly as the new technology is safeguarded by patents for
years to come.
Fieldbus and network gateways for
intelligent safety sensors
Keeping connected when integrated interface is missing
EFI – the Enhanced Function Interface from SICK – enables direct safety-capable communication of sensors and controllers
between each other. Using the EFI gateways makes it possible to
utilize EFI for fieldbus and network integration when no fieldbus
interface is integrated.
EFI gateways are used to integrate intelligent safety sensors from SICK into fieldbus and Ethernet interfaces. In this way,
one can make full use of extended sensor
functionalities available in the sensors,
e.g. contamination control in case of the
S3000 safety laser scanner. Moreover,
with respect to fieldbusses, the EFI gateways permit replacement of a configurable process image between the EFI sensors and the higher-level PLC. Thus, one
can carry out diagnoses conveniently at
a central location and eliminate errors
quickly and specifically – reducing downtimes and optimizing plant availability.
Two inputs for all common networks
The EFI gateways feature two interfaces
for connecting two safety sensors from
Safety controllers from SICK
communicate via EFI with the sensors –
EFI gateways permit fieldbus and
network integration
SICK. This method allows effortless integration of safety solutions into a standard and safe PLC or, respectively, into
an already existing network. In this connection, all of the common network standards are supported, including, among
others, Ethernet, CANopen, PROFIBUS,
PROFIBUS PROFIsafe, and PROFINET
PROFIsafe. The EFI gateways are configured by means of the CDS configuration software. It provides all configuration
and diagnostic data.
EFI gateways – the solution for integrating intelligent safety sensors from
SICK into the world of fieldbusses and
networks.
Further technology information:
www.sick.com/efigateways
www.sick.com/industrial-­
communication
Further technology information:
www.sick.com/W9-3_en
www.sick.com/industrial-­
communication
33
: Technology
Industrial communication & device integration
For “highly connective” identification solutions
Three auto ID technologies, one
­platform, and varied fieldbus options
Identifying in the network by means of fieldbus-flexible data
transmission – the IDpro platform concept from SICK connects
the world of auto ID technologies with information and control
­technology.
>> SICK’s IDpro is the world’s first crosstechnology platform and portfolio strategy for auto ID technologies that are
developed and produced under one umbrella and were created for continuous
operator interfaces, process interfaces,
and connection options. In particular,
openness to different fieldbusses makes
it easy with IDpro to invest in the appropriate auto ID and, respectively, information and control technology in a futureproof way.
Identical fieldbus components for bar
code scanners, image-based code
readers, and RFID interrogators
Based on the standard ID platform,
the CLV6xx, LECTOR®620, and RFH6xx/
RFU6xx product families have all of the
features required for convenient network
integration. Openness to all fieldbusses
common in industry guarantees manifold suitability for networking. In terms of
communication, all of the three auto ID
technologies are directly connectible to
Ethernet (TCP/IP) and EtherNet/IP without
an additional gateway. In case of the bar
code scanners of the CLV6xx family of
products, the label already reads “PROFINET IO directly on board” today – for the
other IDpro sensors, this functionality
will be realized shortly. On top of that, all
of the IDpro sensors can be integrated
into a large number of additional fieldbusses by means of the CDF600 fieldbus module. The fieldbus module also
offers, e.g., connectivity to PROFIBUS DP
and EtherCAT – with gateway functionality for the CLV6xx bar code scanner and
the image-based LECTOR®620 code reader as well as the RFH6xx/RFU6xx RFID
interrogators.
Function blocks from SICK facilitate
integration even more
In order to allow even easier and faster
integration of the IDpro identification
systems into control units, function
blocks are available for PROFIBUS DP
und PROFINET IO. Programmers confirm
that using them results in substantial
time savings. Beyond that, the special
data transmission mode establishes secure data communication between the
sensor and the control system.
Further technology information:
www.sick-idpro.com
www.sick.com/industrial-­
communication
IDpro – a platform that combines three auto ID
­technologies: CLVxxx, LECTOR®620, and RFH6xx/RFU6xx
34
02 2011
: Technology
On track toward the new interface standard
Digital evolution for electrical drive technology
This is what HIPERFACE DSL® ­delivers!
Only one cable, only one connection plug
on the motor – this is what stands out
first in terms of appearance. Less space
requirement, less cabling effort – this
is the benefit that the user reaps. Additional advantages include the exclusion
of analog components, the additional
connection option, e.g. for a temperature
sensor, as well as far easier implementation of the motor feedback system.
Finally, HIPERFACE DSL® and the first
purely digital motor feedback system,
EKS/EKM36 from SICK, provide high security of investment – particularly as the
36-mm type is established in the market,
thus requiring no mechanical modifications.
The digital evolution of HIPERFACE DSL®
– the market-oriented communication
solution for electrical drive technology.
The HIPERFACE DSL® digital interface
enables the entire motor feedback communication using only the motor cable
Twice already – with SSI and HIPERFACE® – SICK has set a communication standard for position finders and, respectively, for
motor feedback systems. Now comes the third stroke, this time
a digital one, with HIPERFACE DSL® – and at the same time, the
first product family: EKS/EKM36.
>> The future belongs to the purely digital protocol. This will make it possible
to realize communication between the
frequency converter and the motor feedback system using only two cable cores.
In addition, it means implementing the
highest safety standards because in
technical terms, HIPERFACE DSL® was
developed up to SIL3 level in accordance
with IEC 61508.
Motor feedback via the motor cable
With HIPERFACE DSL®, the entire motor­ feedback communication takes place
for the first time exclusively via the motor cable. For this purpose, the data
are modulated on to the supply voltage. Special methods and the use of
pulse transformers ensure that the
encoder signal is decoupled from interferences on the motor output cable.
The interface itself meets the RS-485
standard with a transmission rate of
9.375 Mbaud. Data communication occurs over distances of up to 100 m and
synchronously to the controller cycle,
which in the extreme case may be as
short as 11.95 µs.
Further technology information:
www.sick.com/hiperface_dsl
www.sick.com/industrial-­
communication
35
: Know-how
Detection of transparent objects
For the optical “touch of nothingness”
Photoelectric sensor solutions for the world of transparency
Anyone who has ever run against a glass
door knows that seeing through things is not always a good thing. For transparent or highly reflective objects, this
does not apply. They can be detected reliably using so-called glass
photo­electric sensors – even in adverse industrial environments.
>> Transparent plastic packaging, bottles made of glass or PET, ampoules and
pipettes, flat, tubular, and hollow glass,
films for securing loads on pallets – in a
transparent world, automators must deal
with many manufacturing processes.
Moreover, this world is diverse in itself,
since product features, processes, and
ambient conditions differ from industry to industry and often even from one
batch to another. Therefore, the range of
sensors must be designed in such a way
as to cope with varying applications and
to make future-proof solutions possible.
A multitude of requirements
Glass photoelectric sensors must meet a
large number of requirements. Top priority
is precise and reliable detection of trans-
36
parent objects. Mechanical, thermal,
and chemical stability are just as much
in demand as a high level of robustness
against optical disturbance variables
from the environment. Differing installation space, electric connection systems,
and the desired sensor intelligence, e.g.
regarding integration into a machine’s
communication structures, must be taken
into account. Finally, intuitive operation
of the sensor and quick, uncomplicated
commissioning are called for as well.
SICK offers the solution portfolio
for the world of transparency
Wherever such features matter, the
portfolio from SICK offers efficient photoelectric retro-reflective sensors for the
world of transparency.
The WLG4S-3 in the Inox miniature housing is the space saver among glass photoelectric sensors. It delivers convincing
performance due to reliable detection
of highly transparent objects, automatic
switching threshold adjustment, hygienic
design, and it is IO-Link-capable.
The WL11G-2 small photoelectric
sensor in the robust plastic housing is
“number reliable” for regular use in detecting transparent objects such as PET
bottles or transparent film. Moreover, it
provides convincing resistance against
high-pressure cleaning.
Another small photoelectric sensor
– the WL12G-3 with and without adjustment of the switching threshold – guarantees top precision and reliability when
detecting highly transparent objects in
demanding industrial settings. Optionally, the robust metal housing can be
coated with Teflon. Simple teaching at
the push of a button ensures easy and
time-saving commissioning of the IOLink-capable sensor.
The latest technology highlight
among the “transparent ones” is the
WL9G-3 small photoelectric sensor: It
is the first glass photoelectric sensor
featuring digital signal processing. Its
strength is the high-precision option of
setting the adjustable switching point,
which enhances device availability
in harsh environments. The housing
made of particularly tough VISTAL®
plastic as well as a special sensor
construction ensure an extremely high
level of stability and seal tightness. For
the WL9G-3, too, IO-Link is available as
an option.
Welcome to the world
of transparency
The portfolio of glass photoelectric sensors from SICK has a suitable sensor
solution ready for nearly any application
– providing in the world of transparency
maximum functional, handling, and investment security in every operating
scenario.
02 2011
: Products
Contrast sensors
New detection method makes it possible
Packaging technology: Print marks yield to pattern
Packaging in an exemplary way without any print mark – that
is precisely what the ML20 markless sensor from SICK was designed to do. Used like a print mark sensor, it does not require
any optical marking on the package, however, instead detecting a
taught-in design pattern.
>> Thus, the ML20 markless sensor features more flexibility and more design
freedom when planning packaging. It
needs less set-up time when it comes to
changing labels and formats, and avoids
unnecessary use of material and therefore waste.
Pattern instead of mark
The ML20, which can be used, e.g., for
controlling cutting edges, employs a
novel method for contrast pattern detection. This technique involves teaching-in
a pattern sequence to the sensor. The
pattern is detected during processing at
a scanning speed of up to 7 m/s, resulting in the output of a switching signal.
Even in the case of complex designs,
tolerances in the track course of the
continuous material, and high machine
speeds, the ML20 delivers convincing
performance due to reproducibility of
up to 0.6 mm and extremely precise and
stable detection of nearly any pattern.
Tops for creative minds,
design engineers, and cost calculators
The ML20 opens up new possibilities for
packaging processes. Creative minds
benefit from the fact that in designing
packages and labels, they do not have
to integrate any optically distracting
markings. From the perspective of design engineers, the sensor offers a high
degree of ruggedness as well as ease
of integration and commissioning. For
instance, optionally the patterns to be
recognized can be taught-in, saved, and
retrieved either using the sensor’s operating panel, the control cable, or Ethernet. The economic efficiency of the
ML20 in operation is likely to convince
any cost calculator. The stable and process-tolerant detection of even complex
image patterns ensures high availability
and minimizes downtimes. Set-up times
when changing formats are extremely
short – which means set-up costs are
also low.
Sustainability integrated
The ML20 also lives up to the demands
of the “green conscience.” When changing label or film rolls, the sensor avoids
unnecessary cutting loss and waste,
since pattern detection is active immediately, i.e. the material can be used
very soon after the beginning of the roll.
Moreover, in the case of various packaging procedures, e.g. when labeling
The ML20 markless sensor from SICK
detects taught-in design patterns and
does not need an optical mark on
the package
bottles, it is possible to save additional
material that used to be dedicated exclusively to the mark.
This makes the ML20 not only an economical but also a sustainable solution.
Further product information:
www.mysick.com/products
37
: Products
Photoelectric sensors | Vision sensors
Reliable detection of foil-wrapped packaging units
Brilliant solution for shiny and uneven surfaces
Reliably detecting six-packs in
PET film on conveyor systems
is a real challenge for optical
sensors. It can be solved in the
optimum way using the new
WTB27-3 Multipac photoelectric proximity sensor from SICK.
>> In the most diverse industries, automation specialists wishing to detect
shiny and uneven objects, as for instance foil-wrapped six-packs or shiny
metal surfaces, by using photoelectric
sensors, were facing three problems
until now: incalculable reflections from
the film, uneven surfaces, e.g. in case
of containers in the area of shrink-
wrapped bottlenecks, and different
container heights depending on bottle
size.
Implemented for the first time:
dual receiver system with
application software
The WTB27-3 Multipac leaves behind
the previous limits in detecting highly
reflective and at the same time uneven surfaces. This is achieved by
the ideally adjusted combination of
primarily three measures: The use of
two completely separate receiver systems doubles detection performance;
a high-power LED generates an extremely high light intensity; and the
application-specific software controls
the complex evaluation­.
Powerful part inspection
using infrared light
>> The new Inspector infrared variants
are designed to meet a new set of vision inspection challenges. They offer
features that greatly benefit different
applications, such as reducing color dependency and providing safe inspection
in unwanted visible light production. The
invisible infrared light allows in a simple yet highly efficient way a maximum
degree of independence from color.
This constitutes a particular benefit for,
among others, the detection of black
contours on multicolored objects. Using
infrared light in combination with the
optional visible block filter is the easiest
and most cost-effective method to gain
immunity to changes in environmental
lighting. In addition, IR has the quality to
38
be invisible for the human eye. This is beneficial in open production areas where
operators are working next to the sensor.
The infrared variants also inherit all
of the qualities from the Inspector I20
and I40, such as a well-designed tool set
for part inspection and easy-to-use connectivity possibilities.
Best possible integration ensured
for machine builders
The new Inspector PI50 makes inspection and integration solutions possible
that are generally associated only with
smart cameras. Viewing of the images
and change of configuration takes place
by means of a standard web browser.
Integration into the automation and
02 2011
Image-based code readers
WTB27-3 Multipac –
increasing productivity
The WTB27-3 Multipac compact photoelectric proximity sensor is the futureproof solution for checking and controlling, for example, the transport of
packaging units on single or multi-track
conveyor systems very efficiently. On
top of that, the sensor may be mounted
up to 500 mm above the conveyor system in order to detect the most diverse
types and heights of packaging units
with only one fixed sensor position. As
a result, the mechanical height adjustment often required until now becomes
unnecessary – which significantly reduces effort and expense for users.
WTB27-3 Multipac – the benchmark
for detecting packaging units
The approach to a solution offered by the
WTB27-3 Multipac ensures a level of reliability unprecedented in practical operations to date. Users confirm that “this is
the first sensor for detection of packaging units that really works.”
Further product information:
www.mysick.com/products
fieldbus environment of machines is effected via Ethernet (TCP/IP) or EtherNet/
IP and the web API allows users to customize the HMI. This is very convenient
for many machine builders and system
integrators. In addition, the new calibration feature ensures reliable images
even in tight and tilted setups where the
image would otherwise be distorted.The
Inspector PI50, with a speed of up to 50
Hz, is used, among other things, for inspecting and positioning of components
in the automotive and consumer goods
industry or in electronics and solar manufacturing.
Further product information:
www.mysick.com/products
: Products
The new dimension in code reading.
Clever. Simple. Industrial.
With three new products, LECTOR®620 ECO, LECTOR®620
High Speed, and LECTOR®620 DPM Plus, SICK completes the
­LECTOR®620 family of products, offering an economical solution for nearly all requirements and industries for reliable
identification of all common code types.
>> Since the SPS/IPC/DRIVES in 2010,
the LECTOR®620 Professional variant
has seen successful use in many applications, convincing users based on its
compact size, simple operation, great variety of interfaces, and industrial design.
The typical applications for which the
new code readers are already showing
excellent performance include, among
others, identification and code checking of components in car manufacturing,
identification of printed circuit boards in
the electronics industry, as well as the
extensive area of consumer goods packaging, ranging from foods and beverages
to tobacco, cosmetics, and all the way to
products in pharmaceutics and medical
device technology. The introduction of
the new variants entails further specializations and thus tailoring to our customers’ requirements.
More cost-effectiveness –
LECTOR®620 ECO
Reliable code reading for simple applications, reduced to the essentials. This
LECTOR® variant combines quality made
by SICK with an attractive price-performance ratio.
More speed – LECTOR®620 High Speed
Codes on quickly moving objects are
the specialty of the LECTOR®620 High
Speed. Thus, it ensures reliable detection at objects speeds of up to 6m/s. The
algorithms specially developed to this
end make the product a reliable identification solution for packaging machines,
document processing and inserting machines.
More performance –
LECTOR®620 DPM Plus
Directly marked, partially damaged
codes with poor contrasts and on critical material surfaces are the strength of
the LECTOR®620 DPM Plus. It identifies
needle-stamped codes on metal compo-
nents as well as lasered codes on glass
substrates or wafers. This renders the
DPM Plus variant the ideal solution for
the automotive and solar industries.
More efficiency –
LECTOR®620 Professional
This code reader variant covers the
greatest proportion of all industrial applications. The LECTOR®620 is reliable
and rugged, compact and versatile, intuitive in operation and, on top of that,
available at a low price. As an additional
advantage, it can be actuated via Ethernet and various fieldbusses as well as
a large number of testing and analysis
tools that provide great convenience for
commissioning.
Developed by SICK. Created for more.
LECTOR®620.
Further product information:
www.mysick.com/products
39
: Products
Display programming tools | Linear measurement sensors
For number of lines, zero-pulse width, zero set, and output level
Encoder programming without PC
The new PGT-10-S stand-alone display programming tool provides for quick
and simple programming of various encoders from SICK, e.g. when performing
maintenance, service, and configuration work on a machine.
>> Free parameterization and thus fast
availability and flexible use – these features are offered by the programmable
incremental encoders of the DFS60
product family from SICK. The benefit of
being freely programmable for integrators and final customers: flexible setting,
quick availability, as well as minimal procurement and storage expenditure.
The new pocket-size PGT-10-S display programming tool is very handy and
thus the ideal solution particularly for
maintenance and service. Four membrane pushbuttons and two LEDs ensure
simple and intuitive setting of the number of lines, zero-pulse width, zero set,
and output level on the encoders’ electronic type identification plate. Moreover,
the tool permits the cloning of settings
once determined, i.e. transferring them
to as many encoders as desired – an essential saving of labor when it comes to
applications recurring regularly.
Further product information:
www.mysick.com/products
Positioning electrical overhead conveyors with precision and PROFIBUS
Linear measurement sensor for straights and curves
The image-based OLM200 linear measurement sensor with PROFIBUS interface from SICK is the highly available solution for position and speed detection on electrical overhead conveyors, rail-guided shuttles, and curve-going
aisle stackers.
>> The sensor’s robust metal housing,
the integrated contamination control, the
extensive operating temperature range,
the lack of moving parts on the inside, as
well as the LED lighting in redundant design guarantee the service life required in
the intralogistical operating environment.
Precise measurement
across long ranges
The OLM200 is suited for facilities measuring up to 10 km (slightly over 6 miles)
in length and for speeds up to 10 m/s.
The measuring sensor scans a bar code
tape along the travel path, thus detecting
the current position. Reproducibility of
0.15 mm, resolution adjustable in increments between 0.1 mm and 100 mm,
as well as the high output rate of 2.5 ms
provide for maximum precision possible
in position and speed detection. The mea-
40
sured values are output via the PROFIBUS
interface. Furthermore, the OLM200 offers PNP or, respectively, NPN switching
outputs in addition to PROFIBUS.
Intelligent integration
The OLM200 PROFIBUS can be integrated quickly and cost-effectively. Installation of the sensor – either by means
of the through boreholes on the sides
of the housing or the slot on the rear –
is suited to nearly any given situation.
Moreover, the housing design also takes
into account the necessary alignment
angle. As a result, in contrast to other
sensors of this kind offered for overhead
conveyor systems, the OLM200 PROFIBUS requires only alignment on one axis.
Accordingly, installation takes less time.
In terms of connector technology, the
OLM200 PROFIBUS is compatible with
SpeedCon™ as well as standard M12
connectors. This supports rapid and simple mounting.
Whether on straights or in curves
– the OLM200 is the ideal solution for
measuring the position and speed in mechanically guided transport modules in
intralogistics.
Further product information:
www.mysick.com/products
02 2011
: Products
Gas analyzers | Encoders
Monitoring oxygen content in harsh industrial environments
Robust, stable, simple: TRANSIC100LP – the right solution
Oxygen monitoring is mandatory in many production areas, whether as
an economical way to control processes or in order to efficiently identify
hazards. Be prepared with the TRANSIC100LP gas analyzer from SICK to
measure the oxygen concentration in moist and aggressive process gases
precisely with diode laser technology.
>> Measuring oxygen with the TRANSIC­
100LP is a breeze. The meter is compact, requires little space, and can be
easily installed directly in-situ in many
applications. The operation is easy.
Once powered up, the measurement
values are immediately available. Typical applications include monitoring
gas production, fermentation and composting processes, as well as inert gas
atmospheres­.
Compelling laser technology
Essential for the successful measurement of oxygen is the diode laser spectrometry (TDLS: tunable diode laser
spectrometry), a powerful technology
designed for gas measurement.
With its new TRANSIC100LP gas
analyzer, SICK emphasizes its claim
to also offer future-oriented and userfriendly solutions with TDLS technology.
The selections now range from oxygen
measurements in the standard product
segment to high-end solutions for NH3,
HCl and HF measurement.
Further product information:
www.mysick.com/products
For EtherNet/IP, PROFINET IO, and EtherCAT
Ethernet encoders improve availability
Interfaces for Ethernet-based fieldbusses are the latest highlight of the AFS60
and AFM60 single and multiturn encoders from SICK. Featuring extensive options for self-monitoring and diagnosis, they offer a significant advantage in
terms of availability.
>> All of the Ethernet encoders from
SICK include an Ethernet switch (embedded switch technology) and offer two Ethernet ports for “looping through” of the
fieldbus (dual port technology). In operation, they convince users by their varied
diagnostic means. Several LEDs on the
device visualize the operating mode of
the two ports, the encoder status, as
well as data transfer. In addition, the encoders output hierarchically graduated
signals – flags, alarms, and warnings
– which can be used to monitor parameterized threshold or limit values for temperature, velocity, or positions by means
of the machine controller. The highest
level of flexibility is offered by the rotary
axis functionality. In special applications,
e.g. on rotary indexing tables or when
using reduction or transmission gears, it
is possible in setting the encoder to con-
ately. The versions for PROFINET IO and
EtherCAT will follow in the first quarter of
2012.
figure binary resolutions and intervals
per revolution as a decimal number with
decimal place as well.
EtherNet/IP: permanent
monitoring in ring topologies
The DLR functionality (device level ring)
of the AFS60/AFM60 with EtherNet/IP
interface allows active and permanent
testing both of encoder communication
and of the functionality of the entire
­EtherNet/IP ring. Cable breakage and
other failures are detected within a few
milliseconds, with communications in
the network adjusted in such a way that
all devices continue to be active. This
prevents the machine’s immediate malfunction, permitting well-directed diagnosis and troubleshooting.
The encoders of the AFS60/AFM60
for EtherNet/IP are available immedi-
Further product information:
www.mysick.com/products
41
: Products
Photoelectric sensors
variants. Together with the special housing design, these possibilities of electric
connection provide for a large number of
installation options.
Versatile means of installation
Cylindrical photoelectric sensors as installation geniuses
Economical, little, functional – ELF, the new product family of cylindrical photoelectric sensors with flattened housing and two M18 mounting threads, opens
up special kinds of mounting options, for example, in packaging machines or in
material flow and warehousing systems.
>> The ELF product family includes one
photoelectric retro-reflective sensor with a
sensing range of 4.8 m, one photoelectric
proximity sensor with a sensing distance
of 50 mm and background suppression,
as well as one energetic photoelectric
proximity sensor with 100 mm sensing
distance. All of the sensors featuring an
IP 67 enclosure rating are available as
cable variants, as M8, or M12 plug-in
Space-saving housing with two M18
mounting threads
The housing design of the ELF was optimized consistently towards saving
installation space and diverse means
of installation. The two M18 mounting
threads allow installing the sensor ideally at all times, whether attached on
the front or the bottom. The rear housing cover is flattened to permit placing
the sensor even in a narrow space with
minimal installation depth. The cover itself is transparent, providing a clear view
of the two integrated status LEDs, which
makes quick diagnosis of function possible on site.
New possibilities due to an innovative housing design: The ELF cylindrical
photoelectric sensor offers significantly
more than eleven options with respect
to detection and position determination
of objects.
Further product information:
www.mysick.com/products
Portfolio of fiber-optic cables extended
Suitable solution for any operating environment
SICK is extending the portfolio of fiber-optic cables by more than 60 new types.
It leaves hardly anything to be desired in terms of means of detection, ambient conditions, and possible uses. The product finder at www.sick.com shows
which type fits which application.
>> Whether as a through-beam photoelectric sensor or a photoelectric proximity sensor – when small objects need to
be detected or things are cramped in a
machine, sensors featuring fiber-optic
cables are often the ideal solution. Set
off from the actual sensor, fiber-optic
cables in many cases must meet special requirements concerning design of
the end sleeve, resistance of the cable
sheath against ambient conditions, and
the best possible laying – bend radii being the keyword here.
Fiber-optic cables from SICK offer
nearly unlimited possibilities
SICK’s portfolio of fiber-optic cables includes a suitable solution for almost
any application. Array fiber-optic cables,
e.g., allow detecting components falling
freely or differences in size. Fiber-optic
cables coated entirely with Teflon resist
the most extreme loads by oils, greases,
cleaning and disinfecting agents – just
as ideal for machine tools as for applica-
42
tions in plants processing pharmaceutical, chemical, or food-related products.
Special fiber-optic cables permit recognition of particularly detection-critical
wafers, glass plates, or LCDs in the electronics and solar industries.
The detection of levels inside of
tanks and overflow containers, or outside on transparent pipes constitutes another application for fiber-optic cables.
Versions for extreme temperatures from
–55 °C to +315 °C (–67 °F to +600 °F)
are also available.
Product Finder guides
to optimum solution
The new types of fiber-optic cables are
available immediately. The Product Finder at www.sick.com shows which fiberoptic cable is best suited for a particular
application.
Further product information:
www.mysick.com/products
02 2011
Laser measurement technology
: Products
Keeping distances, avoiding collisions
Compact laser scanner for electric
overhead conveyors and mini AGVs
Extremely small, but nevertheless delivering great performance,
and featuring all essentials, such as teach function and four outputs on board – the new TiM300 laser scanner from SICK knows
what matters in mobile intralogistics.
>> The TiM300 is a detecting and
switching laser scanner. The tennis ballsized sensor is used for 2D monitoring,
e.g. for distancing and queue control in
electric overhead conveyors, for checking for projections and compartment occupation on aisle stackers, for preventing collisions, and as back-up protection
of mini AGVs and mobile platforms. The
high energy efficiency of the scanner is
very well suited for these mobile applications: Input power is typically at 3 W
– which is 50 percent less than in comparable sensors.
Great detection performance
The TiM300 works with infrared transmission light, thus achieving a scanning
distance of 2 m even in case of black
surfaces. The 270° scanning angle of
the TiM300 opens up diverse possibili-
ties. Electric overhead conveyors can be
distanced reliably even in curves. It is
possible to monitor reliably both the
travel paths of autonomous vehicles
and the vehicles themselves from the
side as well. Rack compartments can be
checked double-deep for occupation and
for projections.
Flexible: plug & play ex factory
or ­parameterization on site
For these tasks, the TiM300 features
up to 16 so-called triple field sets in the
form of indicator, warning, and stopping
fields. They allow for situational and
anticipatory reaction by the vehicles
to detected obstacles. Three switching
outputs overall are available for this purpose. Ex factory, the TiM300 features
pre-parameterized triple sets. They represent the most common monitoring
scenarios, thus sufficing in many cases
for commissioning the laser scanner. For
individual settings, the TiM300 offers, as
the first laser scanner of its kind, an integrated “touch and teach” function.
Rugged in nearly any way desirable
Availability is everything in intralogistics
– and for this reason, when it comes to
the TiM300, SICK does not use susceptible plastic as a housing material but
instead resistant metal. The ruggedness
can be enhanced further – by a protective hood against influences from the environment or shock absorbers to achieve
nearly vibration- and shock-free installation.
The TiM300 completes the range of
switching and measuring 2D laser scanners from SICK. With its interesting performance features, it constitutes a costeffective and technically convincing solution for many intralogistical applications.
Further product information:
www.mysick.com/products
43
: Products
Level sensors
The new LFP Cubic: level measurement with guided microwave
Top measuring results for most diverse media
With the new LFP Cubic, SICK presents a level sensor that provides maximum amount of flexibility and measuring accuracy.
Thanks to IO-Link, it also opens up excellent possibilities for integration in the type of automation common in machine and plant
engineering.
>> The LFP Cubic combines continuous
level measurement with level detection
in a single device. The level sensor, nearly wear- and maintenance-free, is used in
metal containers and tanks in the water
industry, in machine building, on machine tools, in plant engineering, and in
building services engineering.
Adjusts to the measuring task
The LFP Cubic is designed for a universal range of possible uses. The measuring principle of the “guided microwave”
makes the level sensor independent of
influences related to installation, the
container, and the medium. As a result,
the sensor is suited for nearly any waterand oil-based fluids, e.g. coolants, grinding and hydraulic oils or blends containing cleansing, degreasing, and cleaning
agents. Graduated probe lengths from
200 mm to 2,000 mm are available,
allowing an individual layout of the sensor. In addition, the stainless steel measuring probe is screwed together – i.e.
it can be disassembled, shortened, or
replaced. The LFP Cubic is also flexible
with respect to process conditions: It is
suitable for temperatures up to 100 °C
(212 °F) and process pressures up to
10 bar (1,000 kPa). Sensor setting takes
place using a display-supported, menuguided operation that follows suggestions by the VDMA (German Engineering
Federation). Alternatively, the two switching points as well as the analog-output
measuring range can be parameterized
by IO-Link via the machine control, and it
can also be monitored and changed from
there.
Very precise – even in case of foam
The LFP Cubic ranks among the most
accurate measuring systems of its kind
– even in applications associated with
foam. In contrast to many other sensorbased active principles, the measuring
results are influenced only insignificantly
by the properties of the medium measured, e.g. density or conductivity. In
terms of operations, this means that the
level sensor does not have to be re-configured when physical properties of the
fluids change. Since at any given probe
length the LFP Cubic features only very
small inactive areas, it offers a maximum
>> Vibrating level switch now even more universal
Available immediately with IO-Link
and ½″ process connection
SICK now offers the LFV200 vibrating level switch with
new functionalities. Due to integration of IO-Link , it is
now possible to poll switching states from a central automation system and to detect process temperatures. An
important feature for many applications is evaluation of the
frequency and amplitude signal that is now feasible: It allows
drawing conclusions regarding the density and viscosity of the
media to be detected. The ½” threaded end fitting is also new –
it makes the means of installing the LFV200 even more versatile.
44
detection range in any variant. Measuring accuracy is at ±5 mm – a value otherwise achieved only by considerably more
expensive level measurement systems.
The LFP Cubic makes the advantage
offered by the high-tech sensor principle
of the guided microwave usable for standard applications in factory automation
– and it does so at a superb price/performance ratio.
Further product information:
www.mysick.com/products
02 2011
: Products
Volume measurement systems | Integrative system products
Certified volume measurement, even for irregularly shaped packages
Better processes, better yields
The VMS520 Sorter is the solution for volume detection of rectangular and
irregularly shaped freight objects directly on sorter systems. The system, currently the world’s only certified system of its kind, pays for itself quickly, as it
allows freight calculation according to the actual volume weight.
>> In addition, the volume measurement
system permits accurate recalculation in
case of deviations from declared freight
dimensions.
Efficient, economical,
and sustainable
The VMS520 Sorter is used in high-performance sorting facilities of courier,
express and parcel service providers
(CEP) as well as in automated distribution and transshipment centers. Apart
from the possibilities that it offers in the
context of freight calculation and preparation of freight documentation, the
determined dimension values improve
various handling processes, such as
the stacking of cartons. Moreover, the
VMS520 Sorter makes an important
contribution to sustainable logistics by
supporting optimum use of storage and
vehicle capacities. Loading optimization
by means of the VMS520 Sorter saves
resources and avoids unnecessary environmental impact.
Legal-for-trade measurement even
of irregularly shaped packages
Whether conveyor speeds of up to 3 m/s,
objects with dimensions of 1,600 mm x
1,000 mm x 1,000 mm, the VMS520
Sorter is open to all common sorting
facilities in terms of system technology,
and a real all-round talent. Its precision
makes it legal for trade: Rectangular
objects can be detected on each edge
down to an accuracy of 5 mm; for irregularly shaped objects, this value is 10 mm
for each dimension. Thus, it fulfills the
requirements set by OIML (Organisation
Internationale de Métrologie Légale,
Engl.: International Organization of Legal Metrology) and the MID (Measuring
Instruments Directive).
Further product information:
www.mysick.com/products
Reflector, mounting, and connection systems
Perfect sensor integration made easy
Innovative sensor technology is only one aspect of intelligent automation solutions – the other consists of suitable accessories for professional and costeffective integration.
>> Whether reflectors, mechanical
mounting solutions, or electrical connection systems – only the proper, integrative system products result in a topquality and highly available application
solution. Sensors and accessories are
adjusted perfectly to each other. This
offers not only utmost functional safety
but also saves users the costs of development, production, and storage on their
own. A large number of accessory components are available permanently and
at short notice – together with the sensor technology, comfortably from a single
source. If a special individual solution is
required, that is not a problem either: It
is possible, within a short time, to implement customer-specific developments
and adjustments.
Flexible solutions for any
integration environment
Accessories are the interface between
the sensor technology and the most
diverse integration requirements. The
product family of reflectors lives up to
this function by means of an extensive
selection of reflective tapes as well as
standard and special reflectors in different shapes and mounting variants. The
solutions regarding mounting systems
are adjusted to the individual product
families of standard industrial sensors.
As well, customer- and application-specific installation components provide for
individual means of integration. Reliable
signal transmission in any automation
and fieldbus environment is ensured by
SICK’s connection systems featuring a
wide range of cylindrical plug-in connectors, distribution systems, coupling modules, and gateways.
Accessories from SICK – the solution for
reliable sensor integration.
Further product information:
www.mysick.com/products
45
: Products
Automation light grids | Multiple light beam safety devices
Checking for projections on pallets
Sensors for trouble-free handling of pallets
Whether, where, and to what extent loads project beyond a pallet
can be determined very precisely using the new upgraded version of the MLG automation light grid from SICK. Now, the VLC100
image-based automation light grid, too, lends itself as an alternative light grid solution. A compact and easy-to-integrate unit, it is
particularly interesting as a retrofit solution.
>> In practical everyday operations,
when handling pallets, deviations occur due to vibrations along the conveyor paths, in the course of transport,
respectively, or because of insufficient
fastening – which may cause the loaded
goods to project beyond the pallet. Often
the crucial point is where a projection
is located and whether the permissible
tolerance, e.g. for storing in a high-rise
rack compartment, is maintained or not.
SICK’s portfolio offers two approaches to
a solution that handle different requirements and environmental conditions.
Detecting and localizing
by means of a light grid
The upgraded versions of the MLG automation light grid with new software
for pallet verification offers one solution: The sensor starts from detecting
the base of the pallet at the level of
the conveyor system. If the light beam
is interrupted­ in the area above the
pallet board prior to the pallet base being detected, a projection exists at the
front of the pallet. At constant conveying speed, the interval from detecting the projection­ until detecting the
base equals the extent of the projection. Since, on top of that, the light grid
provides information as to which light
beams were interrupted, one can also
derive an indication­ ­about the position
For safe material flow processes
Differentiating humans and material reliably
Exit monitoring for safe human-material differentiation as well as
guaranteeing utmost plant availability by fast diagnosis in case of
malfunction – both functions are combined in the muting solution
of the M4000 Advanced product family.
>> In combination with the UE403
safety switching device and applicationspecific muting accessories, the system
is capable of monitoring access to hazardous areas and at the same time allowing material transports through the
protective field.
Space-saving and intelligent:
exit monitoring
The M4000 Advanced multiple light beam
safety device with the “exit monitoring”
function was developed for applications
in which the material transport to be pro-
46
tected takes place only in one direction,
out of the storage area. In this arrangement, the two muting sensors are located
in a sheltered place within the hazardous
area – additional muting sensors located
outside are no longer necessary. This
saves time and costs when commissioning and eliminates the danger of misalignment of the muting sensors during ongoing operations, since they are installed in
a protected place within the hazardous
area. In addition, this approach significantly reduces the space requirements in
the facility’s outlet zone.
02 2011
: Products
Hand-held scanners
of the projecting load. By the same
means, projections can also be detected accurately at the rear.
Checking pallets from the corner
The other solution for checking pallets
is the VLC100 image-based automation
light grid with a range of 2.8 m diagonally and – at this distance – a resolution
of 18 mm. The transmitter and receiver
are integrated in a single housing. The
compact, triangular construction permits installation in or at the corner of
a sectional frame but also behind machine paneling – i.e. in places where
the sensor is largely protected against
shocks or misalignment. A reflective
tape is attached to the sides opposite
the mounting location. The imagebased sensor covers the entire reflector
surface, detecting changes within the
2D field thus generated. The VLC100
is very well suited as a retrofit solution
for SICK’s tried and tested OptoTrap/
OTD contour sensor, since one can continue to use the latter’s reflector frame
and there is complete connecting compatibility with all common automation
systems­.
Further product information:
www.mysick.com/products
Even higher availability due to
additional diagnostic functions
The extended diagnostic means of the
M4000 Advanced provide for even higher plant availability and transparency
concerning the monitoring functions
and muting processes. Thus, it is now
possible to represent, free of losses,
any errors occurring in muting processes for all signals engaged in the muting
cycle. This representation can be saved
in a file by means of the data recording
function and it ensures swift and welldirected troubleshooting. As well, an additional staggered functional diagnosis
is also possible: To this end, the M4000
Advanced saves the last shutdowns
of the system in an event history. This
makes it possible to recognize errors in
the muting sequence, to optimize processes, and to minimize downtimes in
the material­ flow.
Further product information:
www.mysick.com/products
With cable, Bluetooth, or WLAN
Robust hand-held scanner for harsh conditions
Featuring an IP 65 enclosure rating and safe functioning even
after being dropped 50 times, the IDM160 hand-held scanner
convinces­ users with a maximum degree of ruggedness. The
attributes­ that provide for special user friendliness include, among
others, a powerful scan engine as well as triple read feedback.
>> Hand-held scanners of the IDM160
product family are the solution for sophisticated operating conditions in industrial
settings. They permit reliable identification of bar codes and stacked codes with
differing resolutions even at longer scanning distances of up to 800 mm. The
industry-compatible, rugged housing design guarantees utmost availability even
in case of severe loads known to occur
in intralogistical processes. In addition,
suitable connectivity elements are available for Fieldbus integration.
High degree of user friendliness
A number of features ensure that users
like picking up the IDM160. They include
uncomplicated alignment and scanning
even at greater distances, fast scanning
with subsequent triple read feedback via
beeper, LED, and vibration, long operating time without recharging, as well as
tool-free battery replacement. The hand-
held scanner is held fast to the charging
station by magnets – thus keeping it
firmly in place even in case of vibrations
in the environment.
Mobile with and without cable
The IDM160s offer every user the appropriate mobility and freedom to maneuver, as the hand-held scanners are
available not only as a cable or Bluetooth
variant but also featuring WLAN in accordance with IEEE 802.11 b/g. The special
advantage is the roaming function of the
WLAN variant: The operator is able to
move completely freely. When changing
from one WLAN reception range to the
next, he or she notices this as little as
with a cell phone – since the connection
is maintained at all times.
Further product information:
www.mysick.com/products
>> IDM140-2 now available as a WLAN variant as well
From now on, among the user-friendly IDM140-2 hand-held scanners, there is
also available a variant with WLAN in accordance with IEEE 802.11 b/g. Thus,
SICK offers another roaming solution for complete freedom of movement in
mobile bar code scanning.
47
: Service & Support
Services for industrial safety systems
Retrofitting machines affects machine safety
Legal security when retrofitting
In many cases, retrofitting/rebuilding machines constitutes a
technically and economically efficient alternative to new equipment. However, what does a retrofit mean in terms of safety
technology? And, above all: When does a substantial and thus
CE-relevant transformation apply?
>> The mother of all laws pertaining to
the safety of machines is the EU Machinery Directive, MD 2006/42/EC. It is addressed to all manufacturers and distributors of machines but also self-producers – thus also applying to operators that
assemble or retrofit existing machines if
they implement substantial modifica-
tions. In addition, the self-producer acting as an operator must comply with the
(German) Act on Health and Safety at
Work (BetrSichV): Only safe equipment
may be made available. Finally, the German Equipment and Product Safety Act
(Geräte- und Produktsicherheits-Gesetz
– GPSG) takes effect as well, since
When does a retrofitting of machines represent a CE-relevant change?
The safety experts form SICK can answer this question
48
based on the definition of “substantial
transformation,” it puts a machine retrofit correspondingly on the same level
with a new machine when it comes to
distribution.
When is a transformation substantial?
The EU Guideline for the use of the Machinery Directive defines in §72 (“New
and used Machinery”) a “substantial
transformation” as a “transformation so
substantial that retrofitting has resulted
in a machine that can be considered
as new machinery.” In the Blue Guide
of the EU Commission, the aspect of
risk is taken up: “If the risk assessment
leads to the conclusion that (after retrofitting the machine) the nature of the
hazard or the level of risk (emanating
from the machine) has increased, then
the modified product (machine) should
normally be considered as a new product (machine).” The party responsible
for retrofitting (self-producer, operator,
retrofitting company, and reseller) must
carry out the entire CE conformity procedure if, through the substantial modification, the retrofit machine becomes a
new machine.
The GPSG interpretation guide entitled “Substantial transformations of
machines” helps to classify the modifications in terms of legal and safetyrelated aspects. It follows from this that
a hierarchy of criteria must be met in
order for a retrofit machine to become
a new machine in accordance with the
MD. The first criterion is the existence of
modifications concerning performance,
function, use, and safety technology.
This is followed by the assessment of
whether new danger or increased risk
exists. If examination of further criteria
reveals that no sufficient technical safety measures on the machine are possible, protective guards cannot be used,
the danger of substantial personal injury and damage to property exists, and
the probability of an accident is high,
new proceedings to evaluate conformity
must be carried out.
In this connection, it is important
that one does not have to take existing
safety technology out of service automatically. What may be used depends
on various factors. Here the safety experts from SICK, an accredited inspection center, will be glad to help!
Further service information:
www.sick.com/service
02 2011
Services for process automation
: Service & Support
SICK services environmental sensors at USIMINAS steelworks
Complete service for Brazil’s Nº 1
USIMINAS, Brazil’s largest steel manufacturer, has placed an
extensive complete service order with SICK for maintaining
and calibrating more than 200 gas analyzers and dust measuring devices.
>> With an annual production output of
9.5 million metric tons of crude steel, a
market share of more than 25 %, and
sales amounting to seven billion US
dollars, the steel manufacturer USIMINAS is today the number one in Brazil.
“Since the Ipatinga steelworks is located in the middle of the city populated
by approx. 250,000 inhabitants, we are
subject to continuous monitoring by
the local environmental agency,” says
Leandro Carrijo, Supervisor measurement- and analysis-related plant equipment at USIMINAS. At the same time,
we have already felt committed to environmental protection for quite some
time, which is documented by the fact
that we were the world’s second steelworks certified in accordance with the
ISO 14000 environmental standard.”
At the Ipatinga plant, USIMINAS uses
more than 200 gas analyzers and dust
measuring devices in the different exhaust systems.
Comprehensive servicing concept for
SICK’s sensors and external brands
When arranging the contents of the servicing approach, the operating and process requirements at USIMINAS were
matched with SICK’s service experience
concerning emissions measurement
technology in the steel industry. “The
resulting catalog of services included,
among other things, intervals and measures for preventive maintenance, help
desk measures in case of suddenly
occurring repair and servicing requirements, as well as calibration and monitoring of the measurement technology,”
explains Leandro Carrijo. The work was
carried out by technicians from SICK
staying at the plant full-time. They are
responsible for more than 200 systems
from different manufacturers. Thus,
when it comes to the operation of emissions measurement technology, USIMINAS always has contact persons available at its plant that are competent in
terms of systems, service, and spare
parts. “SICK was the only company capable of offering us something like that,”
says Leandro Carrijo.
Individual LifeTime Service for
measurable lifetime value
The service contracts for maintenance
and repairs are arranged individually
from customer to customer. “The services that the international SICK sales
organizations advise on, sell, and manage include, among others, maintenance
plans, the inspection and calibration of
analyzers and measurement devices,
Developed a comprehensive service
concept: Leandro Carrijo, Supervisor at
USIMINAS, and Alfredo Schnabel-Fuentes
from SICK Brazil
as well as update and retrofit services,”
explains Alfredo Schnabel-Fuentes. “By
managing the systems, we generate an
economically calculable lifetime value
for clients over the course of service life.”
This statement holds true not only for
process automation but also for SICK’s
factory and logistics automation.
Further service information:
www.sick.com/service
More about the customer:
www.usiminas.com
49
: SICK Tour
Taiwan: different sensor bus for a change
Road show campaign features sensor technology to touch and experience
Customer contact via short distances
The mobile exhibition bus on location
saves interested parties the investment
of time and travel and makes it possible
to reach and get even persons interested
who tend to visit trade fairs rather seldom.
At the same time, it provides the suitable
setting to explain products, present applications, or discuss concrete projects.
Small wonder therefore that after the initial six months, many visitors are thrilled
by the sensor bus, as it allows competent
consulting at a short distance, while at
the same time building up and cultivating direct contact – true to the Chinese
proverb that says, “The shortest distance
between two people is a smile.”
Working the market with a mobile exhibition stand – with its mobile sensor bus,
SICK Taiwan offers customers and interested parties technology, innovations,
and applications to touch and experience.
>> The mobile exhibition takes the performance portfolio and application expertise directly to customers. Dynamic
exhibits and animations convey SICK’s
application competence to a large number of industries. Users see and un-
derstand the benefits that sensor and
control solutions offer them. In addition,
purchasers, development engineers,
technicians, and managers get a chance
to build up confidence in the brand in direct contact with SICK.
Second Automotive Manufacturing Solutions China Conference
Quality through sensor technology in focus
From 28 to 30 June 2011, SICK participated as Bronze Sponsor in the
Second Automotive Manufacturing
Solutions China Conference in Shanghai. A particular focus of attention
among Chinese car manufacturers
was the topic of quality through sensors in automobile production.
Delegates addressed the topic of
improving the quality of automotive
manufacturing
50
>> The car market in China has grown
enormously in recent years. However,
carmakers by no means think only in
terms of the number of units and market shares, instead striving increasingly for excellent quality of vehicles and
processes­.
The presentation by Mr. Xu from
Chery Automobile, among others, underscored the fact that in China, too, SICK
ranks among the renowned partners of
the automotive industry in this field. His
enterprise relies on sensor technology
from SICK wherever it is essential to design processes more efficiently, monitor
quality, and ensure utmost occupational
safety. He had particular praise for the
fact that SICK was one of the few suppliers capable of offering customized
complete solutions from a single source
– starting from the time of the first product or vehicle study all the way to complete project implementation at the customer’s location.
The lecture by SICK on the topic of
sensor and system solutions was also
very well attended. Just how topical the
issue is was evidenced by numerous
conversations following SICK’s presentation, which resulted in a number of interesting contacts and projects.
02 2011
: SICK Tour
Subsidiaries celebrate!
35 years of SICK Netherlands
founded 10 December 1976
30 years of SICK Australia
founded 16 February 1982
15 years of SICK Austria
founded 16 November 1996
interpack: SICK thanks Laetus for for long-standing cooperation
Good Manufacturing Practice (GMP) with respect to packaging and inspection of packaging materials for pharmaceutical products is one of the
strengths of Laetus GmbH. Another one is trustful cooperation with SICK
for many years.
>> Numerous innovations in the field
of bar code identification go back to
the joint exchange of expertise – the
latest example being the LECTOR®620
image-based code reader. This was reason enough for Markus Paschmann, Ex-
ecutive Board member of SICK, to visit
Laetus­ at the interpack 2011 trade fair
to thank them for exemplary cooperation. The meeting with Laetus’ General
Manager, Dirk Hendrik Kneusels, saw
initiation of the next projects.
Successful cooperation:
Andreas Zimmermann, Key Account
Manager SICK Vertriebs-GmbH;
Jörg Liedtke, Senior Sales Manager
Laetus GmbH; Dirk Hendrik Kneusels,
General Manager Laetus GmbH;
Markus Paschmann, Executive Board
Member Factory Automation SICK AG,
and Detlef Deuil, Manager Marketing and Sales 2D code and hand-held
scanners SICK AG (from left to right)
Dorothea Sick-Thies donates
four electric cars for the company fleet
Green cars for SICK
Widespread use of electric vehicles in road traffic is still in its infancy, but SICK
is already part of it: As one of the first enterprises in Baden-Württemberg, it
has complemented its fleet of vehicles with cars featuring electric drives. The
four vehicles were financed by Dorothea Sick-Thies and handed over to the
company fleet in the summer of 2011.
>> By the year 2020, one million electric
cars are scheduled to move on Germany’s roads. At SICK, this era has already
dawned: Using one of the four electric cars
of the “smart” brand, an emission-free trip
covering 18 km (approx. 11 miles) consumes about 4 kWh of electrical energy
and takes roughly 30 minutes. In doing so,
the green snappy little cars have a peak
power output of 30 kW and accelerate
to a maximum of 100 km/h (62.5 mph).
Recharging the lithium-ion battery is the
easiest thing in the world: The small car
takes about eight hours plugged into a
regular electrical outlet to “fill up” once.
The electric cars are used for works transportation between the Waldkirch, Reute,
and Freiburg locations.
Dorothea Sick-Thies, the youngest
daughter of the company founder, Erwin Sick, has donated the four vehicles.
She actively supports the topics of environmental protection and sustainability
within the SICK Group, driving an electric
car privately as well. “There are many
steps from the employees’ trip to work at
SICK all the way to the finished goods. In
this context, one can find many starting
points by which SICK makes sustainable
production and active environmental
protection a reality. The electric vehicles
represent one of them,” she explained to
attending journalists at the official delivery date. Two Executive Board members,
Reinhard Bösl and Markus Vatter, were
also present, as Company Fleet Manager
Klaus Scherzinger received the car keys
from Dorothea Sick-Thies.
51
: SICKinsight [plus]
Historic landmark of the
art of civilengineering
in Germany
Connections with tradition:
Hamburg’s Old Elbe Tunnel
celebrates 100th anniversary
On 7 September 2011, the Old Elbe Tunnel in Hamburg was honored, in the presence of the Lord Mayor of the Free and Hanseatic City of Hamburg, Olaf Scholz, as a “Historic landmark of
the art of civil engineering in Germany” by the Federal German
Chamber of Engineers and the Hamburg Chamber of Civil Engineers. Thus, it now also ranks officially among the most important twentieth-century engineering structures in Germany.
>> The St. Pauli Elbe Tunnel, as it is called
officially, was the first major underwater
tunnel in continental Europe. The Hamburg structure measuring about 450 meters in length has been connecting the
city districts of St. Pauli and Steinwerder
under the Norderelbe since 7 September
1911, constituting an important element
of local traffic between the city and its
huge port. One of the special technical
features of the Old Elbe Tunnel is that it
has no tunnel ramps. Six elevators overall
with a lifting height of 23.5 m take on the
Photo on top: The Old Elbe Tunnel Tunnel was honored by the Lord Mayor of the Free
and Hanseatic City of Hamburg, Olaf Scholz; photo on the bottom: The 450-meter
St. Pauli Elbe Tunnel was the first great underwater tunnel in continental Europe
52
transport of pedestrians, cars as well as
horses and carts of days gone by to the
tunnel floor, whence they reach the other
side on a road about 2 m wide. Even today, the extraordinary construction of the
Old Elbe Tunnel with its huge open shafts,
the elevators moving in an open steel
structure, and numerous ornamental details make it the world’s most beautiful
tunnel building to many visitors – and a
popular destination for outings.
An outstanding civil engineering
structure, even after 100 years
The St. Pauli Elbe Tunnel was and even
after 100 still is a constructional milestone. To anyone wishing to get detailed
information about the diverse challenges that the civil engineers mastered
successfully, wanting to know how the
tunnel drive proceeded in the soft soil
soaked in ground water, and seeking an
answer to the question of how the nearly
6 m wide steel pipes got underneath the
Elbe river, we recommend consulting the
lavishly illustrated anniversary brochure
entitled “Der Alte Elbtunnel Hamburg”
(“The Old Elbe Tunnel in Hamburg”) by
the Federal German Chamber of Engineers and the Hamburg Chamber of Civil
Engineers. The chronicle is available in
many Hamburg bookstores and may
also be ordered from the Federal German Chamber of Engineers by phone
(+49 30-2534 29 01) or on the Internet
(www.bingk.de/order-hw­) for a price
of EUR 9.80.
02 2011
Trade fairs · Imprint · Contacts
: Info
Trade fair dates Germany
Trade fair
productronica
SPS/IPC/DRIVES
Tire Technology Expo
LogiMAT
AUTOMATICA
ACHEMA
Trade fair dates Europe
Trade fair
Pollutec Cfia
Intertraffic
Drives and Controls Hispack SPS/IPC/DRIVES Italia Trade fair dates worldwide
Trade fair
Automotive Testing Expo
Sino-Pack National Postal Forum Aimex Automation World SNEC PV Power Expo MECÂNICA Location
Munich Nuremberg Cologne
Stuttgart
Munich
Frankfurt a.M.
Date 2011/2012
11/15 – 11/18/2011
11/22 – 11/24/2011
02/14 – 02/16/2012
03/13 – 03/15/2012
05/22 – 05/25/2012
06/18 – 06/22/2012
Location
Paris, FR Rennes, FR
Amsterdam, NL
Birmingham, GB
Barcelona, ES Parma, IT
Date 2011/2012
11/29 – 12/02/2011
03/13 – 03/15/2012
03/27 – 03/30/2012
04/17 – 04/19/2012
05/15 – 05/18/2012
05/22 – 05/24/2012
Location
Chennai, IN
Guangzhou, CN
Orlando, US
Seoul, KR
Shanghai, CN
São Paulo, BR
Date 2011/2012
03/06 – 03/08/2012
03/07 – 03/09/2012
04/01 – 04/04/2012
04/03 – 04/06/2012
05/16 – 05/18/2012
05/22 – 05/26/2012
Further trade fair dates with SICK worldwide at www.sick.com/fairs
SICK AG · Erwin-Sick-Str. 1
79183 Waldkirch · Germany
Phone +49 7681 202-0
Fax +49 7681 202-38 63
info@sick.de · www.sick.com
>> Imprint
Publisher: SICK AG · Postfach 310 · 79177 Waldkirch · Germany · www.sick.com
Phone +49 7681 202-0 · Fax +49 7681 202-38 63 · info@sick.de
Project Management: Stephanie Rott · Stephanie.Rott@sick.de
Specialist editors: TOP MEDIA · Dirk S. Heyden · 69469 Weinheim · info@topmedia-weinheim.de
pr-büro hensel · Roland Hensel · 90571 Schwaig · pr-hensel@t-online.de
Layout: ad:johnson Kommunikation · 76133 Karlsruhe · info@adjohnson.de
Translator: Dr. Erwin D. Fink · 79106 Freiburg · info@transmedia-translations.com
Printing: Druckerei Furtwängler · 77211 Denzlingen · info@druckerei-furtwaengler.de
Pictures: ­SICK AG, www.ausloeser-fotodesign.de, fotolia
Individual contributions may be reproduced after prior consent. Please contact us at: Phone +49 7681 202-3878 · Errors excepted · Subject to technical change
Australia Phone +61 3 9497 4100 ·
+1800 3 3480 2 – tollfree
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 3215 4900
sac@sick.com.br
China Phone +852 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
Germany Phone +49 211 5301-301
kundenservice@sick.de
Great Britain Phone +44 17 27-83 11 21
info@sick.co.uk
Hungary Phone +361 371 26 80
office@sick.hu
India Phone +91 22 4033 8333
info@sick-india.com
Israel Phone +972 4 999 0590
info@sick-sensors.com
Italy Phone +39 02 27 43 41
info@sick.it
Japan Phone +81 3 3358 1341
support@sick.jp
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
Republic of Korea
Phone +82 2 786 6321/4
info@sickkorea.net
Romania Phone +40 356 171 120
office@sick.ro
Russia Phone +7 495 775 05 30
info@sick.ru
Singapore Phone +65 6744 3732
admin@sicksgp.com.sg
Slovenia Phone +386 (0)1-47 69 990
office@sick.si
South Africa Phone +27 11 472 3733
info@sickautomation.co.za
Spain Phone +34 93 480 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 2375 6288
sales@sick.com.tw
Turkey Phone +90 216 528 50 00
info@sick.com.tr
United Arab Emirates
Phone +971 4 8865 878
info@sick.ae
USA, Canada and Mexico
Phone +1 (952) 941 6780
info@sickusa.com
More at www.sick.com
Subsidiaries
>> Visit SICK at the trade fair!
53
www.marschner-kuehn.de
Seeing details, understanding the big picture
Cost-cutting starts
with the basics
Order No. 8014704
Sensor solutions for the automotive industry
Innovative solutions can cut costs. Which is why it often rapidly pays to take a look
at every detail. Because what is of great importance for the automotive industry –
reduced costs – originates in the little things. As your competent solution supplier in
industrial sensors, industrial safety systems and automatic identification, SICK can
see how even the efficient production structures of the automotive industry can be
still further optimized.
SICK AG | Waldkirch | Germany | www.sick.com
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising