SICK Magazine

S I C K ’ S C U S T O M E R M A G A Z I N E

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Sensors with IO-Link New means of communication with automation systems

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3D Cameras Ranger EMinimizing costs thanks to the innovative MultiScan function

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Delivery reliability Customers trust in delivery on time

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> 52 new products in 52 weeks

: Applications

2 01 2009

InnOvatIOn MaRathOn – Stage 1

What’s in store after the crisis

Dear Readers,

One year ago, barely anyone would have declared 2009 a year of crisis. and we would have dismissed as doom-mongering any prophecies of the great-est economic crisis since the German currency reform. But suddenly it was here, hitting our industry with full force – a situation we do not wish to gloss over. however, with this issue of SICKinsight, we would like to look at the crisis from a different perspective: For every crisis offers many opportunities – and certainly, it will end eventually. Consequently, now is exactly the time for innovation and for a determined look ahead.

at SICK, we have turned this point of view into an agenda. With our “Innova-tion Marathon,” we will be present you 52 highly innovative products over 52 weeks. thus, we are making one thing utterly clear: precisely in the present crisis, we are committed to our fundamental values. “SICK – Sensor Intel-ligence” thrives on continuous innovation and reliable quality, irrespective of the current situation. In this connection, our activities in research and devel-opment aim at intelligent products and customer-oriented solutions that we will measure against your requirements.

In the context of our “Innovation Marathon,” however, we are pushing ahead even further. Especially in this difficult state of affairs, we would like to join you in looking ahead to the future, following the motto, “When the sea is too rough for fishing, the fishermen mend their nets.”

no doubt, the sea is rough. hence, now is the time to invest your strength in for-ward-looking plans, getting you in shape when the sea calms down. at that very point, the productivity of your machinery and facilities will play a crucial role.

therefore, let us make you an offer: Join our product and application experts at this very moment in discussing optimizations of production, material flow, and machine performance in your company. Let us work together, thinking today about tomorrow and preparing individual solutions for you. Utilize our expertise to address the question of how you can position your enterprise well for the future. You will find some initial good ideas in this issue of SICK-insight. We look forward to developing many more with you. take us up on our offer and confront us with a challenge. We are looking forward to it!

With best wishes

Markus Paschmann | Member of the Executive Board, Factory automation

: Editorial

InnOvatIOn MaRathOn – Preview

InnOvatIOn MaRathOn – Stage 1

InnOvatIOn MaRathOn – Preview

: Applications

hysteresis minimized, process reliability optimized 04Intelligent identification at the Gemini Gate ........05Encoder solutions for wind turbines and solar power plants ..........................................06

Palletizing individually, protecting intelligently ....07Sensors with IO-Link ..............................................08Inspecting processing quality of camshafts .........09Safety agenda 2010 ..............................................10

new photoelectric switch solution for Krones......11Gantry crane optimizes removal of material ........12Delicate solutions for delicatessen packaging ....13Perfect portfolio for rotor spinning machines ......14Olitalia relies on “refined” barcode solution ........15tEEKannE: no tea break for sensors from SICK ...16Safety in the “air envelope”...................................17Component detection in transparent transport packages ...........................183D quality testing for IKEa wardrobes ..................19Precision solutions for position polling .................20

: Technologyautomating in the best way with light grids..........21

: InterviewDelivery competence complets technological competence ...................................22

: Products

Product news .........................................................24Perfect collision protection in any weather ..........27W4S-3 for extreme requirements .........................28

Pressure measurement for factory automation ...29“Minivation” sets new standards in safety light curtains ...........................................30Encoders that set record highs .............................31Product news .........................................................32the CLv6xx barcode scanner platform from SICK ...33Changing of the guard among luminescence sensors .............................34

Product news .........................................................35Safexpert updates ..................................................36Functional accessories for top sensor performance 37

: SICK TourSICK opens application Center in Singapore .......38Subsidiary in toronto founded ..............................38Encoder prize game at the SPS/IPC/DRIvES .......38Successful safetyPLUS® “practice afternoons” ...39SICK as the quality brand – Sensor Intelligence. ..39Subsidiaries celebrate! ..........................................39

: Internetsick.com with a new look .......................................40

: Info ...................................................................41

: News

03

Firm date in logistics specialists’ calendars

>> In the context of the series of events called “Day of Logistics” (an initiative by the German Logistics association), at SICK in Waldkirch experts will address, in a variety of presentations, the wide-ranging aspects of logistics as a com-petitive factor.

among other things, the lectures will

deal with an examination of regional lo-gistics infrastructures, the optimization of logistical processes as interplay of humans and automation, and the utiliza-tion of opportunities that operative logis-tics driven by management ratios offers against the backdrop of the current eco-nomic situation. Of course, part of the event program will be a guided tour of SICK’s modern Logistics Center.

More information on the Day of Logis-tics 2009 as well as the option of online registration is available on the Internet at www.tag-der-logistik.de

>> Runners that cover a distance of 21 or even 42.195 kilometers successfully pos-sess a high degree of power, fitness, and continuity anyway. Equipped with “SICK Innovation Marathon” running shirts that fit this year’s motto and with sights set ahead, 22 employees from SICK par-ticipated in this year’s Freiburg Marathon, joining more than 10,000 runners from 50 nations. Whereas eight employees from SICK tackled the marathon at 11:05 a.m., the other 14 colleagues crossed the starting line for the half marathon at 2 p.m., together with the well-known athlete Dieter Baumann. Positioned along the marathon route, 42 bands provided the lively tunes that spurred the runners on.

Because of the regular joint training of SICK’s Workshop “Endurance,” which took place on a regular basis during the

lunch break, the runners were very well prepared. the speaker of the workshop, Christof J. Meyer, regretted very much that due to an injury he was unable to run the marathon this year. after all, in the two previous years SICK’s marathon team won first place in the team clas-sification of the South Baden Company Championship held in the context of Freiburg’s Marathon.

Clocking an average time of 3:23:54, in this year’s installment, team SICK secured second place in the company marathon, which saw six companies make the rankings. the team results in the team marathon improved by 14 minutes and 20 seconds. Markus Dirr delivered the highlight of the day: he ran his personal best with a phenom-enal time of 2:57:59, more than ful-filling a long-standing dream of his. In the half marathon, Christian Beier, who had registered late, once again secured the first place in team “SICK Sensor In-telligence.”

Power, perseverance, and sights set ahead clearly during SICK’s “marathon year”

Freiburg Marathon 2009at SICK, marathon has become an agenda this year. On 29 March, 22 moti-vated employees from SICK participated in the Sixth Freiburg Marathon, thus driving home the message of “SICK’s Innovation Marathon.” team “SICK Sensor-Intelligence” put up a united front, proving its fitness and missing the third win in succession by a mere 38 seconds.

Now scrolling online!www.sickinsight.de www.sick.com/

innovation_marathon

Dieter Baumann won the half marathon

: Applications

01 200904

Innovation Marathon – Stage 1

>> KERn-LIEBERS is an international supplier for system manufacturers in the automotive, textiles, and consumer goods industries. at more than 50 loca-tions worldwide, the corporate group de-velops and manufactures precision prod-ucts made of flat steel and wire in the highest quality. “here at the Schramberg plant, we looked for a suitable sensor so-lution for a newly developed longitudinal transfer system, a solution with which to detect two switching points in pneumatic cylinders separately – in very confined in-stallation space and at merely 3 mm of stroke,” says Manuel Pfaff from Construc-tion of Operating Equipment and Special Machinery at hugo Kern und Liebers

Precision solution with magnetic cylinder sensor

hysteresis minimized, process reliability optimized

a cylinder sensor that detects and indicates two switch-ing points separately even at merely 3 mm of stroke – for hugo Kern und Liebers Gmbh & Co. KG, the MZ2Q C-slot was the solution for precise positioning of work carriers on a longitudinal transfer system.

Gmbh & Co. KG. “Using the switching signal, the machine controller detects whether each indexing bolt has reached its end position, as a result of which the respective work carrier is positioned on its workstation accurately to within the required ±0.02 mm. If the indexing bolt stops more than 0.1 mm from the prede-termined end position, then positioning accuracy is no longer guaranteed, and the machine switches off.”

The solution: high-precision version of MZ2Q C-slotthe task was solved using a special ver-sion of the MZ2Q C-slot magnetic cylin-der sensor with minimized hysteresis.

Further product information:www.mysick.com/applications

More about the customer:www.kern-liebers.de

the magnetic cylinder sensor offers two freely adjustable switching points in one very compact device. this allows detect-ing the starting and end positions of the cylinder pistons. “a special feature of the longitudinal transfer system, the short cycle times allow only cylinder strokes of 3 mm,” explains Manual Pfaff. “this eliminated conventional sensors – first, because there is no space to accom-modate two sensors in the short C-slot of the pneumatic cylinder; secondly, be-cause the switching hysteresis was too great and the controller incapable of pro-cessing any unambiguous positioning signals.” For this reason, at SICK a high-precision version was developed from the MZ2Q standard sensor. It meets the requirements of Kern-Liebers. Using drop-in mounting, the sensor is installed protected in the C-slot, i.e. inserted from above and fastened with standard tools. “now the switching points can be ad-justed and fine-tuned in a user-friendly way with the cylinder sensor already in-stalled, i.e. this makes shifting the sen-sor mechanically in the slot unneces-sary, since this, judging from experience, usually results in problems concerning secure attachment,” Manuel Pfaff points to a crucial advantage. the minimized hysteresis ensures that even with travel of merely 3 mm, the sensor outputs only the switching signal for one piston posi-tion. “this plus the overtravel, which is short at any rate, plus the short response times of the MZ2Q made it possible to optimize the precision of work carrier positioning and thus the performance and process reliability of the longitudinal transfer system,” confirms Manuel Pfaff.

Incidentally, the high-precision ver-sion of the MZ2Q is generally available, thus representing an appropriate alter-native solution, when the goal is high-precision detection of two switching points in the context of confined instal-lation space and short strokes.

Product of the Month April

The MZ2Q optimizes performance and process reliability of the longitudinal transfer system

www.sick.com/innovation_marathon

05

Innovation Marathon – Stage 1 : Applications

>> In contrast to stationary conveying systems with their defined transport di-rections, the environment of RFID portals in the non-stationary material flow, e.g. involving stacker trucks in the incoming and outgoing goods department, are sub-jected to permanent changes or ambigui-ties. Pallets with their own transponder are parked temporarily near the portal or are transported in different directions through the portal – in some cases with-out being loaded immediately. “For pro-cess reliability in automated tracking of goods flows, however, it is decisive to be able to detect unambiguously whether or not a pallet identified by the RFID portal will be loaded onto or unloaded from a truck – otherwise successive material flow and inventory management systems have no chance to map the goods flow promptly, consistently, and congruently,” says Dr. andré Mannel, team Leader RFID Solutions at Dematic Gmbh. against this backdrop, the Offenbach-based supplier of intralogistics solutions, Dematic, and SICK have cooperated closely to develop the Gemini Gate.

Combined sensor technological solution comprised of RFID system and laser measurement One of the two central components of the Gemini Gate is the RFI644 – a high-performance RFID system on UhF basis designed for logistics automation. Due to the long range of up to 6 m and fast data transmission, the scanning points in the Gemini Gate can be constructed by portal construction method. In addition to the RFI641, the LMS100 laser measurement system is the second central element of the combined solution. It maps the entire environment around the reading portal, detecting and suppressing even complex disturbance variables. “In this way, it is not

RFID + laser measurement in the goods flow

Intelligent identification at the Gemini Gatethe Gemini Gate developed jointly by Dematic and SICK – an RFID reading portal with integrated LMS100 laser measurement system – now allows reliable identification, position determina-tion, and tracking of pallets all the way to the outside areas and to the loading space of a truck or swap body.

only possible to detect the object that is moving through the gate but to determine its location, position, and direction,” ex-plains andré Mannel. Moreover, by means of reference measurements it is possible to eliminate interfering stationary objects from the measurements.” another advan-tage: as opposed to conventional sensor technology, this technology allows mea-suring objects according to size, shape, speed, and position as well as detecting complete movement profiles.

RFID system and laser measurement technology in direct interplayIn the Gemini Gate, the RFI641 and the LMS100 exchange the relevant data di-rectly with one another. “For this applica-tion, we have developed a special reader program that ensures a comprehensive processing of the readings and pre-fil-tering of the results, while at the same time controlling the signal generators mounted on the gate,” explains andré Mannel. “this interplay of the sensor

technology in the Gemini Gate, self-suf-ficient in terms of control technology, fa-cilitates system integration and retrofits of existing gate solutions. For instance, start-up can be adjusted to the respec-tive customer environment in a simple and service-friendly way.”

Evaluation of measured data and mon-itoring of functions in Asset ManagerSince apart from the objects’ track, their size and shape is measured as well, it is possible to infer the respective type of object. For example, it becomes dis-cernible whether a person, lift truck with or without load, or a forklift is mov-ing through the gate. the evaluation of this additional information in the asset Manager software – a tool for tracking pallets and other logistical units devel-oped by Dematic – provides further data concerning the quality and reliability of the reading. “the asset Manager per-mits, via the new information concern-ing object size, type and speed from the laser measurement, additional means of evaluation that can be used both toward process optimization and continuous fault and performance monitoring of the gate,” andré Mannel points out.

the bottom line: By means of integrat-ed detection of the environment via laser measurement technology, the Gemini Gate makes RFID applications and thus processes in the supply chain safer.

Innovation NO 02Central component of the innovative combined solution: the LMS100 laser measurement system


More about the partner:www.dematic.de


: Applications

>> When it comes to automation solu-tions for facilities to generate energy from renewable sources, SICK-Steg-mann is positioned “sustainably:” Just in the field of speed-controlled wind tur-bine generation systems in onshore and offshore operation, more than 20,000 multiturn encoders from the atM60 se-ries are in use today – with numbers on the rise. added to this are tasks in solar power systems in which rotary encoders such as the new programmable DFS60 or the DKS40 determine paths and po-sitions in tracking systems for photovol-taic modules. What is at least equally as important especially for use in wind tur-bine generator systems is their distinct EMC, since, on the one hand, the sen-sors are often installed relatively close to the rotor – and thus near the generator that converts the rotational energy into electric power. On the other hand, due to their construction height, wind turbine generator systems – and thus their com-ponents – are exposed to increased risk of lightning strikes during thunderstorms. Certainly, the rotor blades are generally equipped with a lighting protective and earthing system – nevertheless, a rest of electromagnetic energy remains, to which the encoders mentioned are in-sensitive, however.

Wind power: encoders ensure the generation of energy at a high degree of effectivenessIn many wind turbine generator systems, incremental encoders of the DFS60 series are used to measure rotor speed. Upon reaching the maximum generator torque, but also at the point when the system is switched off in case of high wind speeds with approx. force 10-12 on the Beaufort scale to avoid damage due to mechanical overload, the rotational speed of the rotor must be limited or, respectively, reduced. to this end, the aerodynamic efficiency of the rotor blades is diminished by moving them out of the optimum angle of attack. In many wind turbine generator systems, this procedure, called pitching, takes place by means of absolute multiturn en-coders of the atM60 series and, in the future, of the new aFM60 series, which distinguish themselves by a high degree of ruggedness and concurrently high ac-curacy. Wind turbine generator systems with horizontal axis of rotation featuring variable rotational speeds and controlled pitch have become the standard today. In order to achieve maximum efficiency and also because wind does not represent a constant, it is necessary in these facili-ties to realign not only the pitch of the ro-tor blades but also the nacelle in accor-

Encoder solutions for wind turbines and solar power plants

Rotative is innovativeWhether the goal is to measure the rotor speed of a wind turbine generator system, adjust its rotor blades corresponding to wind conditions, or to track solar panels in accordance with the solar path – everywhere rotary encoders provide for efficient genera-tion of energy.

dance with the wind direction. Installed on the tower and rotatable horizontally, multi-stage planetary gear sets equipped with atM60 or aFM60 encoders, so-called yaw (or azimuth) drives, ensure that the nacelle with the rotor always has “its nose turned toward the wind.”

Solar power: always at the optimum an-gle to the sun with the help of encoders the term azimuth plays a decisive role in efficiently converting “natural” energy into electrical power not only in the sphere of wind power but also in the construction and operation of solar power stations. here azimuth means the respective current de-viation of a solar panel from the orienta-tion due south. this tracking of the panels by means of so-called tracking systems in accordance with the current position of the sun allows the sun to hit the solar cells at a ninety-degree angle all the time. In this way, one can achieve the best possible energy yield, which exceeds that of station-ary panels by up to 40%. Depending on the tracking system, the devices employed for distance measurement and position detection are either incremental encoders of the DKS40 series – mounted directly on the shaft of the tracking system’s main drive – or of the DFS60 series.

Whether wind or solar energy – even today, the encoders from SICK StEGMann are already proving their worth in many places as innovative solutions for innova-tive energies.


Innovation NO 05


01 2009


06

: Applications

>> Grässlin automationssysteme based in St. Georgen (Black Forest) specializes in application-specific solutions for auto-mated palletizing and transfer technolo-gy. the best example of this is the PS 10 palletizing system. With respect to the mechanical model, one can choose from different options regarding the supplying of tray stacks, the degree of automation of the infeed, or the gripper and handling solutions for trays and workpieces. the control philosophy is modular as well: Depending on the robot functionality, the central drive and control design can control up to eight servo axes for tray or workpiece handling, also supporting in-tegration of different handling kinemat-ics via the controller software.

Different sensor technology integratedSince PS-10 palletizing systems are equipped with automated handling and robot systems, the working area of the machine represents a potential source of danger in case a person reaches into the machine during ongoing operation. For this reason, the feeding and discharge section of the tray stacks are monitored with a C2000 safety light curtain. among other things, RE300 non-contact safety switches from SICK are used to protect the safety doors in the area of the robot axes for tray and workpiece handling. however, the added benefit for the PS 10 in terms of automation technology is the modular Flexi Soft, because it offers a great variety of functions and it can be programmed easily.

Planning, configuration and “wiring” on the PC thus, the hardware configuration of the Flexi Soft took place by means of the drag & drop principle via the inter-face of the Flexi Soft Designer, which is structured in a particularly intuitive way. this saves an enormous amount of time

Flexi Soft does a great job as safety solution with utmost flexibility

Palletizing individually, protecting intelligentlyModularity, individuality, and quality distinguish the palletizing systems of Grässlin automationssysteme Gmbh. So what would fit better with these handling solutions than a safe control design, which – like the Flexi Soft safety controller from SICK – supports precisely these machine features in conjunction with functional safety sensor technology?

when configuring the safety solution, making it possible to copy a solution, once defined, as many times as desired for machines featuring the same func-tion. another benefit of the Flexi Soft de-sign is the fact that the safety solution

safety controller in control cabinet 1 is responsible for the safety monitoring of the emergency stop pushbutton and of the C2000 safety light curtain. Both are connected by means of an I/O module, just the same as three UE12 24vDC con-trol voltage load disconnecting relays. In terms of output, the Flexi Soft acts direct-ly on the axes of the palletizing module: the second Flexi Soft CPU in the upper control cabinet is also fitted with a an I/O module featuring eight inputs and four outputs as well as an eight-channel input module. the focus with respect to safety technology is on monitoring the


More about the customer:www.graesslin-automation.de

lends itself to easy modification. If a new safety-monitoring feature is added, e.g. an additional emergency stop pushbut-ton or an external contact, these items are included in the software. as a result, the safety controller fully supports the flexibility of the machine design.

Safety solution integrated into PROFIBUS-DP of the palletizing systemFor reasons of functionality, the PS 10 palletizing system has two separate con-trol cabinets with one safety controller each. Both CPUs communicate via their safe EFI (enhanced function interface) bus interface both with one another and with the PLC of the palletizer via the stan-dard UE1140 PROFIBUS Gateway. the

different safety door switches. all of the safety components from SICK are certi-fied according to the new safety stan-dards and thus represent trendsetting technology.

the upshot: Just as there is not only one PS 10 palletizing system, there is also not merely one Flexi Soft safety controller. Both thrive in crucial ways on the fact that with their help it is possible to generate easily efficient and top-quality system so-lutions from a “module-making kit”.

Innovation Marathon – Preview

Product of the Month August

07

: Applications

01 2009


>> the WtB18C-3 and WtB27C photo-electric proximity switches with IO-Link from SICK are devices featuring different ranges and construction designs. Due to their special chip technology are elec-tronically adjustable, they remain unin-fluenced by disturbances close to the application, e.g. electromagnetic fields of drives on conveyor systems or ambi-ent light sources, providing extremely accurate and reliable detection results – largely independent of object shape or material surface.

Two machines, two processes, one sensor technologyWhen using IO-Link photoelectric proxim-ity switches from the Wt18-3 series in a carton packaging machine, the end user can fully automatically adjust the sen-sors to the geometrical properties of the cartons in accordance with the respec-

Sensors featuring IO-Link open up new possibilities of commu-nication with automation systems. after successfully integrating photoelectric proximity switches or magnetic cylinder sensors from SICK into various applications, well-grounded feedback from practical operations is now available on the question as to what the user gets out of it.

tive packaging batch to be processed by using either the control panel or the stored job data. to this end, upon start-up of the machine, an exact adjustment of the scanning distance of the pho-

toelectric switches was carried out for each format to be processed, using the teach field on the touch-screen machine terminal. During operation, the optimum parameters, e.g. the scanning distance of the sensor, are retrieved from the au-tomation system, transferred to the sen-sors, and, if required, displayed on the panel. Mechanical readjustment of the sensors becomes redundant – more-over, the settings of the WtB18C-3 are 100 percent reproducible from one task to the other and thus reliable. Eventu-ally, the communication capability of the IO-Link sensors – in this case embedded into the existing control and Profibus DP design of the carton packaging system – has simplified the operation of the ma-chine to an unprecedented extent.

With respect to the operation of a wood-processing machine, the focus of attention is on minimizing batch-related make-ready and adjustment times. Prior to feeding the wood products in, hydrau-lic actuating drives are brought into a po-sition that allows collision-free feeding of different sizes. In this context, the maxi-mum travel of the actuating drives is sig-nificantly greater than usually required in process technology. With the WtB27-3 photoelectric proximity switches, it was possible to minimize the respective travel required, thus saving valuable set-up time. In order to guide the actuating drives into the optimum “waiting posi-tion” in the respective instance, the ma-chine controller uses the IO-Link to read into each photoelectric proximity switch the very value that it was taught at start-up for the respective format and that was saved in the controller. after each

>> Info box

IO-Link technology is characterized by a standardized, manufacturer-indepen-dent “protocol” for data exchange between a sensor or actuator and the IO-Link field module, from which data is transferred to a bus system. With respect to data transfer, one distinguishes two categories: on the one hand, IO-Link-spe-cific, e.g. binding on all manufacturers and concerning “only” data polling, e.g. manufacturer ID, device ID, and serial number; and, on the other hand, manu-facturer-specific, the type that made it possible for SICK to extend the data transfer using the chip technology of the photoelectric proximity switches to such an extent that even parameterization, e.g. remote adjustment of scanning distance via IO-Link, became possible. this added value is an essential prerequi-site for controlling processes at all via the sensor, directly out of the machine.

08

Gateway for integration of sensors into the control unit Serves the user right!

Sensors with IO-Link

Innovation NO 20

format change, the value in the photo-electric proximity switch is overwritten by the new value. as soon as the pho-toelectric proximity switch detects the actuating drive in the desired distance, it is stopped.

More flexibility, more availability Both in the packaging machine and in the woodworking machine, IO-Link ren-ders the processes controllable in a flexible way, while at the same time in-creasing machine performance. thus, the technology offers end users crucial added value as compared to “tradition-al” sensor integration. thanks to IO-Link, it is possible to optimize the availability of the entire machine, e.g. by preventive maintenance. Both in the packaging ma-chine and in the woodworking machine, the photoelectric proximity switches in-dicate the degree of their pollution inde-pendently. at this time, the sensor func-tion is still guaranteed unconditionally – but the information allows maintaining the facility during an operating break, thus preventing downtimes caused by unplanned machine stoppages. Con-versely, for scheduled equipment main-tenance, one can poll all of the connect-ed IO-Link sensors via the automation system. In case of a malfunction, the ma-chine operator is able, via this diagnostic function, to get an idea of the possible causes from a central location. all of the important data, e.g. signal quality, the status of the switching output, or a pos-sible short circuit, are displayed on the machine’s operating panel. thus, many errors can be fixed even by operating personnel that has no special knowledge concerning automation.

the upshot: for users, IO-Link opens up new opportunities of increasing ef-ficiency and productivity as well as re-ducing costs. SICK is perfectly suited as a partner for this purpose – on the one hand, because even today, a wide variety of IO-Link devices and integration tech-nologies are available, e.g. photoelec-tric proximity switches, automation light grids, magnetic cylinder sensors, or IO-Link field modules; on the other hand, be-cause all of the sensors and components from SICK meet IO-Link specification 1.0, thus ensuring full interoperability with de-vices from other manufacturers.

>> Every year, Ford Otosan produces 40,000 engines – and an equal number of camshafts. What matters most in one of the quality test stations is the highest possible positioning accuracy of the cam-shafts – on the one hand, to align them precisely for the next process step; on the other hand, to check their surface and polishing quality. OD Max displacement sensors carry out both of these tasks si-multaneously.

Detecting the highest point and orientationat the test station, the camshaft rotates on its own axis at about 80 rpm. “In the first measuring step, the value deter-mined initially is the shortest distance that the surface of the camshaft reaches vis-à-vis the high-precision distance sensor,” explains Ilker Balgoglu from SICK turkey. “this value is then saved in the evaluation unit. In a second rotation run, the point of reaching this value is then transmit-ted to the machine control via a switching signal. Using this procedure, it is possible to determine and align the position of the highest point with an accuracy of +/- 0.01 mm.” Based on this positioning and with

Inspecting processing quality of camshafts

Precise to the dot Ford Otosan in the turkish town of Eskisehir trusts in OD Max displacement sensors for the inspection of camshafts. another crucial point, though, is the presence and technical support of SICK’s sales company on location.

the help of the distance data, it is possible to fix the camshaft for the next process stage or, in case of insufficient surface quality, to sort it out for reworking.

Besides the precision of the ODs, presence on site was decisivethe displacement sensors from SICK re-placed a mechanical system used in the past. “apart from the high-precision, non-contact measurement, the decision in fa-vor of OD Max became easy for us due to the fact that SICK provided such excellent technical support on site,” says hüseyin asa, the head of the Design Group at Ford Otosan.

his statement proves one thing: Even the best sensor only creates real cus-tomer benefit and ultimately optimizes the availability of equipment and plants in conjunction with the appropriate proj-ect support.

09


More about the customer:www.ford.comFurther product information:

www.mysick.com/applications

: Applicationsautomotive Industry

: Applications

10 01 2009


Innovation NO 28

>> today’s industrial enterprises are mov-ing in a global setting: Production sites are shifted worldwide, machines and plants ex-ported to different regions the world over. therefore, compliance with standards is just as much a crucial factor behind the success of globally operating manufactur-ers as the technical safety design of their machines and plants themselves. Produc-tion facilities are becoming increasingly more complex; cycle rates are rising; and the functionalities of the machines are becoming more and more challenging. On the part of machine manufacturers and operators, this results in demands for more efficiency or, respectively, production support as well as the easiest operability possible.

Development of standards: “Recipes” give way to “home-made” creationsWhat makes the task of coping with the aspects of both standardization and those of machine technology more difficult for

design engineers is the fact that both ar-eas influence each other mutually. new sensor solutions – especially with respect to electro-sensitive protective equipment and new control designs – permit new concepts regarding machines and plants that significantly enhance not only their performance and availability but also their operating ergonomics. accordingly, the standardization processes follow the increasingly shortening product develop-ment cycles. In this context, the trend is toward system standards that offer solu-tions less in the shape of “recipes” but rather aim at agreement on specific pro-tective goals. For the design engineer, this means that concrete solutions are super-seded by the challenge, but also the op-portunity, of reacting flexibly to new tech-nologies and trends. For safety experts such as SICK, this entails serving the in-creasing need for information in engineer-ing departments in a cooperative, compe-tent, and comprehensive way, e.g. in the

as of 29 December 2009, many things will change concerning the technical safety assessment of machinery and plants, be-cause the transitional period (DOW = “date of withdrawal”) for the presumption of conformity pertaining to the En 954-1 stan-dard will expire. It will be replaced by En ISO 13849-1, which is characterized by quantitative approaches. By supplying a num-ber of tools, SICK opens up for engineers who design machines and plants those opportunities that En ISO 13849 provides con-cerning the technical safety assessment of machines.

context of En ISO 13849-1 at the press manufacturer Schuler in Göppingen.

Schuler: Updating standards with the design engineers on site In order to recognize early on the opportu-nities offered by the new standards situa-tion from 2010 onward and to put them into practice constructively – in the double sense of the word –, the Schuler Group headquartered in Göppingen, one of the world’s largest manufacturers of presses, has decided in favor of a pragmatic path. together with the safety experts from SICK, a compact training program was car-ried out initially at the Group’s individual locations. thus, based on specific press applications and their technical safety ad-justment to the contents of En ISO 13849-1, in the context of several workshops it was possible to arrive jointly at a practically oriented introduction to the complex topic of “Performance Level & Co.” together with the experts from SICK, design engi-neers from the different technical depart-ments examined which influences arise with respect to different safety functions such as ram locking systems, gripper rail protection, or “speed monitoring in setting-up mode.” In terms of the time involved in connection with the new standard, a differ-entiated picture emerged: Whereas using already “pre-certified” safety blocks, such as light grids, in particular allows a simple and thus time-saving verification of safety functions, more complex problems require a clearly structured approach in order to reach the goal.

the upshot: En ISO 13849-1 ranks among the most important standardiza-tion projects in the area of machine safety in recent years – by 1 January 2010 at the latest, every manufacturer of machines and safety components will be affected by its consequences. Practically oriented training courses and workshops that take into consideration the new “norm”-ality will provide design engineers with new impuls-es to combine trends in machine and tech-nical safety with one another flexibly, thus becoming even more competitive interna-tionally – especially since European safety standardization will continue to serve as a model, being adopted by many countries and regions worldwide.

Update for design engineers

Safety agenda 2010


More about the customer:www.schulergroup.com

: Applications

11


More about the customer:www.krones.de

>> headquartered in neutraubling near Regensburg, the Krones Group plans, develops, and manufactures machines and complete plants for the areas of pro-cess, bottling, and packaging technology, as well as intralogistics. “Whether the products concerned are beer, soft drinks, sparkling wine, or spirits – every second bottle in Germany and every fourth bottle worldwide is filled, capped, labeled, and packaged on facilities made by Krones,” Danuta Kessler-Zieroth, spokesperson of the Krones Group, illustrates the market position of the enterprise, emphasizing this with current figures: “at the five lo-cations in Germany and the more than 50 subsidiaries abroad, Krones employs a staff in excess of 10,000, generating sales of 2.256 billion euros in 2007.” this success is made possible, among other things, by the special knowledge in machine construction and in customers’ sectors, the technological lead, worldwide service, and the cutting-edge production facilities, e.g. at the Rosenheim plant. “this location serves primarily the manu-facturing of packaging and intralogistical facilities and modules, for instance, pack-aging and palletizing robots, packing and

unpacking machines, carton processing machines, as well as palletizing and de-palletizing systems,” explains Friedrich hingerl from the Department of R&D Standardization at Krones in Rosenheim.

The task: optimizing costs, maintaining compatibility“In order to optimize technology and costs, we have analyzed, together with SICK, the types of technical and economical possibil-ities the portfolio of photoelectric switches offers with respect to detection tasks that we have to solve, for example, on beer case depalletizers,” says Klaus Scholz from Pur-chasing at Krones aG’s Rosenheim factory. taking as a starting point a sensor solution tried and tested many times over, Krones was interested in finding a sensor alterna-tive at least equal in quality at lower costs, which at the same time offered – in terms of design, installation, and service – full mechanical and electrical compatibility with the previous model.

The solution: new technology integrated in the existing series “Using these specifications, we devel-oped a customer-specific special device

based on the W23-2 series,” Dr. thomas höfling, General Manager of SICK ver-triebs-Gmbh in Düsseldorf, looks back. “By integrating the PinPoint technology we managed, on the one hand, to meet Krones’ technical requirements concern-ing range, functional reserves, and vis-ibility of the light spot. Since the series concentrates at the same time on essen-tial automation features, we were able to achieve a pricing situation tenable for both parties.”

PinPoint: the technology for more performancePinPoint stands for a novel LED technol-ogy in photoelectric switches and pho-toelectric proximity switches from SICK. “PinPoint LEDs concentrate the energy on a smaller space, increasing the light intensity of the light spot,” says Jürgen Goller, sales representative of SICK ver-triebs-Gmbh. “For users such as Krones, this approach simplifies, among other things, alignment of a photoelectric switch enormously. Friedrich hingerl confirms this: “the PinPoint light spot makes commissioning or readjustment far easier. Moreover, we can use the added range as a further functional re-serve.

Capacity for fast reaction was decisiveWith the WL23-2 SICK meets all of Kro-nes’ performance requirements. apart from the sensor quality, one of the decid-ing factors was that the entire project of sensor conversion took only a few weeks. “SICK did its homework with a high de-gree of flexibility and competence. Only ten weeks passed from the first talks to sampling and the capacity to deliver a large number of pieces,” Klaus Scholz from Purchasing at the Rosenheim fac-tory of Krones aG remembers.

however, another reason why Kro-nes now uses the new WL23-2 PinPoint in various areas throughout the entire group is that apart from the technology, quality, and price, SICK’s delivers logis-tics and worldwide service that are right on the mark.

New photoelectric switch solution for Krones

Cost optimization through technology orientation

a new technology for photoelectric switches – called PinPoint – has enabled SICK to react quickly and cost-effectively to the requirements of the Krones Group, a machine manufacturer.

Machine construction

Capacity for alignment of a photoelec-tric switch was enhanced by integrating PinPoint technology

: Applications

12 01 2009


More about the customer:www.holcim.de www.erler-gmbh.de

>> the outdoor operation at the cement factory makes high demands on the rug-gedness of sensors. the Pomux path-measuring systems used for positioning the gantry as well as the crane trolley meet these requirements just like the

LMS211 outdoor laser measurement system that determines the level in the pit measuring 25 m by 12 m. “however, the bulk material itself also represents quite a challenge,” says alois Erler from Erler Gmbh system integrators, “as vari-

Excavating in the right places

Gantry crane optimizes removal of material autonomously

Where is the bulk cone the highest, where is it the lowest? Where does bulk material need to be distributed in or retrieved from the mine? the gantry crane at the bulk storage of holcim (Süd-deutschland) Gmbh’s cement factory in Dotternhausen knows the answer to these questions – thanks to two Pomux Kh53 posi-tion detection systems and one LMS211 outdoor laser scanner.

ous dark or reflective substitute fuels do not exactly render detection easy be-cause of their weak reflectance.”

Feasibility tests convinced both operator and integratorPomux Kh35 is a very accurate but also extremely robust linear path measuring system. With measured lengths of up to 1,700 mm, it is suited, among other things, for use on cranes and rail vehi-cles. the sensor element determines the actual position by means of non-contact scanning of reference marks mounted along the drive path. these consist of aluminum profiles with integrated per-manent magnets, whose distance to one another represents a fixed position coding identified by the sensor unit’s magneto-resistive sensors. “Because of the non-contact technology, the system, which is mechanically very robust, works completely free of wear,” says alois Erl-er. additional praise goes to the Profibus integration into the controller of the gan-try crane, which allowed very convenient start-up.

the same applies to the LMS211 outdoor laser measurement system. Us-ing a fan-shaped laser beam, it scans the surface of the bulk material, supply-ing the gantry crane with the measured values via serial interface. In order to convince both the operator, holcim Süd-deutschland, and the integrator, Erler, that the device always detects the sub-stitute fuels reliably in the most diverse weather conditions, appropriate tests were carried out at SICK’s application lab in Reute – successfully. “Whether in dry or wet state, in fog or snow – the LMS211 accurately detects all dimen-sions of bulk surfaces,” confirms Egon Schlaich, the responsible project man-ager at holcim. “the laser measurement system allows us to work far more flex-ibly. Moreover, the process of depositing in and retrieving from the storage occurs very evenly.”

Since putting the automation solu-tion into operation, holcim Süddeutsch-land has had absolutely no trouble at all. “that’s a good sign,” says alois Erler, “as it proves that the technology from SICK works perfectly.”

From left: Egon Schlaich, at Holcim (Süddeutschland) GmbH; Peter Steurer, SICK Vertriebs-GmbH, and Alois Erler, of erler gmbh

Building material manufacturing

13

>> as a matter of fact, not long ago to be precise, a so-called “six-fold hand-oper-ated workstation facility for manual salad packaging” was partly automated at this location for the BEECK Feinkost Compa-ny. the enterprise belongs to Deutsche See Gmbh, which, under the second-ary name “Fischmanufaktur” processes and ships to bulk buyers such products as fresh and frozen fish, smoked fish, matjes herring and marinades, as well as seafood and deli salads. the BEECK brand stands for fresh and high-quality delicatessens – therefore the company attaches great importance not only to delicate preparation and processing of the products but also to environmentally friendly packaging solutions that appeal to customers visually. “In this context, sensors from SICK allow efficient and smooth processes, e.g. with regard to the capping station, online labeling, as well as homogenous order picking,” says Michael huhndt, electrical design engi-neer and software developer at SES.

Cylinder sensors at the manual workstations at manual workstations, each of which is equipped with a scale, the salad is por-tioned into a dish. Once the net weight of the package is reached, the employee places the container onto a feed belt. It conveys the package to a slideway. here, a vtF18 cylinder photoelectric switch de-tects the presence of the container. “the photoelectric switch activates the slide-way, which then pushes the container on the linear indexing conveyor in such a way that the type of salad, e.g. Exquisite herring Salad Red or Potato Salad ‘Wild Garlic,’ fits the respective compartment in the index-ing chain with the appropriate electronic coding,” explains Frank Buhr from the Me-chanical Design Department at SES.

a visit to SES-Straßburg-Etikettier-Service Gmbh in Buchholz / nordheide demonstrates how sensors from SICK ensure that ready-made salads portioned in dishes are sealed with a lid and labeled properly.

Content and presence inspections at the capping device at the moment when the filled salad dishfeeds into the capping device, a CvS1 Easy color vision sensor inspects the contents. In fact, only properly filled dishes may be capped with the original lid. “Because of its two-dimensional scanning technique, the CvS1 was the only solution capable of solving this task appropriately from a techni-cal and economical perspective,” says

Michael huhndt. On the inside of the capping device, sensor solutions from SICK dominate as well: MZt6 mag-netic cylinder sensors detect the end position of the automatic lid stacker, vtF18 cylinder photoelectric switches check the height of the lid stack in the destacking magazine, automati-cally signalizing to the controller when reaching low stock. Laser photoelectric switches from the WL9L-P series en-


More about the customer:www.ses-strassburg.de

Delicate solutions for delicatessen packaging

Packaging and labeling ready-made salads reliably

Right: Frank Buhr, mechanical design at SES; Matthias Voigt, SICK Vertriebs-GmbH, and Michael Huhndt, electrical design and software development at SES (from left)

sure that in fact one lid is destacked and applied to each dish.

Double online labelingOnce the lid is attached, the container reaches the labeling machine located in the exit area of the capping device. Photoelectric switches from the WL150-P series make sure that a sufficient amount of labeling material is available at all times: they signal when a new roll of labels needs to be inserted. at the exit area of the labeling machine, the salad dishes are transferred to a cross indexing conveyor, on which are installed CLv630 barcode scanners. “the task they need to solve is detecting the label and ensur-ing that the online contents are imprint-ed and legible,” says Frank Buhr.

Automation menu: “ingredients” from a single source as varied as the tasks in SES’s facility are, it was quite practical that all of the sensors could be obtained from a single supplier. “You really noticed that SICK has plenty of experience with packaging solutions for foodstuffs,” Michael huhndt confirms in conclusion.

Food packaging : Applications

: Applications

14 01 2009

>> Rieter is a globally operating industri-al group with headquarters in Winterthur, Switzerland. apart from the automotive industry, their main area of activity is in the textiles industry. thus, Rieter textiles Systems develops and manufactures machines and plants for the production of yarns and non-woven fabrics. Within this business segment, Rieter Ingolstadt Gmbh manufactures, among other items, rotor spinning machines used to spin and wind yarns made of cotton, viscose, syn-thetic fiber, or blended materials onto bobbins. the machines are used world-wide. Clients expect trouble-free opera-tion with over 8,500 operating hours per year in sometimes warm and humid as well as dusty conditions. In this context, simple setting and maintenance are very important. Sensors from SICK help solve various detection tasks involved in the fully automatic spinning processes.

Different requirements, different sensor solutions, but only one partner: For the rotor spinning machines Rieter Ingolstadt Gmbh, photoelectric switches, photoelectric proximity switches, and in-ductive sensors from SICK are just the right automation “set.”

Positioning with inductive sensorsOn the robot of the rotor spinning ma-chine, IQ10 inductive sensors are em-ployed in a variety of places for position-ing tasks. In contrast to the previous model, the IQ10 offers a significantly reduced physical size while providing the same operating distance – which for Riet-er facilitates installation in the robot with limited space available. an additional bo-nus is the housing itself, which due to its robust material can be fastened applying increased torque. this prevents the type of creeping loosening of screws that can be caused by the machine’s vibrations.

Checking empty bobbins with photo-electric proximity switchthe bobbins used to wind the yarn are conveyed from the store to the individual bobbin locations by means of a narrow conveyor belt. During the transfer from

the store to the conveyor belt, the Wt11 photoelectric proximity switch detects whether a bobbin is lying on the belt be-fore the next bobbin can be placed on the conveyor by the robot.

Detection of pattern tape: any color is recognized In the robot, the Wt18-3 photoelectric proximity switch checks for the presence of the sliver at the spinning point. the sensor dependably identifies even black sliver, which is difficult to detect. apart from detection reliability, in this application the arguments in favor of the Wt18-3 were the minimal construction depth as well as the clearly visible red light, which considerably facilitates align-ment of the sensor to the pattern tape.

Fine adjustment of the robot via laser photoelectric switch after the robot has checked for presence of the sliver in passing by, it has to be fine-tuned very precisely in front of the spinning point for the following piecing operation – the piecing of the yarn end and the transfer to the bobbin. For this task, the Wt9L-2 laser photoelectric switch was selected. Dependably and with great repeat accuracy, it positions the robot in such a way that it can carry out the piecing operation and begin piec-ing the thread to the bobbin.

PinPoint sensors meet the high demands for checking the bobbin conveyor beltthe full bobbin is removed from the wind-ing head by the robot and deposited on the second, wider conveyor belt. Before doing this, it is necessary to check from a farther distance whether the space is

Automation from a single source

Perfect portfolio for rotor spinning machines

Top: Checking bobbins with photoelectric proximity switch

Left: Positioning with inductive sensors

textile industry

15


More about the customer:www.rieter.com

available or occupied by another bobbin. For this demanding detection task, two WtF27-3 photoelectric proximity switches with high-performance PinPoint technolo-gy and foreground suppression are used. Since in the process, the background, i.e. the conveyor belt, serves as refer-ence, the photoelectric proximity switch is capable of detecting any object on the conveyor belt. this applies to glossy yarn, which contingent on a flat angle of inci-dence usually reflects the emitted light away, just as it does to black yarn, which due to its extremely low reflectance ca-pability practically “swallows” the emit-ted beam. In addition to range and detec-tion reliability, the crucial feature in this case, too, is that the very well visible red light spots of the two WtF27-3s facilitate alignment immensely.

Added benefits provide Rieter with clear advantages Where until now Rieter used devices made by several different manufactur-ers, today the company relies on more efficient sensor technology from a single source. this standardization reduces the great variety of suppliers and simplifies procurement, stockpiling, and service. In addition to the comprehensive solution competence that SICK is able to prove in the area of the textile machine indus-try, Rieter also benefits from being able to handle enquiries, orders, and delivery tracking via SICK’s Partner Portal on the Internet.

Top: (from left to right) Bernd Bahlmann, Electro and Control; Jürgen Rothe, Product Management; Helmut Haunschild, Research & Development from Rieter and Günter Leuker, from SICK

>> the Italian Olitalia Company in Forli is a leading producer of high-quality cook-ing oils. the basic ingredients of refined oil – made, among other things, of sun-flowers, olives and grape seeds – derive from nearly all countries of the Mediter-ranean region. at Olitalia, these undergo further processing into first-rate cooking oils for private households and the ca-tering trade. the different grades of oil are shipped to 129 countries on all five continents.

Data capture for production and distributionFollowing production, the cooking oils are bottled and packaged on seven lines. In the process, all of the packages and pallets are provided automatically with a barcode label, which in addition to important details about the customer also contains data regarding the pro-duction batch and the best-before date; these are necessary for the retraceability of the products. “the barcode scanners of the CLv420/430 series inspect all of the packages for presence of the label and for readability,” explains Gianmarco antonelli, It service consultant at Olita-lia. “as soon as a carton or pallet cannot be identified, the unit is extracted and re-labeled to guarantee continuous retrace-ability.” In this way, we can ensure that

the application spectrum of barcode scanners from SICK used at the Italian cooking oil producer Olitalia ranges from processing and bottling all the way to shipping. the “refined” solution not only checks for presence and readabil-ity of the labels but at the same time determines the manufacturing quanti-ties of the different oil qualities as well.

only identifiable packages make it to the forwarding department and from there to the customer.

In addition to identification, at Olita-lia the barcode scanners are also used for recording the production quantity. “With the help of the match-code func-tion of the scanners, we can collect information about the packaged units per grade and thus about the overall quantity produced,” says Gianmarco an-tonelli, who offers words of praise for the devices: “the scanning reliability of the scanners has enabled us to install a data recording solution on every line featuring utmost availability.”


More about the customer:www.olitalia.it

Tracking and tracing in cooking oil production

Olitalia relies on “refined” barcode solution

Food production : Applications

: Applications

16 01 2009

>> In fact, as opposed to the enjoyment of tea as a beverage, tea production is anything but relaxing. “Depending on the season and the brand of tea, the teabag packaging machines at tEEKannE Gmbh & Co. KG are working at cycle rates of up to 400 teabags per minute,” says horst thoenesen, head of the Elec-tric and Energy Department.

TEEKANNE makes the tea – SICK makes the detection around the teabag happennumerous process steps are required before the different brands of tea from tEEKannE with their variety of flavors and feel-good aromas are processed and ready-to-drink. In the teabag pack-

aging machines, the loose tea is pro-cessed at maximum speed. the filter pa-per, unwound from a roll, is first checked by a WL9 photoelectric reflex switch for any potential tear in the material and then shaped into a tube by the machine. Before filling, WLL12 photoelectric sen-sors with fiber-optic cables complete an inspection of the web edges so that after the filling with tea, the material can be sealed flawlessly by knurling. With the help of the Kt5 contrast scanner, the filled filter paper web is then cut in teabag lengths, the bottom and top shapes are formed, and subsequently the tag string is tied to the top part. a Wt12-L laser photoelectric proximity switch is used for detecting the string. after this, each indi-

Just as individual as product assortment of Düsseldorf-based tea producer tEEKannE is, so is the range of sensors used for pro-ducing teabags, tea cartons, and packages. however, while tea is becoming increasingly popular as a beverage for breaks and wellness, the photoelectric switches, camera systems, barcode scanners, and other sensors from SICK in the machines do not get any teatime at all.

vidual teabag receives a wrapping pouch and – e.g. in the case of black tea, rasp-berry & chocolate – is packaged in 20s or other numbers of pieces.

Keeping track of packaging variety reliablyBehind the carton erector, each pack-age is checked directly after closing by means of 2D Smart Cameras of the IvC-2D series, so that during transport there will not be any disruptions due to pack-ages with defective edges, open tops, or protruding teabags. Subsequently, the packages are transported via a plastic-chain conveyor system to final packag-ing in a different workshop.

the sequence of products is not ho-mogenous but completely chaotic: the packages pass the conveying system as a motley assortment. “the whole thing is disentangled on several sorting tables,” norbert Strüver, who heads the teabag production, describes the process. In order for all products to be transported to the tray packaging machine as single varieties, they are identified by means of CLv420 barcode scanners and pushed to a certain infeed track depending on the tea variety. this occurs through pneumat-ic cylinders, whose piston movements are monitored by MZt1 magnetic cylinder sensors. In the tray packaging machines, WLL12 photoelectric sensors with fiber-optic cables scan certain points of the package, initiating an exact gluing job.

Palletizing according to single tea variety after further packaging of the flawless packages in trays according to single varieties, they finally reach the palletiz-ing area via the plastic-chain conveyor system. here, four robots carry out their tasks fully automatically. they are as-sisted by CLv420 barcode scanners that resolve the chaotic sequence of cartons according to single varieties, guiding them to the respective robot. after the robot has closed the last tier of a pallet, it is transported out of the fenced robot area to a pick-up zone, whose occupancy is detected and indicated by a DS60 dis-tance sensor.

From teabag packaging to tray palletizing

tEEKannE: no tea break for sensors from SICK

Inspection of the tea packages using a sensor from SICK

Food packaging

TEEKANNE and SICK – the story of an automation partnership the internationally operating tEEKannE Gmbh & Co. KG is a market leader in the tea sector, combining for over 125 years tea experience with a range of continuously new flavor varieties. the partnership in automation with SICK has admittedly not been quite as long-stand-ing, though lasting several decades al-ready. What has developed in addition to a series of innovative sensor solutions is a profound understanding of the re-quirements involved in tea production. “Immunity to dust, IP65 enclosure rat-ing, versatile possibilities of adjustment, teach functions, compact design, and a wide range of space-saving fiber-optic cables constitute features that go back to our requirements as well,” confirms horst thoenesen. new product trends, including new shapes of tea bags, the further development of the dual-cham-ber teabag, and new varieties of pack-ages with innovative dispenser functions but also progressing machine automa-tion – key word: filter roll replacement – will continue to generate new demands on sensor solutions in the future.


More about the customer:www.teekanne.de


More about the customer:www.dbs-modularesysteme.de

>> In countless producing enterprises active in any given industrial sector, emissions are generated in the assembly shops. there are clouds of smoke and noxious smells, air pollutants, and harm-ful substances accompanying production are released. In an age of occupational safety and environmental protection as well as high demands on product quality, innovative problem solutions in this area are necessary.

“An air envelope” Dr.-Ing. Jürgen Bayer from DBS Modulare Systeme has developed an intelligent system called kommula® for solving these problems. the company develops, manufactures, and supplies modular technology related to the process en-vironment for manual and automated manufacturing facilities in all sectors of industry. By creating an “air envelope” with well-directed ventilation flows calcu-lated beforehand, the use of kommula® achieves protection of the process en-vironment or protection of the process itself. adapted to the respective require-ment and task, this approach allows de-tecting and eliminating emissions direct-ly at the source. the arrangement gives

the DBS Modulare Systeme Company has developed a solution to protect processes and workspaces contaminated with emissions by means of an “envelope of air.” this takes place with specially enclosed and, if required, ventilated S3000s, which in this environment ensure safety around the ma-chines and for operators twenty-four seven.

the encapsulated and ventilated S3000 safety laser scanner the necessary clear view for area protection.

Safe monitoring, independent of emissions Since the S3000 is not designed for the smoke pollution in a welding facility or foundry, for oil mist in a machining cell, or for any other environment contaminated heavily with emissions, DBS has integrat-ed it into a protective housing flushed with air. By means of this solution featur-ing an enclosure and air envelope, the scanner has no contact with the emis-sions that would otherwise settle on the device, possibly impairing its functional-ity. On top of that, the ventilation provides an opportunity to cool the S3000 as well, should conditions become too warm.

the same applies to all air-related parameters such as dehumidification, humidification, thermal radiation, as well as any type of emissions and standard of cleanliness.

17

: ApplicationsProcess environment protection

From teabag packaging to tray palletizing

tEEKannE: no tea break for sensors from SICKS3000 safety laser scanner maintains clear view of what’s going on

Safety in the “air envelope”

Identification of products by the CLV420 barcode scanner

Scanner protection during machine operation

Scanning field freed of emissions

Protected scanning area

: Applications

18 01 2009

>> For 50 years, the sortimat technol-ogy company, whose principal factory is located in Winnenden, has been de-veloping and manufacturing systems for automation technology. the product portfolio includes assembly systems for medical technology and the pharma-ceutical industry as well as feeding and handling solutions for machine construc-tion and the automotive industry. Since 2006, sortimat has been expanding the application radius of its automation so-lutions with industrial handling systems. at the villingen-Schwenningen location, the sortimat’s subsidiary, handling Sys-tems, produces pioneering systems used to transport and singulate products for non-pourable feed parts. “this segment includes, among other things, palletizing and depalletizing systems for the phar-maceutical sector,” says Gabriel King, general manager of sortimat handling

Component detection in transparent transport packages

Detection reliability due to automatic alignment of switching threshold When a photoelectric switch such as the new WLG4S-3 from SICK automatically compensates for contamination or tempera-ture effects, permitting reliable alignment and adjustment within seconds, it offers precisely what users like sortimat expect: fast start-up and utmost availability even in difficult conditions.

Systems. “One of their functions is to pick small parts for pharmaceutical products using gripper arms. among other things, the photoelectric switches must detect highly transparent disposable transport packages, for instance, of medicine dos-ing devices or spray cans who have a wall thickness of 600 µm. For this reason, we are making very high demands on the photoelectric switch in term of detec-tion.” however, when it comes to instal-lation and start-up, too, a sensor has to prove its special operating efficiency.

WLG4S-3: a convincing sensor conceptas small as the WLG4S-3 might be in phys-ical size, as high is its performance. this already starts with installation: on the one hand, based on the PinPoint technology, a highly visible, precise light spot is achieved that allows alignment toward the reflector unrivalled in simplicity; on the other hand,

pressing the teach button on the device for a mere two seconds suffices to put the sensor into operation easily and reliably – even with respect to transparent ma-terials. “Precisely when it comes to trans-parent packages, the WLG4S-3 offers us the decisive added benefit concerning availability because of its automatic ad-justment of the switching threshold,” says Gabriel King. “Sensors with potentiom-eters, intended to solve such a demand-ing task, often fail because in the end the setting always remains uncertain to some extent, which has the consequence that temperature drifts or contamination result in sensor failure. the WLG4S-3, by comparison, literally never loses track of what is going on.” On top of that, the pho-toelectric switches can be put very easily into an insensitive operating mode with fixed switching threshold. “that is particu-larly important when using black transport packages,” Gabriel King adds.

With their high detection reliability and easy adjustability even regarding crit-ical materials, the small WLG4S-3 offers performance feature one searches to no avail in many other large “sensor alter-natives.” this also applies to availability in harsh operating conditions. “Since in the pharmaceutical industry we are mov-ing in a hygienic environment, the sen-sors are often protected – but thus also inaccessible – in a stainless steel hous-ing or, respectively, mounted behind a stainless steel plate,” explains Gabriel King. “the sensors are configured prior to the installation of the protective hous-ing – any subsequent correction of the setting thus becomes impossible.”

WLG4S-3 – the series that guarantees quick start-up and utmost availability even in difficult conditions.


More about the customer:www.sortimat.com

The integrated WLG4S-3 photoelectric switches guarantee a high degree of detection reliability

Industrial handling systems

The innovative MultiScan function of the Ranger E permits simultaneous measurement and evaluation of several different object characteristics

19

: Applications Furniture industry

>> With up to 35,000 contour profiles per second and over 1,500 3D coordi-nates per profile, the camera system from SICK sets the standard for 3D con-tour measurement in an industrial envi-ronment. apart from the world’s fastest measuring speed for 3D applications, Ranger E also offers extremely high ac-curacy for detecting minute details, and a Gigabit Ethernet interface for fast data transmission.

In addition, Ranger E’s innovative MultiScan function allows Swedwood to measure and evaluate several different object features such as, gray scale, sur-face gloss, 3D, and laser scatter simulta-

Ranger E Camera helps IKEA provide quality products

3D quality testing for IKEa wardrobes

at the new production plant of the Swedish Swedwood Company, every minute ten complete IKEa PaX wardrobes are completed. Ranger E 3D cameras from SICK ensure uncom-promising inspection of the coated panels for surface and manufacturing flaws.

neously. the MultiScan feature provides a cost savings when compared with the alternative, to have a 3D camera and several separate 2D camera systems.

Inline inspection for IKEA the two inline inspection solutions in Swedwood’s furniture factory were cre-ated by the Swedish system integrator Optonova – each using the Ranger E 3D measuring systems as central compo-nents. at the first inspection station, the Ranger E checks the surface quality of the coated wooden panels. this involves detecting scratches, cracks, or other damage, which results in the piece be-

ing rejected before the first process step. the second inspection station at the end of the production run has far more com-plex tasks to complete. “here the Ranger E cameras check for a whole series of features simultaneously,” explains Carl-henrik Stenermark, responsible for im-age processing at Swedwood. “the bore-holes are checked for correct position, diameter, and depth. On the panel itself, the cameras measure both squareness and external dimensions. In the course of the same process step, another sur-face inspection takes place. Both mea-surements occur simultaneously – all at a feed rate of nearly 1m/s.”

Ranger E – ideal for tasks in 3D contour measurementthe Ranger E cameras at Swedwood help ensure reliable detection of even the mi-nutest flaw. “a visual, non-automated inspection is not capable of yielding the same test volume and the same test quality,” says Carl-henrik Stenermark. “Moreover, only inspection using a cam-era also offers the opportunity to docu-ment the quality data automatically.” Many of the advantages of the Ranger E solution that are relevant for Swedwood, Optonova, and IKEa can be applied to other tasks as well. this includes, among others

checking component parts in pick & place processes, testing of soldering paste or inspecting circuit boards in the electronics industry; robot guidance, detection of packages, and automatic palletizing in robotics; tire inspection; surface inspection of tiles; portioning meat, fish, vegetables, or guaranteeing the quality of fruit or baked goods in the food industry; optimizing sawing processes or mea-suring logs in the lumber industry.

With its unique features and benefits, Ranger E offers many possibilities for inline inspection solutions in the most diverse areas.


More about the customer:www.swedwood.comwww.ikea.de, www.optonova.se

: Applications

20 01 2009

>> the hamburg-based Conergy aG is one of the major suppliers of regenera-tive energy systems in Europe. Conergy develops, produces, and markets com-ponents necessary for the operation of solar power plants. It plans, finances, in-stalls, and operates solar power systems in 15 countries on four continents – mak-ing it one of the world’s market leaders in solar system integration. On top of that, the enterprise plans, finances, and oper-ates wind parks, bioenergy facilities, as well as large-scale solar thermal power plants. Since being founded in 1998, the group has sold more than one gigawatt worth of renewable energy. In Frank-furt/Oder, Conergy built one of the most up-to-date production facilities for solar modules – with a fully integrated mass production from the wafer and the cell to the module.

at Conergy aG’s solar power systems factory in Frankfurt/Oder, more than 40 aBB robots are able to produce photovoltaic mod-ules capable of generating an annual output of 250 MW. On board in this effort are IvC-2D camera systems and OD Max dis-placement sensors.

IVC-2D takes on the visual guidance of the soldering robots On a total production space of 35,000 m², every day high-performance modules are rolling off five assembly lines. at full manu-facturing capacity, the factory will produce up to 250 MW worth of modules. More than 40 industrial robots from aBB auto-mation Gmbh are used in the fully auto-mated production. after being transported from cell production to the production area for module manufacturing, the indi-vidual solar cells are then fed to the five autonomously operating production lines. there, the solar cells are connected fully automatically into a chain of cells (string) by the by the so-called stringers. One of the following process steps is the interconnec-tion of individual strings into a matrix – the actual photovoltaic module. Per line, four robots each of the IRB 1600 series take

on this task, which entails one important thing above all: precision. two of the four robots are equipped with a special suc-tion gripper, and they handle the solder-ing blocks, insulation foils, and soldering ribbons. the two other IRB 1600s operate one soldering head each with integrated IvC-2D Smart Camera. the cameras help determine the orientation and position of the cells and of the small soldering ribbons on the top and bottom of the module. Only the use of the IvC-2D enables the robots to deposit the foils and soldering ribbons accurately and to position the soldering points very exactly. apart from precision, the features receiving praise from aBB included the simple programming, high immunity to ambient light, as well as the fact that the IvC-2D does not require any additional processor or computer support for operation.

OD Max displacement sensor: posi-tioning accurately to within few µmEvery 100 seconds, one completely in-terconnected module leaves the robot cell via a conveying system. In the next process step, a protective film made of Eva (ethylene vinyl acetate) as well as a weatherproof composite plastic foil are placed on the module. afterwards, four modules per line pass through two laminators, where they are “baked” for approx. 17 minutes into a solid, weather-proof laminated unit. after this so-called lamination, projecting remnants of foil are removed. For this purpose, another robot takes the encapsulated solar mod-ule, puts it down, and measures, accu-rately to a few µm the edge positions using an OD Max displacement sensor. the resulting position data of the mod-ule are utilized by the robot controller to guide the cutting tools, ensuring exact trimming of the projecting foil remnants directly at the glass edge of the module.

Sensor technology from SICK: solution competence for the solar energy sectorPosition detection on robots is only one example of the diverse possibilities that SICK’s portfolio for photovoltaic produc-tion offers – including solutions for iden-tification of panels, checking for edge fractures, or protection of machinery.

Sensor technology from SICK for fully automatic final assembly of solar cells

Precision solutions for position polling


More about the customer:www.conergy.de www.abb.de/robotics

Renewable energy systems

21

ELG: the standard in “switching” applications If the objective is “only” reliable parts detection, binary light grids provide the user with the best possible automa-tion benefit. this applies particularly to the ELG automation light grid. Different monitoring heights are available just the same as different ranges from 0-2 m and 0-12 m, respectively. Moreover, there is the short-range variant, the ELG1, which is optimized for ranges up to 5 m.

HLG: high-resolution, fast and energy efficient the high-resolution hLG light grid lives up to the requirements posed by de-tecting flat objects. It offers a constant resolution of 2 mm extending over the entire detection area, a very low switch-ing hysteresis, as well as today’s fastest response time among such systems of only 2 ms. In operation, the hLG deliv-ers convincing performance due to its

For object detection in two dimensions

automating in the best possible way with light gridsDetecting, measuring, inspecting, or counting objects in two dimensions are typical tasks for automation light grids. Whether this concerns letters, small parts, parcels, persons, or pallets – independent of the item to be detected and the requirements on machine integration, only a complete portfolio of light grids solves the wide range of possible applications.

energy efficiency. Using only 100 ma for 26 beams, it sets the standard in terms of energy and operating costs.

SAS: capable of integration even in narrow machines One of the latest light grid solutions in SICK’s portfolio is the SaS Smart area Sensor – a binary sensor for checking presence, compartment occupancy, and projections. the special feature of SaS is that the light grid is available both as a flat and slim variant.

PLG and SPL: correct picking – without exceptionsthe Pick-to-Light light grids provide all of the functions necessary to avoid errors during manual parts picking from a rack. Starting out with the access openings, one can set the height of the light grid – and thus the size of the monitoring field in keeping with the respective application. the essential differences of the SPL and the PLG concern the housing, the sensor design, and operator guidance. the SPL is available in miniaturized slim and flat housing designs. Job LEDs provided for each light beam detect not only mistaken and missed picks into a given rack com-partment but also indicate if, by mistake, access occurs to another compartment that does not belong to the job.

SGS: Detecting persons at the automatic doorthe SGS Smart-Gate Sensor from SICK is a light grid that offers, in addition to safe-ty for automatic doors, flexibility, easy installation, availability, and protection from vandalism. For instance, it is pos-sible to implement scalable construction sizes that permit, in any installation situ-ation, the monitoring of entrance and ex-it areas that is nearly free of dead spots.

MLG: measuring in terms of function, modular in terms of constructionFor applications requiring an integrated measuring function, the MLG light grid pro-vides a variety of possibilities for individual device design. to many users, the feature that is just as important as the measuring function is the high degree of modularity of the MLG. thus, when ordering the device, one can choose from different resolutions, monitoring heights, ranges, and installa-tion solutions. Once essential secondary conditions of an application have been defined, the MLG can be delivered with pa-rameters already preset by SICK.

: Technology

21


Innovation NO 01


22 01� 2009

: Interview Delivery�competence

Anyone�using�a�sensor,�system,�or�control�solution�from�SICK�al-ways�benefits�from�a�maximum�degree�of�technology�and�applica-tion�competence.�What�constitutes�an�increasingly�more�important�decision�criterion�for�clients�as�well�is�the�confidence�in�prompt�de-livery.�Nikolaus�Becherer,�Head�of�the�Central�Unit�Order�Process-ing�at�SICK,�explains�how�in�the�context�of�nearly�860,000�order�items�annually,�one�succeeds�in�achieving�delivery�reliability�of�95%�and�more�–�a�quantity�measurable�and�confirmed�by�customers.�

SICKinsight:� SICK’s� product� range� in�factory,� logistics,� and� process� automa-tion� includes� more� than� 10,000� items�produced� in� a� decentralized� way� and�stored� largely� in� Waldkirch.� From� this�assortment,� in� 2008� SICK� delivered�

more� than� 315,000� orders� with� nearly�860,000�items�–�almost�all�of�them�on�time�and�complete.�How�does�one�man-age� to� fulfill� clients’� expectations� con-cerning�punctual�delivery�to�such�a�high�degree?�

Nikolaus Becherer, Head of the Central Unit Order Processing at SICK

Delivery reliability: the measurable added benefit, more important all the time

Delivery�competence�complements�technological�competence

Nikolaus Becherer:� First,� this� has� to�do� with� our� fundamental� orientation.�Delivery�reliability�and�delivery�capacity�are�crucial�added�product�benefits�that�are� extremely� important� to� customers,�especially� in� the� business� related� to�standard�components�and�spare�parts.�In� order� to� meet� clients’� expectations�reliably,�the�Central�Unit�Order�Process-ing�coordinates�the�demands�made�on�the� product� segments,� materials� man-agement,� manufacturing� processes,�logistics,� and� sales.� For� instance,� it� is�responsible� for� a� regular� revision� of�the� list� of� inventory� items� but� also� for�how� to� handle� short-term� large� orders�or� special� device� variants� efficiently� in�terms� of� order� logistics.� Particularly� in�the�current�recessionary�phase,�this�is�a�challenging�task.�

SICKinsight:� Does� this� mean� that� the�adaptation� to� the� current� market� and�business� behavior� entails� special� tasks�towards� the� maintenance� of� delivery�competence?

Nikolaus Becherer:�Precisely.�Currently,�we�are�operating�between�the�poles�of�inventory� optimization,� delivery� capac-ity,� and� flexibility.� By� means� of� weekly�planning�coordination,�we�are�adapting�inventory� levels�to�the�incoming�orders�

23

: Interview�

generally� expected.� At� the� same� time,�however,�we�must�be�capable�of� filling�orders�at�very�short�notice,�e.g.�when�a�machine�manufacturer�in�turn�receives�an� order� to� be� filled� at� short� notice.�Moreover,�especially� these�days,�many�customers�are�searching�for�new�prod-uct� and� technology� alternatives,� which�they�also�expect�to�deliver�fast�and�suf-ficient� availability.� After� all,� large-scale�orders� result� in� major� fluctuations� of�workload� at� different� points.� We� from�the� CU� Order� Processing� are� engaged�in� permanent� dialogue� with� all� of� the�people� whose� cooperation� is� required�for� maintaining� our� delivery� reliability�and�delivery�capacity.�

SICKinsight:�How�do�you�know�wheth-er� your� activities� are� successful?� Is�delivery� reliability� measurable;� is� it�possible� to� recognize� deviations� and�analyze�reasons?�What�are�the�relevant�indicators?

Nikolaus Becherer:� For� this� purpose,�SICK� AG� has� built� up� special� online� re-porting� that�maps� transparently� the�en-tire�order�processing�–�in�principle,�from�our�suppliers�all� the�way� to�our�client’s�incoming�orders�department.�In�this�con-nection,�we�have�defined�two�important�performance� figures:� delivery� reliabil-ity�as�delivery�on�the�first�deadline�con-firmed�to�the�customer�and�the�delivery�capacity�–�i.e.�delivery�on�the�first�dead-line�desired�by�the�customer.�Both�quan-tities�are�measured�regularly�and�on�the�level�of�the�ordered�items�as�well�as�eval-uated�in�detail.�In�February�of�2009,�for�instance,�we�achieved�a�delivery�reliabil-ity�of�94�%:�92.7�%�of�orders�were�deliv-ered�on�the�specified�day,�2.1�%�early.�Of�the�orders�delayed,�59�%�–�that�is,�3.2�%�of� total� orders� –� were� delivered� with� a�maximum�of�two�days’�delay.�It�was�pos-sible�to�identify�individual�reasons�for�all�of�the�delayed�items,�which�can�be�rath-er� varied,� e.g.� delayed� goods� received,�manufacturing�delay,�missing�order�item�for�complete�delivery�or�delay�in�advance�payment�by�the�customer�in�case�of�ces-

sation�of�deliveries.�Through�this�report-ing�we�are�able�to�recognize�weak�points�and� to� remedy� them� in� those� respects�we� can� influence,� optimizing� processes�materials� management,� production,� or�logistics�permanently.

SICKinsight:�Do�the�customers�know�to�what�great�extent�they�can�trust�in�SICK’s�delivery�reliability?�

Nikolaus Becherer:� That� is� something�we�can�assume.�On�the�one�hand,�after�all,� our� delivery� reliability� is� one� of� the�decisive�selling�points,�especially� in� the�component� and� spare� parts� business.�On� the� other� hand,� the� clients� them-selves�are�obviously�interested�in�improv-ing�their�own�course�of�business,�which�naturally� entails� the� evaluation� of� SICK�as� a� supplier.� With� the� help� of� the� ap-

propriate�reporting�systems,�they�record�a� number� of� performance� figures� con-cerning�delivery�reliability,�quality,�coop-eration,�or�their�cost�prices.�Many�of�our�customers�provide�us�with�the�results�of�their� reporting� automatically,� data� that�we�will�then�compare�with�the�measured�values�of�our�reporting�tool.�In�this�way,�the�clients�know� just�how�good�we�are;�at�the�same�time,�this�ensures�that�with�our�key�indicators�we�are�measuring�and�analyzing� the� deciding� quantities� that�are� important� to� our� clients.� Thus,� the�feedback�from�the�market�confirms�the�effectiveness�of�our�efforts�toward�deliv-ery�competence.�

SICKinsight:� Well,� in� that� case� you� are�fully� prepared� for� tackling� the� 100-per-cent�mark.�All�the�best�in�this�effort�and�many�thanks�for�the�interview!

Delivery reliability: the measurable added benefit, more important all the time

Delivery�competence�complements�technological�competence

The special online reporting allows transparent mapping of the entire order processing as well as measuring and evaluating the criteria of delivery reliability and delivery capacity

24 01� 2009

: Products Innovation�Marathon�–�Stage�1

Flexibility with safety laser scanners

Safety�expert�manages�monitoring�variety

>>�The�S300�Expert� is�an�electro-sensi-tive�protective�device,�approved�as�such�in�compliance�with�Type3�according�to�IEC�61496-3,�performance�level�d�according�to�EN/ISO�13849�as�well�as�SILCL2�ac-cording� to� EN� 62061.� The� device� was�designed�with�a�scanning�angle�of�270°�for� mobile� and� stationary� monitoring� of�smaller� hazardous� areas� with� a� maxi-mum�protective� field� radius�of�2�m�and�warning�zones�with�a�depth�of�up�to�8�m.�Measuring�only�105�x�102�x�152�mm,�the�S300�Expert�is�the�world’s�most�compact�and�cost-effective�safety�solution�based�on� laser� scanner� technology,� which� on�top�of�that�can�manage�up�to�eight�differ-ent� monitoring� scenarios� directly� in� the�sensor�and�without�limitation.

Now� offering� the� possibility� of� implementing� up� to� eight� different�monitoring� scenarios� directly� in� the� sensor,� the� world’s� smallest�

safety�laser�scanner,�the�S300�Expert,�takes�mobile�transport�systems,�moving�workbenches,�or�autonomous�service�robots�for�industrial�use�–�to�name�but�a�few�–�not�only�along�a�safe�path�but�also�on�the�right�economical�track.�

For� mobile� use,� this� means� that� the�monitoring� functions� for� individual� sec-tions�of�the�path�can�be�designed�in�an�even� more� differentiated� way.� This� ap-proach� allows� reducing� downtimes� and�optimizing�travel�times.�If�both�directions�of�travel�need�to�be�protected,�one�can�also�combine�two�S300�Experts�to�form�one�system�using�the�integrated�EFI�(the�safe�device�communications�interface).

Inserting� or� handling� stations,� ro-tary� or� lift� tables,� pick-up� or� transfer�points,� are� examples� of� stationary� ap-plication� scenarios� in� which� the� S300�Expert� protects� personnel� from� acci-dent� risks�when�handling�automatic�or�semi-automatic� machines.� Since� the�S300� features� the� “contour� as� refer-

ence”�function,�the�safety�laser�scanner�is�also�approved�here�for�use�as�vertical�protection.�

OS2000 – the world’s first outdoor safety scanner system with TÜV certificate

For�machine�safety�in�outdoor�areas

With� the� OS2000,� SICK� presents�the�world’s�first�safety�laser�scanner�system�approved�for�outdoor�use.�It�combines�the�hardware�and�software�of�well-tried�LMS�laser�measurement�systems,� specifically� designed� for�outdoor�applications,�with�the�safety�level�of�the�certified�UE4470�safety�controller.

rain,�humidity�(fog),�or�intense�light�in-cidence� due� to� low� sun.� The� protective�fields� can� be�parameterized�and�evalu-ated�in�any�desired�way�within�the�safety-oriented�range�of�up�to�20�m.

Safety spanning the entire active chain The� UE4470� programmable� logic� con-troller�from�SICK�endows�the�laser�scan-ners� and,� respectively,� the� all-inclusive�OS2000�solution�with�the�required�safe-ty�level.�It�takes�on�the�task�of�controlling�the�cyclical� testing�of� the�sensors,� thus�ensuring� continuous� monitoring� of� the�active�chain,�i.e.�sensor�–�output�signals�–�controller.�

Further�product�information:www.mysick.com/produkte

Innovation NO 03


>>� Typical� application� examples� of� the�system� solution� certified� by� TÜV� Rhein-land,� which� complies� with� the� require-ments� of� performance� level� “d”� ac-cording�to�ISO�13849-1�as�well�as�SIL2�according�to�IEC�62061,�are�access�pro-tection�for�doors�and�gates,�crane�facili-ties,� manned� and� unmanned� vehicles,�shipping�facilities�such�as�bascule�bridg-es�or�sluice�gates,�rail�tracks�or�conveyor�systems.

Outdoor sensor technology for any weather conditionsThe� OS2000� can� be� used� in� any� place�where�hazardous�outdoor�areas�need�to�be� monitored.� Depending� on� the� task,�laser� scanners� with� IP�67� featuring�scanning� angles� of� 100°� or� 180°� are�available� that� can� be� used� in� ambient�temperatures� ranging� from� –30�°C� to�+50�°C.�In�terms�of�sensor�performance,�they�will�not�be�impaired�by�either�snow,�

Innovation NO 06



25

: ProductsInnovation�Marathon�–�Stage�1

Innovation NO 07

>>�The�inductive�sensors�of�the�IME�se-ries� contain� high� tech� within� extremely�small� space.� With� its� exceedingly� com-pact�platform�technology,�the�integrated�ASIC�chip� (Integrated�Electronic�Switch)�offers� significantly� enhanced� manufac-turing� tolerance� spanning� the� entire�range�of�devices.�After� the�manufactur-

ing�process,� the�sensors� from�SICK�are�not�adjusted�manually�per�potentiometer�or�laser�trim�but�rather�digitally.�Storage�of� the� values� in� the� ASIC� guarantees� a�very�accurate�switching�point�as�well�as�very�high�reproducibility�–�and�it�does�so�with� respect� to� all� production� batches.�This�facilitates�not�only�the�construction�

design�of�machines�and� the�start-up�of�the� sensors� but� also� allows� the� fastest�possible�replacement�of�devices.

Tough exterior, soft coreInside� the� housing� of� the� IME� sensors,�the�“hotmelt”�used�as�casting�compound�ensures� very� high� shock� and� vibration�resistance.� The� robust� cylinder� housing�with�a�torque�of�up�to�100�Nm�delivers�another�feature�guaranteeing�maximum�availability� and� long� service� life� of� the�sensor.�

Suitable solution for any applicationIn� recent� years,� SICK� AG� in� Waldkirch�has�built�up�a�broad�portfolio�of�proxim-ity�sensors.�No�matter�if�the�requirement�is�cylinder�or� rectangular�standard�sen-sors�with�single,�double,�or�triple�switch-ing� distances� or� special� sensors� for� EX�areas,� rugged� environments,� or� for� the�food� and� beverage� industries� –� SICK�always� offers� the� solution� suiting� your�needs.�

Precision,�maximum�availability,�long�life�cycle,�diverse�construction�designs,��utmost�switching�accuracy,�and�global�availability�–�all�of�that�is�combined�in��the�IME�series�from�SICK.�With�these�sensors,�there�is�nothing�stopping�auto-mation�from�a�single�source�anymore.�

With�the�“Safe�Machines�Guide,“�SICK�offers,�as�one�of�the�first�suppliers�of�solutions�and�services�related�to�safe�machines,�safety�expertise�from�one�prac-titioner�to�another�in�a�120-page�publication.�The�backdrop�is�the�updated�Ma-chine�Directive�2006/42/EG�as�well�as�safety�standards�EN�ISO�13849-1�and�EN�62061�taking�effect�on�29�Dec.�2009.

>>� The� “Safe� Machines� Guide”� first� de-scribes�the�legal�and�normative�principles�for�machines�in�Europe�taking�effect�as�of�29�December�2009.�There�are�six�steps,�divided� into� risk� assessment� –� safe� de-signing� –� technical� protective� measures�–� user� information� concerning� residual�risks�–�overall�validation�of�the�machine�–�selling�the�machine.�The�items�explained�with�the�help�of�examples�include,�among�others,� the�application�of� the�new�safety�standard� and� spacing� calculations,� e.g.�the�determination�of�the�Performance�Lev-els�(PL)�or�the�Safety�Integrity�Level�(SIL).�Additionally,�based�on�typical�applications,�the� publication� shows� in� practical� terms�the� most� diverse� variants� of� protective�

devices�and�safety�technologies�spanning�the�entire�safety�chain,�from�the�sensor�to�the�actuator.�

Comprehensive support beyond the “norm”ality As� an� expert� for� safety� technology,� SICK�offers� numerous� services� concerning�the�topic�of�safety.�This� includes,�among�other� things,� customer� workshops,� con-sultation�and�engineering�services,�plant�walk-throughs�with�a�safety�specialist,�and�SICK’s� product� library� for� SiSteMa� (the�software� assistant� for� safety� of� control-lers�on�machines,�available�free�of�charge�from�the�Institute�for�Occupational�Safety�and� Health� [Berufsgenossenschaftliches�

Institut�für�Arbeitsschutz�–�BGIA]).�On�top�of� that,� SICK� backs� information� events�presenting�the�status�of�standards�current�at�any�given�stage,�which�are�organized�by�professional�societies�and�trade�associa-tions.�These�events�are�aimed�at�develop-ment� engineers,� design� engineers,� plan-ners,�and�those�in�charge�of�safety.�


Innovation through new platform technology

Automating�inductively�=��automating�intelligently�


Standards update for safe machines and plants

SICK�implements�2010�safety�agenda

Innovation NO 08



01� 2009


Solve more applications with the Inspector I20

Flexibility�in�focus

tor�I20�very�convenient�for�both�end�users�and�system�integrators�who�want�to�solve�a�large�number�of�different�applications�us-ing�only�one�kind�of�device.�

Flexible outputLogical�output�options�are�available�in�the�Inspector� I20.� With� simple� and/or� logic,�multiple� inspections� can� be� combined� to�give�the�end�user�more�detailed�feedback.�These� inspection� results� can� be� used� for�sorting� based� on� defects� or� for� detailed�control�of�other�process�steps� in� the�pro-duction�chain,�for�example.

Flexible I/O functionality Extended� I/O� support� is� available� via� an�external�I/O�box.�With�the�I/O�box,�it�will�be�possible�to�extend�the�number�of�outputs�from�3�to�16.�All�of�the�outputs�can�be�user�defined�with�logical�operations�or�be�used�for�single�inspection�results.�Moreover,�the�I/O�box�enables�more�inputs�as�well.�Input�selection�up�to�16�taught�reference�objects�

is�now�possible�without�compromising�oth-er�input�functions�like�trigger,�encoder�and�teach�control.

More� functionality� through� flexibility:� the�new� Inspector� I20� is� more� versatile� than�nearly�any�other�2D�vision�sensor.�

>>� The� Inspector� series� consists� of� com-pact,� easy-to-use,� and� reliable� 2D� vision�sensors�with�integrated�lighting,�image�eval-uation�and�Ethernet�interface.�The�devices�were� designed� to� solve� a� diverse� range�of�applications�–�and�they�are�capable�of�checking�parts�in�any�orientation�and�posi-tion�at�a�predictable�response�time.�The�vi-sion�senor’s�robust�design�is�suited�for�diffi-cult�applications�and�its�intelligent�and�fast�evaluation�algorithms�enable� Inspector� to�keep�up�with�high�process�speeds.�

Flexible field of view Inspector� I20�allows�easy� replacement�of�

the� optical� lenses�for� different� dis-tances� and� fields�of�view�while�main-taining�a�high�enclo-sure� rating� (IP�67).�This,� together� with�integrated� lighting,�makes� the� Inspec-


Innovation NO 11

>>�Based�on�image-processing�technol-ogy,�the�V300�WS�is�an�electro-sensitive�protective� device�for�operating�areas�on� assembly,� han-

dling,� and� industrial� robots� or�testing�equipment.�The�lighting�unit�and�receiver�of�the�sensor�are�integrated�in�a�single�hous-ing� –� the� same� applies� to� the�additional� functions� of� reset�and�EDM�(external�device�moni-

toring).�The�compact�triangular�construc-tion�design�allows�installing�the�device�in�or�on�the�corner�of�the�slotted�bar�frame�of� a� work� station,� i.e.� in� a� place� where�the� sensor� is� largely� protected� from�shocks�or�misalignment.

Opens up possibilities for barrier-free monitoring Beyond� that,� the� V300� WS� now� makes�it� possible� to� secure� work� stations� in�particularly� ergonomic� and� process-compatible�ways.�Even�as�a�single�sen-sor,�the�V300�WS�generates�a�diagonal�

protective�field�with�a�maximum�range�of�1.41�m�for�protecting�apertures�measur-ing� up� to� 1� m� by� 1� m.� With� respect� to�large�intervention�openings,�there�is�the�possibility�of� linking�two�devices�via�the�synchronization�input,�thus�doubling�the�size� of� the� protective� field.� Monitoring�action�is�also�possible�diagonally�across�without�the�center�brace.�

Cost-effective: Safety in the appropriate categoryThe�V300�WS�is�the�optimum�solution�for�Types�3�or,�respectively,�PL�“d”�and�SIL2�according�to�IEC�61508�that�are�not�cov-ered�by�safety�light�curtains.�This�means�that�the�user�has�the�opportunity�of�uti-lizing� a� more� affordable� Type-3� system�for� applications� not� requiring� a� Type-4�safety� level� according� the� risk� assess-ment.�

The�new�V300�WS�safety�camera�system�is�space-saving,�quick,�and�suited�for�hand�protection.�It�is�the�first�device�of�its�kind�for�protect-ing�hazardous�zones�according�to�Type�3�–�in�compliance�with�EN�61496-1�(SIL2�according�to�IEC�61508).�

Suited for work stations and Type 3

Safety�out�of�the�corner

Innovation NO 10


Let� us� introduce� the� newest� member� of� the� Inspector� family:� I20!� With� its�exchangeable� lens� concept,� new� output� logic� solution� and� expandable� I/O,��the�Inspector�I20�can�solve�a�wider�range�of�applications.

26



: ProductsInnovation�Marathon�–�Stage�1

27

Perfect collision protection in any weather

Collision�prevention�at�the�port:��no�crash�thanks�to�LMS�

For� crash-free� container� handling� at� ports,� there� is�now�a�particularly�compact�and�space-saving�solution:�the�LMS111�laser�measurement�system.�Even�in�poor�weather�conditions,�the�device�achieves�good�results�–�thanks�to�double-pulse�technology�and�electronic�filters�countering�fog,�rain,�snow,�and�leaves.�

against� strong� light� incidence,� e.g.� by�spotlights�or� low�sun,� the�new�LMS111�laser�measurement�system�offers�a�max-imum�amount�of�detection�reliability.� In�poor�weather�conditions,�software�mod-ules�ensure� that�even� in� rain,� snowfall,�or� fog,� a� reliable� monitoring� function� is�guaranteed.� Added� is� the� fact� that� the�LMS� is� not� only� prepared� for� external�influences�by�an�IP�67�enclosure�rating,�but�that�it�also�features�a�saltwater-resis-tant� special� housing� for� extreme� cases�and�may�also�be�operated�behind�a�glass�screen.�

Precise and flexible in monitoringThe� scanner� of� the� measurement� sys-tem,�actively�scanning�at�a�270°�angle,�

achieves�utmost�accuracy�due�to�scan-ning� frequencies�up� to�50�Hz�and�a� maximum� angle� resolution� of�0.25°.� Double-pulse� evaluation�of� the� measured� reflectance� in�conjunction� with� integrated� dis-tance�measurement�renders�field�monitoring�extremely�stable,�per-mitting� very� precise� localization�of� existing� obstacles.� Within� the�space�covered�by� the�scanner,� it�is� possible� –� depending� on� the�size� and� geometry� of� the� travel�paths�and�areas�to�be�monitored�–�to�parameterize�up�to�ten�sepa-rate� monitoring� fields,� retrieving�them� conditional� on� the� situa-tion.� Actuating� the� device� via� the�

encoder� input� also� allows� speed-dependent,� dynamic� switching� of� the�

protective�fields.�

More� possibilities� for� collision� protec-tion� in� the�maritime�environment�–� the�LMS111�has�them�onboard,�as�standard�features!

>>� Even� when� faced� with� adverse� con-ditions� and� dark� object� surfaces,� the�LMS111�achieves�a�range�of�18�m�–�ide-al�for�collision�prevention�on�crane�instal-lations,�derrick�booms,�straddle�carriers,�and�automatic�container�transporters.�

Laser measurement, reliable in any conditionsIndependence� from� influences�of�ambi-ent�light�and�adverse�environmental�con-ditions�distinguishes�the�LMS111.�In�any�light�conditions�and�effectively�shielded�


Innovation NO 02



28 01� 2009

The�new�W4S-3�Inox�from�SICK�is�the�extension�of�the�W4�series�for�the�food�&�beverage�sectors.�The�device�technology�in�the�stainless�steel�housing�is�designed�consistently�toward�the�harshest�hygiene,�cleaning,�and�disinfecting�cycles�that�far�exceed�the�demands�on�IP69k.� The� user� benefits� from� “best-in-class”� performance� data�documented�in�various�tests.

>>�The�W4�series�has�established�itself�in�the�market,�impressing�in�terms�of�sensor�technology�by�peerless�resistance�to�am-bient�light�and�reliable�detection�of�reflec-tive,�transparent,�and�deep�black�objects.�The�W4S-3�Inox�is�a�unique�combination�worldwide�of�superb�photoelectric�switch�technology� –� tested� and� proven� –� and�housing� technology� oriented� without�compromises�on�the�requirements�of�the�packaging� food� and� beverage� industry,�the� pharmaceutical� sector,� or� the� semi-conductor�solar�energy�industry.�Whether�the� issue� is�aggressive�cleaning�and�dis-infecting�agents,�e.g.�in�bottling�lines,�the�treatment�of�pharmaceutical�sterile�boxes�

with� hydrogen� peroxide,� H2O2,� or� caustic�spray� mist� and� vapors,� as� they� occur� in�wet-chemical� processes� during� the� pro-duction�of�solar�cells�–�anywhere,�the�new�W4S-3�Inox�guarantees�reliable�operation�for�many�years�of�use.�

Forget about IP69k – the new refer-ence for ruggedness is W4S-3 Inox!The�housing�technology�of�the�W4S-3�Inox�sets�the�new�standard�with�respect�to�ma-terials�used�and�construction�design.�An-other�noteworthy�highlight�is�the�new�op-erating�concept.�The�sensor�is�configured�via�a�stainless�steel�membrane�mounted�flush� into� the� cover� –� without� gaps� and�

W4S-3 Inox family of photoelectric switches for extreme requirements

Exceeds�IP69k!�


projecting� plastic� parts.� The� housing� is�made�of�extremely�resistant�14435�/�AISI�316L� stainless� steel� and� approved� for�contact� with� food.� The� display� LEDs� are�also� mounted� flush� –� the� same� as� the�SIOx-coated� front� screen.� The� M3� fixing�holes� can� be� sealed� without� gaps.� The�completely�smooth�surface�of�the�W4S-3�Inox�achieved�in�this�way�is�easy�to�clean�–�as�it�lacks�any�corners�and�edges,�thus�preventing�the�development�of�dirt�of�bac-teria�hotbeds.�Due�to�its�design�structure�and�the�choice�of�materials,�the�W4S-3�can�be�used�long�term�in�any�known�cleaning�and�environmental�conditions:�It�exceeds�by�far�IP69k�as�well�as�the�standards�set�by�all�test�methods�common�today.�

W4S-3:�Only�a�device�that�is�“best�in�class”�can�meet�the�ultimate�demands�placed�on�automation�technology.�

Product of the Month March


29

: Products�Innovation�Marathon�–�Preview


SICK�presents�a�new�range�of�products�for�pressure�measure-ment� technology.� High� accu-racy�and�robust�design�are�the�common� features� of� all� the�devices.�

>>�In�order�to�solve�the�demands�made�by�industrial�clients�on�the�sensor�tech-nology� of� their� machine� or� plant� in� a�customer-oriented�way�and�from�a�single�source,� SICK� is� expanding� the� product�range� by� a� series� of� high-performance�pressure� transmitters� for� measuring�pressures�in�liquids�and�gases.

Pressure� measurement� technology�from�SICK�is�used�in�machine�and�plant�construction,� in� machine� tools,� in� hy-draulic�and�pneumatic�systems,�for�pres-sure� control,� as� well� as� on� pumps� and�compressors.�Whether�in�the�automotive�industry,�in�vehicle�manufacturing,�in�the�electronics� industry�or� in� the�packaging�industry,� the� product� portfolio� with� the�innovative� PBS� pressure� switch� as� well�as� the� PBT� and� PFT� series� of� pressure�transmitters� is�very�well�suited�not�only�to�cover�the�most�diverse�requirements�but� also� to� provide� the� client� with� the�best�possible,�cost-effective�solutions.�

Particularly compact and flexible: the PBS pressure switchThe�PBS�is�an�efficient�and�space-saving�pressure�gauge.�The�sensor�is�available�with� relative� pressure� measurement�ranges�from�0�to�1�bar�and�from�0�to�600�bar,� though� it� is� also� suitable� for� abso-lute�and�vacuum�measuring�ranges.�The�PBS�combines�several� functionalities� in�one� device:� pressure� transmitter,� pres-sure�switch�and�indicating�device.�Thus,�besides�the�up�to�two�switching�outputs,�an�analog�output�–�4�to�20�mA�or�0�to�10�V� –� is� available� as� an� optional� feature.�The� intuitive� configuration� by� means� of�two� buttons� and� a� display� on� the� de-vice� is� oriented� on� VDMA’s� (Verband�Deutscher� Maschinen-� und� Anlagenbau�–�German�Engineering�Federation)�Stan-dard� 24574-1� and� makes� operation�particularly�simple:�The�menu�is�easy�to�understand,� incorrect� inputs� are� practi-cally�impossible�and�set-up�takes�only�a�few�moments.

A� special� degree� of� flexibility� distin-guishes�the�PBS�in�terms�of�the�installa-tion�situation.�Thus,�the�PBS�is�available�with� the� common� process� connections�and�therefore�requires�no�adapters.�The�electrical� connection� of� the� PBS� takes�place�via�M12x1�circular�plug-in�connec-tors.� The� highlight:� the� display� and� the�

Solutions for a variety of applications

Pressure�measurement�for�factory�automation�

electric� output� can� be� twisted� both� in�relation� to� the� process� connection� and�against� each� other,� allowing� an� undis-turbed�view�of�the�display�and�optimum�cable�routing.

The� attractive� price-performance�ratio� in� conjunction� with� the� minimized�set-up�times�provides�the�user�with�a�sig-nificant�cost�benefit.

PBT and PFT: the pressure transmitters for universal and special measurement tasksJust� like� the� pressure� switch,� the� pres-sure� transmitters� from� SICK� also� offer�relative,�absolute,�and�vacuum�measure-ment�ranges.�As�a�standard�transmitter�for�measuring�liquid�and�gas�pressures,�the� PBT� basic� series� delivers� superb�price-performance� ratio,� covering� the�majority� of� applications� in� factory� auto-mation.�The�available�measuring�ranges�for�relative�pressure�are�0�to�2�bar�up�to�0� to� 600� bar.� Simple� and� fast� installa-tion,� availability� of� all� common� process�connections,�and�the�compact�construc-tion�design�complete�the�picture�of�these�uncomplicated� and� yet� highly� efficient�devices.

Special�application�fields�are�covered�by� the� PFT� series.� Here,� the� available�measuring� ranges� for� relative� pressure�are�0�to�0.1�bar�up�to�0�to�600�bar.�Ad-ditional�optional�features�available,�such�as�higher�measuring�accuracy,�extended�temperature� range,� diaphragm� face�flush�with�the�front,�or�the�great�variety�of� available� process� connections� make�the�PFT�a�real�specialist� for�demanding�measuring�tasks.

The�characteristics�that�are�the�same�for�both�pressure�transmitters�are�the�in-dustrial�standard�output�signals�of�4� to�20�mA�or�0�to�10�V�as�well�as�connection�via�M12x1�circular�plug-in�connectors�or�angled� plug� according� to� DIN� 175301-803�A.

The� newly� presented� portfolio� of�pressure�measurement� technology� from�SICK� is� another� step� toward� becoming�a� supplier� of� comprehensive� solutions.�The� benefits� for� the� customer� are� obvi-ous:�Ultimately,�only�innovative�and�high-quality� products,� optimum� consultation,�and� custom-made� product� offers� result�in�more�efficient�and�cost-effective�solu-tions.�

Innovation NO 26

30 01� 2009

: Products Innovation�Marathon�–�Preview

With�the�miniTwin�from�SICK,�a�new�era�in�light�curtain�technology�is�about�to�begin.�For�the�first�time,�the�sender�and�receiver�elements�are�accommodated� in�one�miniature�housing�stick.�Another�new�feature�is�that�the�standalone�and�host/guest�versions�are�identi-cal.�Thanks�to�very�small�resolution,�blind�zone-free�monitoring�with�minimized�safety�distances�is�possible�even�with�respect�to�corner-mounting�cascaded�systems.�All�of�these�benefits�are�available�on�the�highest�safety�level,�as�the�miniTwin�meets�Type�4/PL�e/SIL3.

>>� Optimum� integration� and� ultimate�flexibility� through� miniaturization.� The�miniTwin� safety� light� curtain� is� cur-rently� the� smallest� system� of� its� kind.�The� most� conspicuous� feature� on� the�outside�is�the�significantly�slimmer�con-struction� as� compared� to� other� light�curtains.� The� symmetrically� structured�device�connection,�suited�for�industrial�use,�is�screwed�to�the�back�of�the�mini-Twin,�with�connection�to�the�control�unit�realized� via� the� 5-pin� M12� plug.� The�concept� has� two� crucial� advantages:�Depending� on� installation� conditions,�the� cable� outlet� can� be� run� either� up-ward�or�downward,�with� the�protective�field�reaching�all�the�way�to�the�end�of�the�housing.�This�applies�to�any�of�the�possible�resolutions�of�14�mm,�24�mm,�and�34�mm.� In�applications�diagonally�across,� the� miniTwin� maintains� the�

required� safety� distance� even� at� the�critical� corner� positions.� The� small�

“Minivation” sets new standards in safety light curtains

miniTwin�–�the�trick�with�the�uniform�safety�stick�

>> With SICK’s single-housing concept on the way to the top

As�an�innovation�leader,�SICK�not�only�banks�on�novel� light�curtain�concepts�like�miniTwin�when� it�comes�to�safety� technology,�but�also�on�safety�camera�technology�such�as�featured�in�the�V300.�Both�solutions�are�designed�for�pro-tecting�partly�automated�workspaces�and�areas�on�fully�automated�manufac-turing,�handling,�and�assembly�machines.�Both�solutions�aim�at�reducing�the�diversity�of�variants�–�miniTwin�through�the�concept�of�the�sender/receiver�in�a�single�stick,�the�V300�safety�camera�through�its�flexibility�regarding�protective�areas�of�different�sizes.�For�smaller�apertures�and�applications�in�Type�3�and,�respectively�performance�level�(PL)�“d”�or�SIL2,�the�V300�is�the�ideal�solution.�The�miniTwin�is�very�suited�for�protecting�higher�and�wider�openings�and�with�respect� to� requirements� in�accordance�with�Type�4�and,� respectively,�Perfor-mance�Level�PL�“e”�according�to�EN�ISO�13849-1,�or�alternatively,�SIL3�accord-ing�to�IEC�61508.miniTwin�and�V300�from�SICK:�a�strong�team�for�protecting�hazardous�spots�that�faces�up�to�any�task.�

resolution� and� fast� response� times� of�the�miniTwin�–�even�when�setting�up�a�maximum� of� three� cascaded� systems�–�permit�short�safety�distances�for�op-timized� work� ergonomics� if� required.�The� protective� field� heights� feasible�with� the� miniTwin� range� between� 120�mm�and�1,200�mm�–�they�can�be�indi-vidually�graduated�by�increments�of�60�mm.�The�range�is�0�–�4�m.�

World novelty: the uniform-stick concept of the miniTwinThough�not�noticeable�from�the�outside,�the� sensor-related� design� of� the� mini-Twin� is�completely�novel.�One� looks� in�vain�for�a�separate�sender�and�receiver�–� on� the� new� light� curtain� from� SICK,�both�sender/receiver�elements�are�ac-commodated�in�the�identical�Twin�stick�–�symmetrically�distributed�to�one�half�of� the� housing� each,� and� separated�by� the� synchronization� beam� in� the�middle.�The�safety� light�grid� is�created�by� mounting� two� identical� Twin� sticks�tilted� at� 180°� to� each� other,� causing�the� sender/receiver� modules� to� be� lo-cated�opposite�one�another.�The�unifor-mity�of�the�miniTwin,�however,�does�not�just�refer�to�the�sender/receiver�design�but�also�to�the�cascading�of�several�de-vices.� Which� miniTwin� serves� as� host�and�which�as�guest�is�defined�by�the�re-spective�variant�of�connector�plug�with�one�or�two�outgoing�cables.�

Product of the Month May

31

: ProductsInnovation�Marathon�–�Preview

Plug & play due to intelligent mounting solutions and automatic configurationNo� other� safety� light� curtain� achieves�the� plug� &� play� level� of� the� miniTwin.�To�begin�with,�this�is�made�possible�by�intelligent�mounting�solutions.�Applica-tion-oriented�L-Fix�and�O-Fix�brackets�for�face�mounting�as�well�as�C-Fix�brackets�to� snap� in� the� housing� profile� permit�fast�attachment�of�miniTwin�to�the�ma-chine.�Electrical�wiring�is�realized�via�a�standard�connection�cable�and�a�5-pin�M12� system� connector,� offering� full�functionality�of�external�device�monitor-ing�(EDM)�and�the�restart�interlock�(re-set).�Their�optional�configuration�takes�place� after� the� electrical� connecting�during� the� power-up� cycle� –� automati-cally�with� respect� to�EDM�and�with� re-spect�to�reset�by�pressing�the�button�of�the� restart� interlock� button� only� once.�Moreover,� the� simple� mechanical� and�electrical� integration� of� the� miniTwin,�the�automatic�hardware� configuration,�as�well�as�the�manifold�alignment,�sta-tus,� and� diagnostic� indicators� via� LED�line�permit�intuitive�handling�–�with�the�advantages� of� faster� start-up� and� in-creased�availability.�

“Minivation” sets new standards in safety light curtains

miniTwin�–�the�trick�with�the�uniform�safety�stick�

Further�product�information:www.sick-minitwin.com


The�new�AFS60�absolute�encoder�singleturn�has�now�been�sup-plemented� by� two� mechanical� variants.� Both� models� are� now�available�in�blind-hollow-shaft�and�through-hollow-shaft�design.�Another�highlight�is�the�construction�depth�of�less�than�50�mm.

>>�As�a�result,�the�AFS60,�which�features�18-bit� resolution�and� thus� ranks�as�one�of�the�best�devices�in�its�market�segment,�is� suited� for�particularly�harsh�operating�conditions,�where�only�a� limited�amount�of�space�is�available�for�installation,�as�is�increasingly�the�case,�for�example,�in�the�handling�and�robotics�sector.

More robust due to code disk made of nickel and optimized shaft bearingThe� AFS60� production� series� distin-guishes� itself� by� ruggedness� that� is� ex-traordinary� for� an� optical� system.� The�component�responsible�for�this�is,�on�the�one�hand,�the�code�disk�made�of�nickel.�Compared� to�code�disks�made�of� glass,�it�is�considerably�more�robust�while�offer-ing� the� same� resolution;� in� comparison�to�code�disks�made�of�plastic,�it�has�sig-nificantly�better�resolution�but�is�cold-�and�heat-resistant�to�such�an�extent�that�the�AFS60�can�be�used�at�operating�temper-atures�ranging�from�–20�°C�to�+100�°C.�In�the�AFS60,�the�shaft�bearing,�widened�to� 30� mm,� provides� considerably� more�ruggedness�than�in�the�case�of�encoders�with�blocked�ball�bearings.�Even�at�maxi-mum� operating� speeds,� the� increased�distance�between�bearings�results�in�un-precedented�freedom�from�vibrations�and�optimum�concentric�running�–�regardless�

of�whether�the�solid-shaft�or�hollow-shaft�variant�is�used.

Variants that make senseThe�AFS60�series� in� the� industry-proven�60-mm�design�is�now�available�in�all�me-chanical�variants.�In�addition,�the�user�can�choose� among� M12� or� M23� connector�outlets,�or�opt� for� radially�or,� respective-ly,�axially�usable�cable�outlets� in�various�connecting� lengths.�The�shaft�diameters�range�from�8�mm�to�15�mm�(resp.�3/8“,�1/2“,� 5/8“).� This� facilitates� installation�with�very�limited�space�available.�

Programming: same look & feel spanning the entire encoder portfolioAlready� familiar� from� the� complete� new�family� of� absolute� encoders,� the� AFS60�features�an�SSI�interface.�In�addition,�the�AFS60�is�programmable�using�the�same�programming�tool�that�has�already�proven�its�worth� in�the�DFS60�series�from�SICK�STEGMANN.�In�this�way,�incremental,�sin-gleturn,�and�absolute�multiturn�encoders�can� now� be� parameterized� for� the� first�time�with�one�programming�tool.

AFS60�–�accurate,�compact,�and�robust.�

Minimum construction depth & high resolution

Encoders�that�set�record�highs�

Two identical miniTwin sticks, each equipped with sender/receiver elements, make up a safety system.

Innovation NO 25

32 01� 2009


With�the�vibrating�fork�sensors�of�the�LFV300�and�LBV300�series,� SICK� extends� its� portfolio� of� level� measurement�technology.� The� vibration� switches� detect� level� heights� of� liquids� or� bulk��materials;�they�can�be�configured�appropriate�to�the�respective�processes;�they�are�certified�for�diverse�fields�of�application;�and�they�deliver�convinc-ing�performance�due�to�their�wear-free�and�maintenance-free�operation.

>>� Typical� tasks� of� the� LFV� series� in-clude� use� as� overfill� detectors� or� for�protecting� against� dry� running� of� all�pumpable� liquids.� The� vibrating� fork�sensor�of�the�LBV�family�are�designed�

specifically� for� containers� holding�bulk� materials� or� powdery� sub-

stances� such� flour,� wood� pel-lets,� granular� plastic� material,�or� rubber.� Whether� LFV� or� LBV�

–� in� both� series,� the� piezoelec-tric� measuring� principle� and� the�symmetrical�structure�of�the�vibrat-

ing� probes� ensure� high� immunity� to�

contamination,� build-ups,� and� external�vibration�influences.�As�well,�differences�in�pressure�and�turbulences,�e.g.�during�the� filling� of� containers,� foam,� and� the�formation�of�gas�or�bubbles�have�no�in-fluence�on�either�the�sensor�function�or�the�switching�accuracy.

Capable of modular configurationStarting�out�with�the�actual�sensor�unit,�which� consists� of� the� vibrating� fork� de-signed� to� be� resistant� against� the� rele-vant�substances�and�of�the�piezoelectric��element,� the� vibration� level� switches�

Evaluating vibrations, detecting levels

Good�vibrations


from�SICK�are�capable�of�modular�con-figuration�depending�on�the�task�in�ques-tion.� Following� the� concept� of� modular�assembly,�to�begin�with,�one�can�choose�among� process� connections� of� differ-ent�size�and�design.�Threads�of�various�dimensions� are� available� for� both� the�LBV�and� the�LFV�sensors;� furthermore,�the� latter� series� can� be� combined� with�Tri-Clamp� pipe� connections� or� flanges.�If� the� sensor� in� standard� design� does�not� reach� the� desired� actuation� height,�it�is�possible�to�set�the�vibrating�fork�off�from�the�sensor�housing�by�means�of�a�pipe� extension� or� a� messenger� cable,�thus� allowing� operation� on� the� desired�level.� With� respect� to� housings� and� ca-ble� glands,� there� is� a� choice� of� plastic,�aluminum,�and�stainless�steel.�The�vari-ants�regarding�the�switching�electronics�include�a�non-contact�switch,�a�relay�out-put,�or�a�transistor�output.�

New long-range ICR845-2L FlexLens code reader

Best�solution�–�by�a�long�shot


When�it�comes�to�identifying�1D�and�2D�codes,�the�ICR845-2L�FlexLens�cam-era�code�reader� is�the�best�solution�–�by�a� long�shot�–�whenever�the�goal�is� to�manage�reading�distances�up�to�2�m.�Short�evaluation�times�even� in�

case�of�large�reading�fields�and�high�reading�reliability�concerning�both�stationary�and�moving�objects�open�up�interesting�application�fields� for� the� ICR845-2L�FlexLens,�particularly� in�car�manufactur-ing,�packaging�systems,�and�in�intralogistics.

>>�This�applies�equally�to�new�plants�and�retrofitting,�since�the�connection�system�of�the�ICR845-2L�FlexLens�and�the�CLV�series�laser�scanners�from�SICK�is�identi-cal�–�which�permits�simple�switching�to�the�camera�code�reader�if�required.�

Flexibility means versatility Flexibility� is� one� of� the� distinguishing�marks� of� the� long-range� code� reader.�Interchangeable� camera� lenses� and�varied�means�of�lighting�allow�adjusting�the� ICR845-2L� FlexLens� to� nearly� any�reading�task.�Reading�distances�of�up�to�2�m� are� possible� –� which� is� important,�for� instance,� if� the� reading� device� can-not� be� mounted� closer� to� the� object� or�needs� to�be� installed�outside�of�a�han-dling� area.� The� 1D� or,� respectively,� 2D�

codes�are�identified�reliably�in�any�state�of�movement�–�whether�at�a� standstill,�in�constant�movement,�or�during�braking�or�accelerating�by�a�transport�system.�An�additional�bonus�is�the�fact�that�even�if�the� reading� device� needs� to� detect� the�code� within� a� large� reading� field,� the�reading�result�becomes�available�quickly�due�to�the�short�decoding�time.�

User friendliness means fast and high availability The� ICR845-2L� FlexLens� also� distin-guishes� itself� by� a� high� degree� of� user�friendliness.�Changing�the�lens�is�a�mat-ter�of�seconds,�involving�only�a�few�sim-ple�touches.�The�connecting�and�mount-ing�systems�meet�SICK’s�industrial�stan-dard,� thus� accelerating� start-up.� Live�Image� and� AutoSetup� permit� fast� and�efficient� implementation� of� the� read-ing�task�without�a�PC�–�especially�since��users�are�familiar�with�the�operator�inter-face� from� other� code� readers� made� by�SICK.

With� the� ICR845-2L� FlexLens� object�identification�in�many�applications�is�no�longer�a�question�of�distance.�

Innovation NO 17

Innovation NO 30

33

: ProductsInnovation�Marathon�–�Preview

The� CLV6xx� barcode� scanner� platform� from� SICK� offers�customized� solutions� all� the� way� to� the� high-end� segment.�Besides�maximum�reading�results,�noteworthy�features�include�the�intuitive�parameterization�and�user�interface,�as�well�as�the�manifold�possibilities�for�network�and�fieldbus�integration.�

>>� The� laser� scanners� comprising� the�CLV6xx�series�offer�scan�frequencies�up�to�1,200�Hz�for�conveying�speeds�of�up�to�6�m/s,�permitting�a�customized�solu-tion�for�different�identification�problems.�Furthermore,�various�CLV6xx�devices�are�also�available�as�a�variant�with�oscillat-ing� mirrors.� Because� of� the� processor�technology�used�the�devices�also�feature�substantial�performance�reserves�whose�utilization�allows�achieving� reliably�high�reading� rates� even� with� a� view� to� de-mands�growing�in�the�future.�

CLV650 – Reading everything The�new�CLV650�is�the�high-end�device�in�the�series.�For�instance,�in�the�reading�field�from�200�mm�–�1,600�mm,� the�scanner�features�real-time�autofocus�with�integrat-ed�distance�measurement�function,�which�ensures�utmost�reading�reliability�even�for�high�plant�throughput�and�the�most�diverse�object�sizes.�On�the�device,�this�is�visualized�by� a� bar-graph� display,� which� eliminates�the�need�for�checking�reading�performance�by�means�of�a�PC.�From�the�CLV620�fixed-focus� basic� version� upward,� Ethernet� on�

Board�and�integrated�web�server�function-ality�for�scanner�diagnosis�are�just�as�much�included�in�the�scope�of�features�and�ser-vices�as�the�reliable�two-stage�fieldbus�con-cept�with�a� separate�connection�box�and�the�parameter�cloning�option�for�minimized�device�replacement�times�–�either�using�a�cloning� module� or,� from� the� CLV630� up,�a� micro� SD� card.� Additional� features� are�the�SMART�decoding�algorithms�that�have�been�developed�further.�

Integrated intelligenceFurthermore,�nearly�all�scanners�can�be�considered�to�be�“intelligent,”�since�they�are�capable�of�recording�and�saving,�e.g.�contrast�conditions,�at�the�push�of�a�but-ton� via� two� function� keys,� of� activating�the�required�barcode�symbologies,�or�of�reading�the�contents�of�codes�in�a�sorted�manner�and�outputting�them�specific�to�the� application.� For� this� purpose,� it� is�possible�not�only�to�adjust�the�data�out-put�flexibly�by�means�of�Wizzard�technol-ogy� but� to� process� individual� data� seg-ments�separately�and�to�output�them�via�two�different�ports.�

Simple operation and integrationThe�operating�concept,�which�is�second�to�none�in�simplicity,�is�based�on�the�SOPAS-ET�software.� It� is�an� intuitive�engineering�tool� across� device� types� that� offers� the�same�look�&�feel�for�all�devices�from�SICK�–� from� the� connection� assistant� for� net-work�applications�all�the�way�to�a�diagnos-tic�window�that�can�be�activated�through-out� the� entire� parameterization� process.�The� event� monitor� visualizes� the� inputs�and�outputs�of�the�CLV650,�helping�to�vary�parameters�during�start-up.�Access�to�the�device�is�“compatible�with�target�groups.”�Depending�on�the�complexity�of�a�task�or�the�respective�user,�it�is�possible�to�permit�different�accessibility�levels�to�the�system�parameters,� e.g.� for� programming,� start-up,�service,�and�maintenance.�On�the�one�hand,�this�protects�already�parameterized�data�and�it�reduces,�on�the�other�hand,�the�number� of� parameters� to� the� minimum�level�required�in�the�respective�scenario.�

With� respect� to� communication,� all�CLV6xxs� are� available� with� CAN-bus� or�with�Ethernet�interface.�In�addition,�field-bus�gateways�are�available,�allowing�in-tegration�into�Profibus�DP�and�DeviceNet�networks.� Finally,� the� platforms� offer� a�Multiplexer� function� enabling� operation�of�the�devices�within�SICK’s�CAN�sensor�network.

Diagnostic tool supports preventive maintenance Due�to�their�suitability�for�networking,�the�scanners�of�the�CLV6xx�series�provide�the�opportunity�of�remote�maintenance�–�via�the�RDT400� remote�diagnostics� tool.�Us-ing�graphic�visualization�permits�monitor-ing�and�controlling� the�barcode�scanners�both� locally�on�the�respective�device�and�centrally�from�a�control�computer�or�from�any�place�in�the�world.�Thus,�it�is�possible�to� implement� plant-specific� solutions� to-ward�preventive�maintenance.�

High� reading� performance,� simple�parameterization,�and�manifold�fieldbus�options�–�the�CLV6xx�platform�is�very�well�prepared�for�top�performance�in�barcode�identification.�

Platform completed with autofocus scanner

Top�performance�guaranteed�


Product of the Month June

34 01� 2009


On illuminating and luminous solutions

Changing�of�the�guard��among�luminescence�sensors�


Innovation NO 24

>>� Luminescence� sensors� are� capable�of� detecting� “invisible”� markings� reli-ably.� To� this� end,� the� so-called� lumino-phores,� invisible� in�usual�ambient� light,�are�caused�to� light�up�when�stimulated�with�a�source�of�UV� light.� In�the�field�of�automation� technology,� luminophores�are�generally�added�to�substances,�e.g.�paints,� marking� chalk,� or� adhesive� ta-pe.�In�the�area�of�high-quality�consumer�goods,� such� as� champagne,� invisible�markings�with� luminophores�do�not� im-pair�the�high-grade�design�of�labels,�whi-le�still�permitting�their�alignment�during�a�labeling�process,�for�instance.�

To�detect�luminophores�reliably�under�such�industrial�operating�conditions�lumi-nescence�sensors�must�meet�a�series�of�

additional�requirements�concerning�user-friendliness,�detection�speed,�and�range.�That�is�the�case�with�respect�to�the�new�LUT8� and� LUT9� luminescence� sensors�from� SICK.� A� particularly� helpful� feature�for�adjusting�the�luminescence�sensor�is�the�bar�display�on�the�device,�which�indi-cates�luminophore�content�in�the�marking�and�thus�detection�reliability.� In�addition�to� that,� its� optical� filter� allows� for� a� dif-ferentiation�of�various�wave� lengths�and�does�not�suppress�relevant�luminescence�signals�from�the�environment.�

LUT8: The user-friendly standard solution Clear� operating� design� is� the� strength�of� the� LUT8.� With� the� help� of� the� ope-

rating� knob,� the� sensitivity� of� the� LUT�–�and�thus�switching�reliability�–�can�be�adjusted�to�the�marking�to�be�detected.�Whereas� the�LUT8� represents� the�solu-tion� for� standard� applications,� e.g.� for�detecting� markings,� labels,� or� package�inserts,� the� LUT9� is� well� prepared� for�more�demanding�tasks.

LUT9: the solution with IO-Link and extended detection rangeFeaturing�an�IO-Link�option�and�a�very�high� detection� range� of� 200� mm,� the�LUT9� sets� the� new� standard� for� lumi-nescence� sensors.� Due� to� the� poten-tially� considerable� distance� between�the� sensor� and� the� object,� it� is� possi-ble� –� e.g.� in� the� lumber� industry� –� to�detect� markings� reliably� on� different�thicknesses� of� wood� without� mecha-nical�readjustment�of�the�sensors.�The�teach�function�and�the�manual�fine-tu-ning� allow� a� maximum� degree� of� pro-cess� reliability.� This� is� also� the� case�even�with�complex�ambient�conditions�as� they�can�be� found,� for� instance,� in�wood�or�paper�processing.�Anyone�op-ting� for� the� LUT9� version� with� IO-Link�can�integrate�the�luminescence�sensor�actively�into�the�machine�visualization,�parameterizing,�monitoring,�and�using�the�sensor�directly�from�the�control�sy-stem�for�capturing�process�data.

LUT8�and�LUT9�–�their�performance�data�render�them�luminous�solutions�for� illu-minating�markings.�

Improved�operating�designs�with�bar�display,�increased�scanning�distances�and�IO-Link�–�the�LUT8�and�LUT9�ring�in�a�new�era�in�the�product�segment�of�luminescence�sensors.�

Phot

o:�W

eini

g�AG

: Products

35

In�emissions�monitoring,�sulfur�dioxide�and�nitrogen�oxide�are�impor-tant�measuring�components.�However,�this�measurement�does�not�constitute�the�only�focus�of�the�new�GM32�in-situ�gas�analyzer�from�SICK.�In�process-gas�monitoring,�too,�the�analyzer�takes�on�a�major�role.�Additionally,�it�measures�ammonia�in�raw�and�clean�gas.�

>>� All� of� these� gases� have� one� thing� in�common:�they�are�reactive.�During�trans-port� through� dirty� filters� and� sampling�pipes�not�heated�in�the�optimum�way,�they�may�react�with�other�accompanying�sub-stances�or� they�become�bound.�Memory�effects�and�reduced�material� to�be�mea-sured�are�the�consequence.�Depending�on�the�length�of�the�sampling�pipes,�consider-able�time�lags�may�also�occur�because�of�

transport� to� the�extractive�analyzer.�As�a�result,� the� measured� value� is� indicated�only�with�a�delay.�This�time�lag�can�easily�reach�as�much�as�one�minute.

In�this�context,�the�concept�of�in-situ�measurement�delivers�convincing�perfor-mance.�The�GM32�uses�the�gas�duct�as�measurement�path,�measuring�in�the�UV�range�directly� in�the�flowing�gas�–�with-out�sampling�and�transport.�Another�bo-

The new GM32 measures aggressive gases without detours

Visual�contact�suffices

nus:� probe� or� cross-duct� measurement�achieves�a�far�more�representative�mea-surement� than� by� point� sampling� with�a�probe.�Eliminating�any�time�lag�or�un-desired� reactions� during� transport,� the�gases�are�measured�quickly,�accurately,�and�without�any�distortion.�

GM32 – tough when the going gets toughObviously,� this� measuring� strategy� also�means�that�the�analyzer�system�must�be�installed� directly� at� the� measuring� point.�“As�pioneers�of� in-situ� technology�we�put�the� main� development� emphasis� on� the�unqualified� technical� design� of� our� mea-suring�devices,”�Dr.�Volker�Wilke,�Head�of�the� Development� Department� in� process�automation,�confirms�SICK’s�product�phi-losophy.�Therefore,�the�GM32�is�equipped�with�automatic�beam�alignment�in�order�to�keep�the�measuring�beam�focused�in�the�optimum�way�on�the�detector�–�even�when�it�comes�to�swaying�smokestacks�or�chang-es�through�thermal�shifts.�Eventually,� the�GM32�had�to�prove�its�stability�in�a�tough�vibration�test�during�the�technical�aptitude�test.�This� involved�acceleration� figures�of�up�to�12�times�the�standard�values.�

Certified in accordance with the latest EU directivesGM32�is�the�first�UV�in-situ�analyzer�for�SO2�and�NO�tested�entirely�in�accordance�with� the� new� European� EN15267-3��Quality�Directive.�

Further�product�information:www.gas-insitu.com

requirements� of� automation,� the� WMF�has� a� lot� to� offer.� For� instance,� the� ro-bust� aluminum� housing� and� the� multi-functional� display� visible� from� all� sides�constitute� important� features� for� practi-cal�operation.�The�different�construction�designs�–�five�overall�–�with�fork�widths�up�to�180�mm�as�well�as�fork�depths�up�to�120�mm,�permit�selection�of�the�best�possible�sensor�for�the�most�diverse�ap-plications.�Automating�cost-effectively�to�a�dot�–�WFM�is�the�solution.�

>>� The� WFM� complements� SICK’s� port-folio� of� fork� sensors� for� standard� ap-plications.� Concentrated� on� essential�


New fork sensors in “quick-start design”

WFM�–�concentrating�on�the�essentials�The�fixed�factory�settings�as�well�as�simple�alignment� toward� the�object�with�the�help�of�the�visible�red�light�make� the� new� fork� sensors� of� the�WFM� series� from� SICK� a� fast� plug�&� play� solution� for� a� large� number�of� detection� tasks,� e.g.� monitor-ing� parts� in� production� processes,�checking�for�presence�in�bottling,�in�intralogistical� processes,� or� in� han-dling�systems.�

Product�News

36 01� 2009

: Products

36

Standards

>>� The�procedure�and�documentation�of�the�CE�Safexpert�7.0�safety�software�corre-spond�to�the�requirements�of�the�new�Ma-chinery� Directive� (MD)� 2006/42� EC.� And�SICK�makes�a�product�library�available�for�the�SiSteMa�software�issued�by�the�Insti-tute� for� Occupational� Safety� and� Health�(Berufsgenossenschaftliches� Institut� für�Arbeitsschutz�–�BGIA),�which�allows�easier�assessment�of� the� required�performance�level�of�safety-related�machine�control�sys-tems�according�to�EN�ISO�13849-1.

With� the� changes� to� the� Machinery�Directive�taking�effect�on�29�December�2009,� all� machine� and� plant� manu-facturers� must� design� and� build� their�equipment� in� accordance� with� the� re-quirements� in� effect� at� that� time.� Even�today,�it�is�necessary�for�manufacturers�to� address� the� topic,� since� numerous�machines� currently� in� the� planning� or�construction�stage�will�probably�be�mar-keted�only�after�the�deadline.�

Considering today what will be in effect tomorrowWith�the�assistance�of�Safexpert�7.0,�both�machine�manufacturers�and�plant�opera-

Safexpert updates, product library SiSteMa integrates

Ready�for�the�new��Machinery�Directive!

tors�are�on�the�safe�side.�The�CE�software�accompanies�them�along�the�entire�con-formity�process�all�the�way�to�the�CE�la-bel.� Working� with� Safexpert� 7.0� makes�implementation�of�the�new�requirements�easier�than�ever.�Thus,�the�new�Machin-ery� Directive� 2006/42� EC� is� attached�and�linked�as�a�text�in�full�–�in�case�ques-tions� emerge,� the� user� is� guided� to� the�appropriate�passage�via�mouse�click.�At�the�same�time,�all�of�the�requirements�of�the�new�Machinery�Directive�have�been�edited� –� thus� clients� spare� themselves�the�trouble�of�picking�out�passages�from�the�official�texts.�In�this�connection,�too,�the� new� reports� demanded� by� the� Ma-chinery� Directive� are� already� attached�in� Safexpert� 7.0.� The� standards� man-ager� included� in� the�software�offers�us-ers� the�additional� convenience�of�being�informed�continuously�about�the�current�standards� situation� –� the� status� of� the�standards� is� shown� with� just� one� click;�the�function�also�indicates�which�projects�are�affected�by�the�changes.�Existing�us-ers�can�compile�projects�according�to�the�extant�Machinery�Directive�2006/37/EC�and,�if�necessary,�convert�projects�to�the�procedures�of�the�new�MD�2006/42�EC.�In�Safexpert�7.0,�the�requirements�of�the�conformity� processes� are� depicted� in�keeping�with�the�future�Machinery�Direc-tive� so� that� users� receive� the� best� pos-sible�support�for�maintaining�a�compliant�process�at�all�times.�

Safexpert 7.0 – the “MD insurance” Certainty�instead�of�uncertainty,�time�sav-ings� instead�of�huge�effort,� flexibility�and�sustainability�–�Safexpert�7.0�offers�all�of�that� to� its�users.�Moreover,�anyone�wish-

The product library for the SiSteMa software of the BGIA

The standards manager integrated in the Safexpert software offers continu-ous information concerning the stan-dards situation

Whether�machine�manufacturers�or�plant�operators�–�anyone�cur-rently�planning�a�facility�and�intending�to�market�it�in�early�2010�already�needs�to�work�according�to�the�new�Machinery�Directive�in�order�to�have�a�compliant�machine�eventually.�Moreover,�the�tran-sitional�period�(DOW�–�date�of�withdrawal)�concerning�the�safety-re-lated�parts�of�control�systems�will�expire.�The�calculation�according�to�category�will�be�eliminated�and�the�assessment�according�to�per-formance�level�will�become�binding.�In�order�to�make�life�easier�for�plant�manufacturers,�SICK�provides�support�for�both�issues.

37

: ProductsAccessories


>>� SICK’s� mounting� systems� for� indus-trial� sensors�allow�optimum� installation�solutions.�For� instance,�a� large�number�of�standard�mounting�brackets�are�avail-able� for� easy� and� fast� installation� of�photoelectric�switches�and�photoelectric�proximity�switches.�In�addition�to�mount-ing�of�the�sensors�that�is�adapted�to�the�environment,� the� universal� fastening�system�with�rod�brackets�guarantees�the�greatest� possible� variability� for� installa-tion� and� alignment.� Special� alignment�brackets�for�sensor�protection�or�for�high-precision�sensor�alignment�are�available�as� well.� Also� interesting� to� many� us-ers�of�pneumatic�drive�systems�are� the�mounting�solutions�for�magnetic�cylinder�sensors� that� allow� reliable� fastening� of�SICK’s�cylinder�sensors�to�a�great�variety�of�pneumatic�cylinders.�

Maintaining the connection under any conditions SICK� also� offers� a� maximum� degree� of�competence� with� respect� to� connec-tion�systems.�The�spectrum�ranges�from�field-wired� plugs� and� connecting� or� link-ing� cables� of� many� descriptions� all� the�way� to� sensor/actuator� cable� terminal�boxes�and�plug�connectors�for�integration�into�fieldbus�systems.�Many�solutions�are�

Not� only� is� SICK� technology� and�market� leader� in�many�areas�when�it� comes� to� sensor� technology;� the�company� also� offers� what� is� prob-ably�the�most�comprehensive�range�of� mounting� solutions,� connection�systems,�and�reflectors.�

available�in�sector-�or�application-specific�designs,�for�instance,�in�order�to�meet�the�high�demands�caused�by�drag-chain�load,�exposure�to� lubricants,�or�use�directly� in�the� cleaning� process.� The� best� example�is� the� food� &� beverage� compatible� con-nection� solutions� in� M8� and� M12� from�SICK.� Maximum� leak� tightness� in� IP69k�enclosure� rating� and� top� resistance� to�aggressive� chemicals,� cleaning� agents,�acidic� and� alkaline� solutions� due� to� a�choice�of�suitable�materials�such�as�PVC�and�1.4404/316L�stainless�steel�guaran-tee� high� durability� of� sensor� connecting�cables�and�cable�terminal�boxes.�

Reflector solutions In�the�area�of�reflectors,�too,�SICK�offers�a�large�portfolio�of�the�most�diverse�sizes�and� shapes� as� well� as� for� different� ap-plication�conditions.

The�upshot:�Instead�of�stinting�in�the�wrong�department,�a�constantly�increas-ing� number� of� users� rely� on� solutions�from� SICK� when� it� comes� to� mounting�and� connection� systems� as� well� as� re-flectors.� The� benefits� are� obvious:� fast�availability,� fully� developed� technology,�assured� compatibility� with� the� sensors�–� resulting� in� the� potential� of� sensors�from� SICK� in� their� various� jobs� being�exhausted�to�the�maximum.�As�compre-hensive� as� the� portfolio� of� accessories�may�be�–�beyond�that,�it�still�offers�room�for�new,�customer-specific�solutions�that�can� serve� to� make� allowances� for� spe-cial�application�requirements.�

Who would want to stint in the wrong department?

Functional�accessories�for��top�sensor�performance�


ing�additional�support�concerning�the�safe�design�of�machines�and�plants�beyond�this�“MD�insurance”�may�trust� in�comprehen-sive�services�from�SICK�–�from�a�CE�consul-tation�to�assistance�with�the�risk�analysis�and�all�the�way�to�the�plant�walk-through�and�the�appropriate�advisory�service�con-cerning�safety-oriented�application.�

Parameter of safety sensors from SICK usable directly in SiSteMa Risk� assessment� involves� defining� the�control-related� measure� and� determin-ing� the� necessary� PL.� In� SiSteMa,� one�calculates� whether� the� architecture� of�the�safety�solution�reaches�the�demand-ed�PL.�Clearly,�having�the�library�with�the�relevant� values� already� available� facili-tates�the�calculations�immensely.

For� each� product� of� the� safety-re-lated�portfolio,�all�of� the�safety-relevant�parameters� such� as� PL,� PFHD� (prob-ability�of�a�dangerous� failure�per�hour),�category,� B10d� (the� number� of� switch-ing� operations,� in� which� statistically�speaking�10�%�of�the�samples�result�in�a�dangerous�failure),�are�stored;�so�is�the�permissible� operating� duration.� This� al-lows�the�user�quick�access�to�all�of�the�necessary� data,� ensuring� that� they� are�taken� into� consideration� when� assess-ing� individual�safety� functions.� In� terms�of�evaluation,� SiSteMa� reconstructs,� as�a� Windows� tool� with� integrated� Wizard,�the�structure�of� the�safety-related�parts�of�a�control�system� (SRP/CS)�based�on�the� so-called� designated� architectures.�Using�direct�access�to�SICK’s�library,�the�program�calculates�the�reliability�values�on�different�levels�of�detail,�including�the�performance�level�(PL)�achieved.�

The� bottom� line:� As� of� 2010,� every�machine� manufacturer� will� be� affected�by�the�new�Machinery�Directive.�Without�the� appropriate� software� tools� such� as�SiSteMa�and�Safexpert�7.0,�an�efficient�implementation� toward� meeting� the�new� requirements� involves� a� lot� of� ef-fort.�Products�from�SICK�will�continue�to�conform�to�all�of�the�relevant�normative�requirements�in�the�future,�thus�making�an� important� contribution� to�conformity�assessment�in�accordance�with�the�new�Machinery�Directive.�On�top�of�that,�SICK�supports�manufacturers,�system�integra-tors,� and� operators� with� respect� to� the�standardized� design� and� implementa-tion�of�their�safety-relevant�applications.�

01� 2009

: SICK Tour

15 years of SICK Polandfounded on 12 July 1994

20 years of SICK Optex Japan founded on 1 April 1989

Subsidiaries��celebrate!

>>�As�a�long-standing�and�successful�busi-ness�partner,�AMKO�has�already�been�con-tributing�considerably�to�the�promotion�of�SICK�as�an�environmental�brand,�among�other�things,�with�respect�to�analyzers�for�flue-gas�and�dust�measurement�in�power�stations� and� cement� factories.� Substan-tial� technical� competence� and� customer�orientation� of� the� employees� taken� over�from� AMKO� form� the� basis� for� targeted�further�development�of�SICK’s�business�in�environmental� and� process� instrumenta-tion�in�Canada.�Precisely�at�this�time,�the�reinforcement�of�activities�in�process�auto-mation,�a�segment�less�dependent�on�the�economic� situation,� is� an� interesting� op-portunity�for�the�SICK�Group�to�strengthen�its� position� in� Canada� specifically� and� in�North�America�generally.

With� the� new� Canadian� subsidiary�SICK�Ltd.,�which�took�over�operations�from� the�previous�project�and�distri-bution�partner�AMKO�SYSTEMS�INC.,�SICK�is�expanding�its�activities�in�en-vironmental�monitoring�on�the�Cana-dian�market.�

Environmental monitoring by SICK for Canada

Subsidiary�in��Toronto�founded

38

>>�SICK�would�also�like�to�congratulate�the�winners�of�the�other�main�prizes:�an�outdoor�navigation�system�and�a�back-packer’s� rucksack�complete� the�equip-ment�needed�for�a�voyage�of�discovery.

Visitors� could� gain� many� interesting� in-sights�at�SICK’s�exhibition�stand,�includ-ing� the� highlights:� the� DT50� distance�sensor� and� the� W4S-3� Inox� miniature�photoelectric�switch.�A�successful�trade�fair�all�around�(the�world)!

New York, Rio, Tokyo – on a voyage of discovery with SICK!

Encoder�prize�game�at�the��SPS/IPC/DRIVESFor�Martin�Linke� from�Siemens�AG,�it�was�a�successful�visit�to�the�SPS/IPC/DRIVES� 2008� trade� fair� –� not�least� because� of� the� main� prize,�a travel voucher valued at € 500, which� he� won� in� our� encoder� prize�game.�He�was�able� to�give� the�cor-rect�answer�to�the�question�“What’s�the� name� of� the� new� absolute� en-coder�from�SICK?”:�the�AFM/AFS60.�

>> In� addition,� the� ACA� offers� the� op-portunity�of�training�the�company’s�own�staff�as�well�as�employees�of�customers�directly�at�the�systems�and�applications�under�real-life�conditions.�

Live tests with up-to-date technologiesThe�ACA�provides�the�means�to�assem-ble�automation�applications�or�solutions�in� realistic� conditions� at� different� sta-tions,� e.g.� at� a� test� conveying� section�or� in� application� labs,� thus� preparing�the� respective� system� for� fast� imple-mentation�in�the�client’s�productive�set-ting.�The�arrangement�covers�all�of� the�current� technologies� and� applications�related�to�factory�and�logistics�automa-tion,�such�as�RFID�or�image�processing.�SICK’s�contact�persons�at�the�ACA�clari-fy�technical�questions,�prepare�possible�

1,000 m² for system solutions in factory and logistics automation

SICK�opens�Application�Center�in�SingaporeJust� recently,� SICK� has� officially�opened�the�first�“Application�Center”�(ACA)� in� Asia.� Nearly� 1,000� m²� of�floor� space� allow� assembling,� test-ing�and�optimizing�system�solutions�for� factory�and� logistics�automation�in� an� environment� that� realistically�reproduces� subsequent� productive�operations.�

approaches� toward� solutions,� imple-ment� them� using� innovative� products�and�solutions,�and,�if�required,�carry�out�software�adjustments.�

: SICK Tour

Working�in�the�morning,�having�lunch,�and�then�heading�for�the�in-house�af-terwork�lectures�in�the�afternoon�–�the�idea�of�the�safetyPLUS®�“practice�af-ternoons”�organized�by�SICK�on�the�topic�of�“Implementing�safety�standards�easily”�enjoys�great�popularity�in�many�companies.

>>�In�terms�of�safety�technology,�the�turn�of�the�year�will�be�quite�momentous:�the�widely�known�standard�EN�954-1�will�ex-pire�on�29�Dec.�2009,�being�replaced�by�EN� ISO� 13849;� furthermore,� important�changes�to�the�Machinery�Directive,�MD�2006/42� EC,� will� take� effect.� How� will�protective� measures� according� to� the�regulations�look�like�from�that�point�on-ward�–�both�in�theory�and�practice?�

Getting the picture in only four hoursThe�answers�are�delivered�by�SICK’s�four-

hour�safetyPLUS®�“practice�afternoons.”�In�addition�to�the� introduction�of�the�re-forms� and� changes� to� the� MD� and� the�relevant� standards,� a� lot� of� attention� is�devoted� to� the� typical� case� studies� of�safety-related� tasks� and� approaches� to�solutions.�The�presentation�includes�the�safetyPLUS®� technology� from� SICK� just�as� it�does� the�working�method�with� the�SiSteMa�software�tool�issued�by�the�Insti-tute� for�Occupational�Safety�and�Health�(Berufsgenossenschaftliches� Institut� für�Arbeitsschutz� –� BGIA).� An� aspect� par-

ticularly�interesting�for�users:�SiSteMa�is�supported�by�a�product�library�from�SICK,�which�allows� importing�all�of� the�safety-relevant�key�numbers�and�data� into�the�safety-related�calculations.�At�the�conclu-sion�of�the�event,�enough�time�is�sched-uled�for�questions�and�discussions.

Please register – an event will be held in your area as wellIn�the�weeks�ahead,�too,�SICK�again�in-vites� interested�parties�to�participate� in�the� safetyPLUS®� “practice� afternoons.”�The� info� box� below� shows� when� and�where�the�“practice�afternoons.”�

To�register,�please�visit�www.sick-safetyplus.com.

Afterwork lectures attract participants

Successful�safetyPLUS®�“practice�afternoons”

>>� In� the� future,� process� automation�will� be� operating� in� the� market� under�the� umbrella� brand� of� SICK.� This� con-tributes� to� the� increasing� integration�into�the�group’s�global�sales�and�service�organization.�“SICK�–�Sensor�Intelligence.”�combines�great�demands�on�quality�with�the�solu-tion� competence� in� analyzers� and� pro-cess�instrumentation.�The�joint�presence�on�the�market�strengthens�relations�with�

Offering�analyzers�and�instrumentation�systems�for�emission�monitoring�and�process-gas�measurement,�the�group’s�segment�of�SICK�process�automation�had�been�very�successful�to�date�as�a�supplier�of�complete�systems�operat-ing�under�the�label�of�SICK�MAIHAK.�The�global�market�presence�and�above-average�growth�rates�have�made�process�automation�an�important�business�segment�within�the�SICK�Group.

our�clients�and�conveys�the�security�of�a�strong�and�innovative�corporate�group.The� legal� designation� of� SICK� MAIHAK�GmbH�will�remain�unaffected�by�this,�en-suring�that�approvals�and�certifications�of�the�products�retain�their�validity.�

SICK�as�the�quality�brand�–��Sensor�Intelligence.�

>> The upcoming dates

Hamburg�� 04/30�

Ingolstadt�� 05/12�

Frankfurt�a.M.�05/26�

Stuttgart�� 06/02�

Munich�� 06/09�

Leipzig�� 06/23�

Hannover�� 08/25�

Berlin�� 09/08�

Waldkirch�� 10/13

Düsseldorf�10/29

>> Five�years�ago,�the�Swedish�IVP�Com-pany,�specializing�in�vision�products,�was�acquired�by�SICK�AG.�Today,� the�vision�segment�has�become�firmly�established�within�the�SICK�Group.�In�the�future,�the�vision�segment,�too,�will�do�business�un-der�the�uniform�umbrella�brand�of�SICK�and�no�longer�under�the�SICK�IVP�brand.�The�company�name�of�SICK�IVP�AB,�how-ever,�will�continue�to�exist.�

One�“Vision”�–��one�umbrella�brand�

39

: Internet

40 01� 2009

Group web site even more visitor-friendly

sick.com�with�a�new�look

>>� With� the� new� sick.com,� it� was� pos-sible�to�achieve�the�decisive�milestone�for�SICK’s� internationally�uniform�pres-ence�on�the�web.�

Search functions optimized furtherWeb� sites� serve� to� inform.� Shorter�searches,� quicker� finds� –� the� innova-

A�short�while�ago,�the�SICK�Group’s�new�web�site�www.sick.com�went�online.�The�look�is�new,�the�feel�significantly�improved�thanks�to�a�new�navigation�structure.�Featuring�the�content-management��system�Microsoft�Office�Sharepoint�Server,�sick.com�is�on�the�cut-ting�edge�in�terms�of�information�technology�as�well.�

tive� navigation� structure� of� sick.com�makes� it�possible.�This�new�navigation�structure� was� developed� together� with�SICK’s�subsidiaries�and�based�on�feed-back� and� requirements� on� the� part� of�customers.� Thus,� the� new� web� site� of-fers�possibilities�for�a�quick�introduction�to�clients�who�are�either�looking�for�spe-

cific�products,�wish�to�obtain�details�on�solutions,� need� specific� sector-related�information,�or�simply�want� to� find� the�right� product� for� a� certain� application.�In�addition,�all�parts�of�the�web�site�are�now� integrated� into� the� search� func-tion.� In� this� way,� visitors� receive� the�information� quickly,� directly,� and� tai-lored� precisely� to� their� requirements.�Furthermore,�the�communication�struc-ture�in�the�area�of�“Products�and�Solu-tions”� is� arranged� in� the� same� way� as�one� will� encounter� again� in� all� other�publications�by�SICK,�e.g.�in�catalogues.�Whether�print�of�electronic�–�for�parties�interested�in�SICK,�this�achieves�a�high�recall� level,�extending�over�all� types�of�media.

The latest content- management technologyBy�using�the�content-management�sys-tem�Microsoft�Office�Sharepoint�Server,�SICK�relies�on�the�most�up-to-date�infor-mation�technology.�Apart�from�the�multi-site�management�that�is�unique�in�this�form�and�ensures�a�high�degree�of�con-tent� reusability� for�SICK’s�subsidiaries,�the�web�site’s�IT�solution�also�allows�ef-fective�change�management.�Visitors�to�sick.com�will�always�be�presented�with�the� latest� and� most� current� contents�–�something�exceedingly�important,�for�example,� in� the� area� of� safety-related�standards�or� for� the�update�of�product�features.�

sick.com� –� visit� the� new� web� site� to�check�out�the�world’s�leading�technical�expertise�in�sensor,�control,�and�system�technology.�

Product or sector? SICK’s new web site provides clients with the possibility of a quick introduction

Subs

idia

ries

Australia Phone�+61�3�9497�4100�·��+1800�3�3480�2�–�tollfree�[email protected]�Phone�+43�22�36�62�28�8-0�[email protected]/Luxembourg��Phone�+32�2�466�55�66�[email protected]�Phone�+55�11�3215�4900�[email protected]�Phone�+852�2763�6966�[email protected] Republic�Phone�+420�2�57�91�18�50�[email protected]�Phone�+45�45�82�64�00�[email protected]�Phone�+358�9-25�15�800�[email protected]�Phone�+33�1�64�62�35�00�[email protected]�Phone�+49�211�5301-0�[email protected] Britain��Phone�+44�17�27-83�11�21�[email protected]�Phone�+91�22�4033�8333��[email protected]�Phone�+972�4�999�0590�[email protected]�Italy�Phone�+39�02�27�43�41�[email protected]�Phone�+81�3�3358�1341�[email protected]�Phone�+31�30�229�25�44�[email protected]�Phone�+47�67�81�50�00�[email protected]�Phone�+48�22�837�40�50�[email protected] of Korea�Phone�+82�2�786�6321/4�[email protected]�Phone�+40�356�171�120�[email protected]�Phone�+7�495�775�05�30�[email protected]�Phone�+65�6744�3732�[email protected]�Phone�+386�(0)1-47�69�990�[email protected]�Phone�+34�93�480�31�00�[email protected]�Phone�+46�8�680�64�50�[email protected]�Phone�+41�41�619�29�39�[email protected]�Phone�+886�2�2375�6288��[email protected]�Phone�+90�216�587�7400�[email protected] Arab Emirates Phone�+971�4�8865�878�[email protected]�USA�Phone�+1�(952)�941�6780�[email protected]�at�www.sick.com

Publisher: SICK�AG�·�Postfach�310�·�79177�Waldkirch�·�Germany�·�www.sick.com��Phone�+49�7681�202-0�·�Fax�+49�7681�202-38�63�·�[email protected]

Coordination: Stephanie�Rott�·�[email protected]

Specialist editor: TOP�MEDIA�·�Dirk�S.�Heyden�·�69469�Weinheim�·�[email protected]

Layout: johnson][braun�Direktwerbung�·�76133�Karlsruhe�·�[email protected]

Translator:�Dr.�Erwin�D.�Fink�·�79106�Freiburg�·�[email protected]

Printing: Dinner�Druck�·�77963�Schwanau�·�[email protected]

Pictures: SICK�AG,�www.ausloeser-fotodesign.de,�getty�images,�fotolia�

Individual�contributions�may�be�reproduced�after�prior�consent.�Please�contact�us�at:��Phone�+49�7681�202-3878�·�Errors�excepted�·�Subject�to�technical�change

>> Imprint

: InfoTrade�fairs�·�Imprint�·�Contacts

>> Visit SICK at the Trade Fair!

Trade fair dates GermanyTrade�Fair� Location� Dates�2009ACHEMA � Frankfurt�a.M.� 05/11–05/15TOC Europe� Bremen� 06/16–06/18drinktec� Munich� 09/14–09/19VISION� Stuttgart� 11/03–11/05Productonica� Munich� 11/10–11/13SPS� Nuremberg� 11/24–11/26

Trade fair dates EuropeTrade�Fair� Location� Dates�2009Mocon� s’-Hertogenbosch,�NL�� 04/08–04/09EXPO-GAS Kielce,�PL�� 04/22–04/23easyFair Verpackung Zürich,�CH� 04/22–04/23MCERTS� Bretby,�UK�� 04/29–04/30HISPACK Barcelona,�E� 05/11–05/15

Trade fair dates worldwideTrade�Fair� Location� Dates�2009IRAN OIL & GAS Teheran,�IR�� 04/22–04/25Butech� Busan,�ROK� 05/20–05/24Korea Pack Ilsan�City,�ROK� 06/02–06/05MIOGE� Moscow,�RUS� 06/23–06/26

Further�trade�fair�dates�with�SICK�worldwide�at�www.sick.com/fairs

SICK�AG�·�Erwin-Sick-Str.�179183�Waldkirch�·�Germany

Phone�+49�7681�202-0Fax�+49�7681�202-38�63�

[email protected]�·�www.sick.com

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SICK AG | Waldkirch | Germany | www.sick.com

Innovation Marathon 2009:52 weeks, 52 innovations.

All year long: innovations to power up your productivity

Applications may vary, but requirements stay very much the same: increased productivity and decreased costs. In 2009 SICK brings you 52 innovative sensor solutions for factory, logistics and process automation to provide the basis for lasting efficiency improvements.

Visit www.sick.com and discover the power of innovation – and a new product each week!

SICK Magazine

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Transcript of SICK Magazine