LD PDS protects valuables and prevents vandalism Page 40 2004 www.sick.com 2 SICKs customer magazine TPM servo actuators from WITTENSTEIN Perfect positioning with the SRM 50 motor feedback system Page 12 Curtains down! The vertical protective field of the S 3000 safety laser scanner Curtains down! The vertical protective field of the S 3000 safety laser scanner Page 06 10 years success in the Middle Kingdom It is exactly one decade since SICK turned its attention to the Chinese market with its SICK Hong Kong subsidiary. It all started in Guangzhou with the first of- fice, which was soon followed by another in Hong Kong itself. What originally be- gan with just four personnel has since developed into a company with almost 60 employees at a total of four sites Beijing and Shanghai came later. The quality of the products, the enormous industrialisation boom of recent years, and the support received from the German headquarters in Waldkirch meeting all our technical and commercial needs, were undoubtedly of decisive importance in this success. But also of decisive importance was, and remains, the fact that ba- sically it is the Chinese who run the business in China and Hong Kong. Thus the mentality interface, with all its challenges, remains within the company commu- nication in the Group, instead of a clash of cultures in customer contacts. In the next decade, too, China the Middle Kingdom will remain a market of di- verse challenges. What SICK Hong Kong began ten years ago will be continued by SICK Optic-Electronic Co. Ltd., Guangzhou China, founded last year: the success- ful opening up of one of the worlds largest markets for industrial sensors. We thank all those who have accompanied us along the path up to now, and all those who will help shape our future path. With best wishes from the Far East Danny Chan, Managing Director, SICK Hong Kong and SICK China 03 Editorial insightTELEGRAM ++ New Safexpert 4.2 update of CE-software Straightforward adaptation of hazard analyses: checklists, lists of hazards, cross-references, etc. The Check and Acceptance Assistant Simple checks complying with the Machine Directive or German Safety at Work Legisla- tion (BetrSichVer) EN 292 withdrawn and replaced by EN ISO 12100 Info on new stan- dard and Safexpert www.sick.de/safexpert ++ Three wide-awake trainees at SICK AG de- velop pulse-controlled sleeping aid for tinnitus patients Win Jugend forscht competition (for young researchers) Appear on television and receive Gallileo Prize from Pro7 TV channel Prize: a new Toyota Prius ++ Inter- esting info on Year of Technology 2004 from Federal Ministry for Education and Research at www.bmbf.de and www.jahr-der-technik.de Reports, events and brochures on all aspects of technology and the future ++ Product spotlight ..................... 28+29 UE 440/470 safety controllers: flexible, compact and reliable......... 30 New W 190L series of laser photoelectric switches ..................... 31 SICK IVP innovative cameras for industrial image processing ........... 32 The IN 4000 safety system switches on metal ......................... 33 The KT 3 Laser compact contrast scanner ........................... 34 The IT 3810 hand-held scanner: bar codes in focus........... 34 The DKS 40 incremental encoder the compact and robust cost-cutter.......................... 35 UM 18 when space is limited ...... 35 Reliable image processing on press brakes.................................. 36 The KT 5 contrast scanner display: a straight back for comfortable use............................. 37 The ELG 1 short range the reason- ably priced automation light grid..... 38 Automatic counting of persons with LD PeCo ................................. 38 DT 500/DS 500 distance scanners offer long range and great accuracy 39 LD PDS protects valuables and prevents vandalism.................. 40 Large-format colour detection with the CVS 1............................... 41 SICK supports standardised teach-in 42 Parameterisation and diagnosis via Bluetooth................................. 42 Autoworld in Brussels.................... 43 Company founded in Turkey............ 44 DeviceNet Safety on the march....... 44 ecatalog.sick.com...........................45 10 years SICK Hong Kong............. 45 Eat that frog ............................. 46 Imprint/Service ............................. 47 Trade fair dates ............................. 47 ................................................... 03 Valo validates vertical S 3000 Standard............................ 06 S 3000 double safety for travelling production gantry............ 07 S 3000 Vertical protective field for safety on wafer robots.............. 07 Encoders in blue kit regulate knitting machines.......................... 08 Phoenix commissioning rises from the ashes ...................... 09 Safer punching machines with greater productivity........................ 09 The DRS 60 encoder: printing and packaging in tandem................ 10 SICK sensors dominate at Hansen Transmissions .................. 11 Perfect positioning with the SRM 50 motor feedback system ................. 12 Staying on the go with the driverless metro............................ 13 LMS 400 top pot-picking ............. 14 Whether cheese sticks or contact lenses into the box with them...... 15 Machine safety with ATEX light curtains................................. 16 Coca Cola Beverages Polska checks with the CM 30.................. 17 Protective field zapping with the DME 5000 ...................... 17 On the right path with illuminated guidance ....................................... 18 Stationary and mobile bar code read- ers control recycling process.......... 19 SICK sensors control automatic egg labelling.................. 20 Seamless identification of sutures 21 The ATM 60 absolute encoder: the robust solution for a harsh environment .................................. 22 LMS 200 laser measurement systems detect projecting car parts 23 DT 500 laying it on the line for mattresses............................ 24 WL 2S handles auto-filling shelves.. 24 Device and product safety legislation (GPSG) clears up uncertainties........ 25 In conversation with Dr. Werner Jansen of the BGFE....................... 26 SICK insight 2/2004 04 Contents Book corner Products Standards Info 06 Curtains down! The S 3000 sets standards The ATM 60 absolute encoder: the robust solution for harsh conditions The V 4000 Press Brake optimises safety and processes 22 SICK insight in conversation with Dr. Werner Jansen of the BGFE 26 36 Interview Museum Applications SICK Tour Editorial Know-how SICK insight 2/2004 05 News in brief insightBOOK CORNER Brian Tracy Eat that frog Eat a frog? Not particularly appetising at first glance. Whats it all about? Is this a book offering advice on unusu- al delicacies? The puzzle is solved on Page 46. Corn fields as far as the eye can see. But theres no 500-tonne monster of a combine harvester in sight. Just a small, smart, high-tech robot with an LMS Laser Measurement System for navigation. The agBot (agricultural robot) was developed at the University of Illinois, USA. As industrious as an ant, it works through fields row by row, and will soon be used for weeding, watching out for harmful insects and taking soil sam- ples. Its LMS Laser Measurement Sys- tem ensures that the agBot stays strict- ly on path, doesnt run anything over and, at the end of the field, easily Free download service from SICK Laser classes: greater clarity for users Those who produce or distribute laser sensors or other devices with point-form- ing light sources must comply with standards such as IEC 60825 or EN 60826. But users must also observe other regulations. In Germany these principally include the Trade Associa- tions BGV B2 regulation and its BGI 832 information sheet. Both works, however, not only refer to more detailed sub-divisions within the individual laser classes, but also include a range of secondary content. For users this raises the concrete question: What is of relevance to me, and what do I re- ally have to comply with? The comprehensive, practical de- scriptions and graphic explanations in the article Laser classes and their ap- plication for users of laser devices pro- vide answers to questions on all aspects of the classification and use of lasers. It is available at www.sick.de/infopool as a free download. Current trade fair info: From 2325 November in Nuremberg... ... as usual, SICK is offering an overview of its product range at this years SPS/IPC/DRIVES. We are looking for- ward to your visit at Stand 7-370 in Hall 7 See our special trade fair page at: www.sick.de/sps2004 General information direct from the organisers at: www.mesago.de From 610 December in Paris... ... the biennial international ELEC fair: with a new design, and integrating MESUCORA for the first time. Drop in and visit us at Stand 13k4 in Hall 6 Further information on the trade fair at: www.eleclive.com A-MAIZE-ing achievement from the land of unlimited opportunity Watchful robots tend cornfields moves into the next aisle between the plants with two elegant 90 turns. The ultimate goal will be to check plants in- dividually and perhaps protect them from pests by precision-spitting pesti- cides where necessary. Our farm robot only costs US$ 7,000, agricultural en- gineer Tony Grift is proud of the elec- tronic farm helper that is very reason- ably priced despite its high level of technological sophistication. LMS in agriculture another task CORNered! www.gizmodo.com, search for: agbots INFO 201 SICK insight 2/2004 Title topic: The vertical protective field of the S 3000 safety laser scanner 06 Applications When unhindered machine access is essential Valo validates vertical S 3000 Standard The French automotive supplier Valo has validated the S 3000 Stan- dard safety laser scanner for vertical machine protection in several ap- plications at their La Suze sur Sarthe works. Apart from its Safety Category 3 according to EN 954-1, the possibility of unhindered ma- chine access for operators was the decisive argument. insightLINK You can obtain further product informa- tion with the attached card under: INFO 202 or on the Internet at: www.sick.de/S3000 More about the customer: www.valeo.com Vertical machine protection with the non-contact electro-sensitive S 3000 safety laser scanner at Valo in France T I T L E
T O P I C >> With sales of over EUR 9 bn. and more than 68,000 employees at almost 130 production sites in 26 countries, Valo is one of the leaders in the auto- motive supplier market. The product programme split into ten application- specific divisions enjoys a high-tech reputation. Correspondingly, production at the various sites not only exploits the latest production technologies, but also utilises safety technology of the highest standards. Manual handling of parts requires free access The machines protected with the S 3000 at Valo require the manual in- sertion and removal of workpieces. This immediately ruled out a mechani- cal protective system, reports Thierry Pouchol of SICK France, who provided support for the project. The S 3000 non-contact safety laser scanner simul- taneously safeguards the work area and raises machine performance. The first choice for vertical use thanks to contour monitoring Response time: 60 ms, resolution: 30 mm, protective field height: about 2 m, with 450 mm distance to the haz- ardous machine area these are the facts of the application at Valo. In prac- tice, this task was only soluble because the S 3000 had the necessary auxiliary contour as reference function. With- out this it would have been impossible to gain certification for vertical use in compliance with EN 61496-3. The scan- ner exploits this function to reliably de- tect when a protective field edge, in this case the floor of the hall, changes its relative position to the scanner. This re- liably detects any mechanical misalign- ment of the scanner, and thus any un- guarded access to the hazardous area. The device immediately switches off the protected plant if the actual contour de- viates from the reference contour be- cause of any re-alignment of the sensor in its supporting bracket. Thus the S 3000 offers Valo and other users a currently unique, real lead in vertical machine protection. SICK insight 2/2004 07 Applications Wing production for the Airbus A380 S 3000 double safety for travelling production gantry >> The plants produced by the Spanish company M. Torres join carbon fibre tape together, layer for layer, for the production of wings and other compo- nents of the Airbus A380. As a result of the size of the wings they are, after Only the S 3000 could do it Vertical protective field for safety on wafer robots With its reliable view from above, an S 3000 Standard protects the operators of a wafer-polishing plant from reaching into the workspace of the handling robot. Only the S 3000 could solve this task because it is the only safety scanner of its type to be approved for vertical pro- tection. all, 40 m long the processing tool travels over the aeroplane part under production by means of a gantry. Four S 3000s for the drive path Two S 3000 laser scanners per direc- tion of transport ensure that no per- sons or objects are present on the tracks along which the gantry moves. An automatic switching of the two scan- ner pairs takes place to match the di- rection of gantry movement. Four S 3000s for the production zone Employees put down layers of the car- bon fibre tape while the gantry is in mo- tion. The application tool on the gantry then applies a glue-like material to join the individual carbon fibre tape layers together. Four further S 3000s form an invisible protective barrier around the tools operating area in order to protect workers. Eight S 3000s for the Airbus A380 not an everyday application. >> Peter Wolters Surface Technologies GmbH & Co. KG in Rendsburg, one of the leading producers of highly accurate fine- smoothing and polishing machine tool systems, was looking for a reliable solu- tion that prevented operators reaching into the robots workspace during opera- tion but did not hinder access to the dou- ble-sided wafer polishing plant. The S 3000 Standard was best suited for the machine conditions. The device is in- stalled on the upper section of the ma- chine framework with a sufficient safety distance. With its resolution of 30 mm the scanner instantly detects if a hand reaches into the machine. The haz- ardous movement of the robot in the pol- ishing plant is then immediately halted. Vertical monitoring with the S 3000 the perpendicular safety solution. insightLINK You can obtain further product informa- tion with the attached card under: INFO 202 or on the Internet at: www.sick.de/S3000 More about the customer: www.peter-wolters.com insightLINK You can obtain further product informa- tion with the attached card under: INFO 202 or on the Internet at: www.sick.de/S3000 More about the customer: www.mtorres.es T I T L E
T O P I C Polishing plant protected with the S 3000 Eight safety laser scanners in use on a production gantry for Airbus components in Spain S 3000 safety laser scanners not only monitor the 50 m long and 11 m wide path of a giant production gantry for Airbus components they al- so protect employees who are working below the gantry. SICK insight 2/2004 Incremental encoders in automated machines for warp-knitted fabrics at Karl Mayer 08 Applications For jerseys and lingerie Encoders in blue kit regulate knitting machines >> Almost any textile application, from the finest lace to materials for lingerie, girdles and sports clothing, from home textiles to carrier materials for reinforc- ing concrete, can be economically pro- duced with the computer-controlled high-performance automatic warp-knit- ting machines. Three areas of use one encoder type The driven components of HKS 2 warp- knitting machines (particularly suitable for producing heavy velour and lighter tulle net, as well as materials for jer- seys) are the machines main shaft, the roller system for output of the Automated machines for warp-knitted fabrics (otherwise known as tricot machines) are one of the main areas of production at Karl Mayers tex- tile machine works in Obertshausen, Germany. DGS 60 series incremen- tal encoders from SICK-STEGMANN detect the number of revolutions and the positions of various machine shafts rotating at speeds of up to 3,500 r.p.m. allowing nifty knitting process control by the computer. goods, the rolling-up attachment, and the two so-called warp beams with the reels of yarn. Although the power and the number of revolutions of the indi- vidual drives vary, the same version of the DGS 60 is used for each of them. This keeps purchasing and storage costs down to a minimum and simpli- fies rapid encoder replacement should it become necessary. The encoders cover three different functions on the machine. First they are used as the main encoder for the thread guide com- puter (as the machines control system is called) on the machines main shaft rotating at speeds of up to 3,500 r.p.m. The second function is regulating the number of revolutions in connection with the drive amplifiers. The DGS 60s third task on the warp- knitting machines is to regulate posi- tion for process control by the thread guide computer. The circumferences of the warp beams reels of yarn de- crease as they are unwound from full to empty (known as beam travel in the trade). The thread guide computer cor- respondingly modifies the rate of drive revolutions up to 3,000 r.p.m. to en- sure constant, and thus error-free, ma- terial feed to the knitting process with minimum thread tensions. Encoders for the worlds quickest bathing suits The DGS 60 is also an important com- ponent of the worlds quickest warp- knitting machine (also developed by Karl Mayer) that produces material for bathing suits at record speeds far ex- ceeding 3,300 r.p.m. Nifty knitting processes with the DGS 60 encoder. insightLINK You can obtain further product informa- tion with the attached card under: INFO 203 or on the Internet at: www.sick.de/insight/en More about the customer: www.karlmayer.de Encoders detect the number of rotations and positions of rotating machine shafts on Karl Mayers high-performance automated machines for warp-knitted fabrics A variety of materials are produced on the warp-knitting machines SICK insight 2/2004 Bar code scanners at Phoenix Pharma in the Czech Republic Safe punching machines 09 Applications insightLINK You can obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.mypin.cz and www.phoenix-ag.de Bildtext N E W S Protection and PSDI mode with the C 4000 Safer punching machines with greater productivity Customers of punching machine pro- ducer Busch in Seevetal, Germany, profit doubly from the use of C 4000 Standard safety light curtains on the machines: operators are reliably pro- tected against the risk of accidents, and PSDI mode increases machine performance by up to 30%. >> Labels, brochures, credit cards, childrens books and saving books are typical examples of punched products. Naturally, with sharp blades and punching pressures of 5.7 tonnes, safety is our top priority, says owner Burkhardt Busch. Non-contact moni- toring with C 4000 light curtains means that we can also offer our cus- tomers production advantages. Standard safety with additional advantages Busch punching machines are equipped with the C 4000 Standard that has a protective field height of 300 mm and a resolution of 14 mm. The light curtains signals are evaluat- ed in the UE 402 switching unit. The advantage: in this way the machine can be operated in either single- or double- break mode. Thus there is neither a mechanical barrier to be opened and closed on insertion or removal of the goods to be punched, nor does the punching process require manual initia- tion. This simplest possible handling saves a lot of time and therefore short- ens the machine cycle. Compared to using mechanical protection, machine productivity has been increased by up to 30% thanks to the C 4000 Standard and the possibility of employing PSDI mode, confirms Burkhardt Busch. www.buschgraph.de SICK scanners at the Czech Republics largest pharmaceutical distributor Phoenix: commissioning rises from the ashes >> More than two dozen CLV 420 bar- code scanners have started work at a recently equipped first depot. With the help of CDB 420 connection boxes, a SICK-CAN scanner network was cre- ated without any major installation problems and connected to the host computer via Profibus. A CMC 400 Con- nection Module Cloning was also inte- grated in each connection box. Pharma commissioning without side effects The new commissioning processes at Phoenix prevent the side effects of manual data handling such as delays, lack of transparency or spurious com- missioning. Each order is stored on computer and printed out on a card placed inside the commissioning boxes, which are also externally labelled with a permanent bar code. CLV 420 scan- ners along the conveyor system read the bar code on the box and guide it to the first storage location for the goods. These are placed in the box. After ac- knowledgement, the box travels to the storage location for the next article. When the order has been completely processed, the box is transported to the despatch area. Online transmis- sion of scanner data within the network ensures optimum synchronisation of material and information flow. New commissioning processes at Phoenix Pharma controlled by SICK scanner networks Light curtain on an automatic punch- ing machine Clonable parameter sets min- imise parameterisation These plug-in memory modules store all the inheritance information of the connected bar code scanner. Thus new scanners can be cloned by back-transfer as often as required. This allows individual devices to be ex- changed very rapidly and without extra parameterisation costs. Phoenix, the Czech Republics top pharmaceutical distributor, has completely revamped commissioning at its nationwide distribution centres with SICK scanner networks. The old documentation lies in ashes (so to speak) and, in its place, bar codes and Profibus have given Phoenix flight. Substantial time-savings and fewer rejects with the DRS 60 incremental encoder Simple electronic zero-impulse alloca- tion at the touch of a button SICK insight 2/2004 British printing system with CoreTech series incremental encoders 10 Applications >> An increasing number of cigarette manufacturers have relocated their ad- vertising messages to the inside of the pack since the introduction of legisla- tion stipulating that warnings about the risks of smoking must be prominently displayed on the outside. The text must be accurately positioned as the area available for printing is relatively small. As a result, printing and cutting sys- tems for the inner frames of packs must be synchronised with extreme precision. ACCU-PAC has it down to a turn ACCU-PAC, produced by Britains Indus- trial Automation Systems, is a registra- tion system which can be retrofitted to any make of cigarette packaging ma- chine. ACCU-PAC registration systems have been designed as a retro-fit kit to Those who use DRS 60 incremental encoders, from the CoreTech se- ries, in their printing and packaging systems can reduce the time re- quired for zero-pulse adjustment by 90%. Instead of an intuitive co-ordination of devices as is necessary with conventional encoders pressing a button suffices with the DRS 60. register film, tear tape, inner foil or in- ner frame, all components of the fin- ished cigarette packet. But how can one synchronise the cutting and regis- tration systems? How does the regis- tration system know the knife cut posi- tion? The encoder zero pulse triggers at the cut position, reports Peter Evans of Industrial Automation Sys- tems. It used to be necessary to ad- just an estimated offset, based on where the cut occurred, to synchronise the registration and cutting systems after the encoder had been fitted. This offset was entered into the system and the machine operated again. The process was repeated until synchroni- sation had been achieved. This method was far from ideal in a modern au- tomation environment. It can be done more intelligently with the DRS 60. insightLINK You can obtain further product informa- tion with the attached card under: INFO 204 or on the Internet at: www.sick.de/insight/en More about the customer: www.accupac.co.uk Pressing a button in the device is suffi- cient to electronically assign a me- chanical reference point to the zero pulse. Incredible savings potential achieved What used to take up to 20 minutes can now be completed in two minutes at most, reports Peter Evans. Re- move the cover, press the button and off you go its as easy as that. And one doesnt have to reject up to 50 packs like before; at most just one or two. So its no wonder that the DRS 60 is not only now standard equipment for Industrial Automation Systems, but has also been retrofitted to many ma- chines that have already been deliv- ered worldwide. Zero-pulse adjustment (teach-in) by button The DRS 60 encoder: printing and packaging in tandem SICK insight 2/2004 SICK sensors in automatic pallet warehouse at Egemin in Belgium 11 Applications Single-source automation of three pallet warehouses SICK sensors dominate at Hansen Transmissions >> Hansen Transmissions produces components and drives for wind-driven power stations, among other things, at the new factory in Lommel. Of deci- sive importance in choosing SICK was that Egemin, as system integrator for the most varied of tasks, can always offer the most suitable, technologically high-quality sensor solutions from a single source. Detection and measurement WL 27 series photoelectric reflex switches detect pallets and transport Egemin, one of Belgiums leading system integrators of automation and safety technology, has equipped three new warehouses in Lommel for machine and drive constructor Hansen Transmissions entirely with SICK sensors. containers at a wide variety of points in the material flow. Long range, simple commissioning and reliable operation characterise these devices. Elsewhere in the warehouses and production area it is important to reliably detect per- sons, not pallets, to prevent the risk of accidents. M 2000 multi-beam photo- electric safety switch here meet all the demands. Their particular advantage: the machines to be protected are di- rectly accessible for maintenance work or equipping purposes, for example. The MLG automation light grid handles measurement functions at Hansen Transmissions. Checking for projec- tions and overheights, as well as in- specting pallets for damage, are the principal areas of use. As these tasks were already known about when the systems were ordered, the MLG units could be pre-parameterised in advance at SICKs works and were therefore im- mediately ready for use. Identification and communication Which pallet is where on the conveyor system, and its intended destination, is determined by CLV 410 and CLV 420 se- ries stationary bar code scanners. Com- pact and easy to install, with a reading distance of up to 400 mm and a rapid frequency of 1.2 kHz, these are the right devices in the right place. Finally, ISD da- ta-transmission photoelectric switches handles online communication between the storage and retrieval devices and the appropriate aisle or plant control systems at the three pallet warehouses. Rapid installation of the ISD, with me- chanical, optical and electronic adjust- ment aids, soon got storage and re- trieval devices ready for operation. The all-round sensor package that Egemin has assembled with SICK products has proved to be an all-round trouble-free package at Hansen Trans- missions. insightLINK You can obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.egemin.com and www.hansentransmissions.com Bildtext Bildtext Bildtext Bildtext Left: Equipped with SICK sensors by Egemin: the new automated pallet warehouse Top: Safe maintenance work with M 2000 multi-beam photoelectric safety switch Losing weight with the TPM: The weight of this robot from SIG Pack Systems could be reduced from 130 kg to 46 kg by using innovative TPM servo actuators. SICK insight 2/2004 Motor feedback systems in geared motors at WITTENSTEIN AG 12 Applications For compact, light and highly dynamic TPM servo actuators Perfect positioning with the SRM 50 motor feedback system Unique dynamism, extremely compact housings and high rigidity char- acterise the new TPM series of geared motors, so-called servo actua- tors, from WITTENSTEIN Motion Control GmbH. Further advantages, in- cluding automatic parameterisation of the control system, precise posi- tioning and a high level of user-friendliness are provided by the integrated SRM 50 motor feedback system from SICK-STEGMANN. >> High-tech machine constructor, top employer and a trend-setter in drive technology are phrases often used by the specialist and business press to describe WITTENSTEIN AG. So it is no surprise that the Igersheimer- based group of companies, with its 800 employees, achieves double-digit annual growth rates, reinvests 10% of its profits in research and develop- ment, has a training ratio of 11% and personnel with an average age of 34. 85% of WITTENSTEIN products sold are less than five years old, Siegfried Wallauer, Product Manager responsible for the TPM series, underlines the in- novative strength of all Group mem- bers. The best example of this is the highly developed series of servo actua- tors developed by WITTENSTEIN Motion Control. The compact SRM 50 motor feedback system has made a consider- able contribution towards motor sizes that offer substantial space savings. TPM compact combination of gears and motor The TPM is a rotary actuator consisting of an AC servomotor and a low clear- ance, precision planetary gear. One of the special features of the TPM is its short length, explains Siegfried Wallauer. Thanks to its integrated design, the smallest TPM is just 113 mm long thats 50% smaller than conventional motor/gear combi- nations. And it weighs considerably less too. Further features are its ac- celeration of up to 100,000 1/s 2 , achieved with state-of-the-art motor technology, and its high gear rigidity that permits optimum control. N E W S SICK insight 2/2004 The driverless metro in Denmark 13 Applications Easy riding in Copenhagen thanks to LMS Staying on the go with the driverless metro >> The LMS units are an important component of the obstacle detection system (ODS). All objects larger than 450 x 450 x 450 mm 3 are detected by one of the six scanners at each station and evaluated by the ODS, then a sig- nal is transmitted to the automatic traf- fic alarm control system (ATC). Great safety reserves The projects safety planning was ex- cellent. The entire system structure (in- cluding the sensors) is designed with redundancy. Each metro station has its own warning and visualisation system. The scanners themselves are designed for outdoor use and programmed in such a way that spurious signals are re- liably prevented. All in all, the entire system has a mean time between fail- ure (MTBF) of 115 years according to the system integrator. So its easy riding in Copenhagen: sta- tistically speaking, the first system breakdown can be expected in 2119. Not only is the metro new for Copenhagen, but also its driverless con- cept. The central control system and the metros complete automation could not be completed until laser measurement systems were in place at each station to provide warnings about objects on the tracks. insightLINK You can obtain further product informa- tion with the attached card under: INFO 205 or on the Internet at: www.sick.de/insight/en More about the customer: www.wittenstein.de and www.sigpacksystems.com New metro system in Copenhagen with the obstacle detection system The SRM 50: communication, precision and ease of use in all TPM applications The TPM is ideally suited for use, for example, as a drive for compressing hy- giene articles in packaging; in automat- ic feed systems for wood processing machines and machine tools; as a drive for dosing pumps; as an axle drive on spraying robots (theres an Ex- protected TPM version for use here); or as a part-turn valve actuator in plants for producing optical media and semi- conductors. Whatever the application, the SRM 50 Multiturn motor feedback system integrated in every TPM unit ensures bi-directional communication between the drive and the plant control system via its standardised Hiperface interface. Information on commutation and rotor position is transmitted as ab- solute values when the TPM is switched on, thereafter counting con- tinues incrementally via sine/cosine signals. In this regard, the EEPROM offers important advantages as a so- called electronic type label in the SRM 50, Siegfried Wallauer mentions the devices integrated control system parameterisation. Gear and motor characteristics, and commissioning data, can be stored here and used for autonomous setting of TPM parame- ters. Programming data for the motor feedback system, such as resolution or a shift in zero position, can be stored in a different EEPROM memory area and called up from there. This feature of the integrated motor feedback system (which has been test- ed and approved by WITTENSTEIN for connection to more than 20 different control systems) provides easy and reliable commissioning of the TPM. The TPM can also fully exploit the SRM 50s resolution of more than 134 m. increments and its high preci- sion of less than 1 minute of angle. insightLINK You can obtain further product informa- tion with the attached card under: INFO 206 or on the Internet at: www.sick.de/insight/en More about the customer: www.m.dk The measurement system (above), installed at a height of 2.7 m, moves over pots and pans stacked up to 1.6 m (below) SICK insight 2/2004 Three-dimensional object detection at WMF with the LMS 400 laser measurement system 14 Applications For high-precision pick & place LMS 400 top pot-picking Precise object detection in three dimensions is the great strength of the LMS 400 laser measurement system. Automatic pick & place robots, in particular, profit from this because parts of different sizes can now be gripped in mixed operation, e.g. pots and pans of differing diameters at WMF AG. >> Cutlery, tableware, cutting devices, coffee machines, as well as pots and pans from WMF AG, based in Geis- linger, are greatly appreciated by housewives, amateur cooks and pro- fessional chefs. The high quality requirements are reflected in the mod- ern production sites. Thus WMF has re- cently started using the LMS 400 for three-dimensional visual guidance of robots during the production of pots and pans. The robot must reliably move pots and pans with varying heights, differing diameters and optically dissimilar appearance, on and off pallets. The LMS 400 allows this without the need to adapt robot programs, mechanical components or control system software. The new view of the robots visual guidance system The LMS 400 offers visible advantages in pick & place applications. Only iden- tical goods could be transported in the past to ensure the precise position- ing required by the robot. The third object dimension and gripping point of each object was known. This is now no longer necessary because the LMS 400 provides data with which all the necessary robot information is pro- vided rapidly and accurately. This not only convinced end-user WMF, but also those responsible at robot integrator Komatec. At WMF the measurement system, installed 2.7 m above the ground, moves over the stack of pots (that can reach heights of up to 1.6 m) measuring each pot with 0.1 resolu- tion and a scanning rate of 500 scans per second. A major advantage over solutions based on camera systems is that ambient light and reflections do not interfere with the measurement process. All the positional and distance information required for targeted and reliable robot activity is provided within milliseconds thanks to rapid evaluation. Rapid, precise and flexible, the LMS 400 sets new standards in 3-D object detection. insightLINK You can obtain further product informa- tion with the attached card under: INFO 207 or on the Internet at: www.sick.de/insight/en More about the customer: www.wmf.com and www.komatec.de SICK insight 2/2004 Safe sensors on high-speed packaging machines in the Netherlands 15 Applications >> Langenpac mainly produces pack- aging machines for cakes and biscuits (e.g. cheese sticks), dry food, tissues, and industrial non-food products such as film spools, batteries and lamps. These are all mass-produced articles that require high throughput capacities during packaging and cartoning, says Pieter van Summeren, Manager of Elec- trical Engineering at Langepac. And we are particularly strong here. SICK sensors ensure rapid and in- telligent system solutions The tasks that Langenpac machines handle differ in complexity. The vertical cartoning machine for cheese sticks fills sales trays at high speed. Type WT 12-2 photoelectric proximity switch- es, mechanically robust sensors with a rapid switching frequency of 1.5 KHz, monitor the continuous flow of sales packaging. A special high-speed pack- aging machine for 200 boxes per minute was constructed for a producer of tissues. The requirements of a con- tact lens producer were complex: apart from the pure packing function, this al- so involved coding and sorting accord- ing to lens strength, sell-by date and batch number. SICK scanners are first-class here, confirms Pieter van Summeren. Finally, a really futuristic cartoning machine for food products was developed with the Canadian com- pany Langen. The machine is charac- terised by a high speed and a wide range of formats. In addition to a vari- ety of detection functions, safety tech- nology here reliably protects machine operators. insightLINK You can obtain further product informa- tion on the Internet at: www.sick.de/insight/en More about the customer: www.langenpac.com Monitoring gap-free feed of sales packaging with the WT 12-2 photoelectric proximity switch High-speed packaging machines and cartoning equipment are staples for Dutch producer Langenpac. Capacities of 450 and more boxes per minute require reliably functioning sensors. Thus safety systems, bar- code readers and photoelectric switches from SICK (e.g. the W 12-2) have become standards at Langenpac. SICK is standard Whether cheese sticks or contact lenses into the box with them ATEX package offers reasonably priced retrofitting Certification of the C 4000 for cate- gories 3G (G = gas) and 3D (D = dust) has been obtained in compliance with the demands of the ATEX directive for protection by mechanical safety meas- ures. This applies for a variety of protective field heights, as well as all possible resolutions or single-beam separation distances. Even the nor- mal C 4000 fulfils many of the ATEX requirements among other things, the front screens of the transmitter and receiver are made of shockproof polycarbonate. The ATEX package nec- essary to provide the remaining supplementary safety measures basi- cally consists of end caps for the housing (which protect the connection areas from dust in a non-connected state), and the ATEX plate to be at- tached to the device. This ATEX up- grade offers plant planners high levels of flexibility and safety. They can locate individual C 4000 units accord- ing to the demands to be met in situ, and the systems can then be rapidly and extremely cost-effectively supple- mented with the ATEX package when necessary. SICK sensors also for 2G and 2D In addition to the C 4000 in its various versions for 3G and 3D applications, safety light curtains are also available as electro-sensitive protective devices for Category 2G. Their certification for 2D is also in preparation, as is ap- proval of a multi-beam photoelectric safety switch for 2G and 2D. Moreover the W 24 Exi series of 2G-certified pho- toelectric switches is available for gen- eral object detection tasks in automa- tion technology. ATEX light curtains safe and cost-ef- fective solutions for the Ex-Zone. SICK insight 2/2004 Safety light curtains on spraying plants at BMWs Regensburg works 16 Applications Machine safety with ATEX light curtains EXcellent solutions >> This electro-sensitive protective equipment (ESPE) can be used in Zones 2 and 22 according to directive 94/9/EG (ATEX). Application examples include filter presses in sewage plants; printing machines; filling plants in the chemical and food industries and spraying lines in the automobile indus- try. This is where BMWs Regensburg works has installed numerous ATEX- conforming C 4000 light curtains in a co-operation with spraying plant pro- ducer Drr Systems. insightLINK You can obtain further product informa- tion with the attached card under: INFO 208 or on the Internet at: www.sick.de/insight/en More about the customer www.bmw.com and www.durr.com Standard and Advanced: C 4000 ATEX with graduated functionalities The safety light curtains of the C 4000 series are used for protecting hazardous points of operation on machines and plants. They all comply with EN 61496, Type 4 as well as IEC 61508, SIL 3. The Standard and Advanced device ver- sions are designed to meet different levels of automation and functional re- quirements. The Standard version is available with, among other features, ranges of up to 19 m, resolutions of 14 mm, 20 mm, 30 mm or 40 mm, and protective field heights of between 300 mm and 1,800 mm. Compared to the Standard version, the C 4000 Advanced offers a variety of additional functions that can, for example, reliably differentiate between workpieces that temporari- ly jut into the protective field (for process-related reasons) and a finger or arm. With the new C 4000 ATEX series of safety light curtains it is now also possible to prevent persons from reaching into the hazardous areas of machines during operation in which sporadic or temporary potentially explosive mixtures of gases or non-conducting dust can occur. The C 4000 safety light curtain for ATEX applications in Zone 2 for gas, and in Zone 22 with a connector end cap for dust. N E W S SICK insight 2/2004 Counting bottles with capacitive sensors Distance measurement system 17 Applications Bottle present, cap on? Coca Cola Beverages Polska checks with the CM 30 >> After filling, the bottles are com- bined into multi-packs with the help of shrink foil. Then its straight onto the pallets and off to the shops. It is, of course, annoying if packs arriving there are missing a bottle or have overflowed. So Coca Cola Beverages Polska wanted to ensure that every pack was complete and that every bottle was in perfect condition. Four in a row per line For this purpose, Coca Cola Beverages Polska engineers installed four CM 30 capacitive sensors next to one another above every transport line. Are all the bottles behind the shrink foil, and does each bottle have a cap? CM 30 capacitive sensors at two Coca Cola Beverages Polska works put the in order ticks on the checklist. The plastic housing of the CM 30 is ev- idence of their IP 67 enclosure rating, so repeated cleaning work on the machines cannot affect them. Sensitiv- ity and the switching distance are set on the sensors themselves. As soon as the multi-pack, held together by the foil, passes through the sensor gate, a CM 30 detects the absence of a bottle or a cap by means of the constant ca- pacity of its condenser. Such packs are immediately diverted out of the flow. If, however, the capacity of the CM 30 changes in accordance with the defined value,the pack is in order and can be palleted. Make it clear with the CM 30. insightLINK You can obtain further information about the product on page 29. More about the customer: www.cocacola.com Always active in the right direction Protective field zapping with the DME 5000 >> Protective field switching was origi- nally triggered by initiators at least that was what was supposed to hap- pen. But other operations in the area, and above all stacker traffic, kept de- Paper rolls, weighing up to five tonnes, are transported on a rail-mount- ed transport vehicle at Nordland Papier in Drpen. PLS laser scanners monitor both directions of movement. Two DME distance measuring de- vices activate the PLS protective fields according to their position. stroying the initiators switching flags glued to the floor of the hall. The result: switching proved impossible. Robust and precise the DME 5000 Two DME 5000 laser distance measur- ing devices recently installed on the transport vehicle manage far better. During transport, the two sensors (re- dundant for the particular direction of transport) continuously measure the time-of-flight of their transmitted light pulses to the end of the drive path and back. The electronics determine the position of the transport vehicle from these measurements and transmit this information to the vehicle PLC via Profibus. The data is processed here and the appropriate binary signals are generated. These are passed on to the LSI, that activates switching of the PLS protective field. This solution has proved very robust and reliable during operation this is hardly surprising when one considers that the DME 5000 was specially developed for distance measurement and position determination in conveyor systems and warehouses. And it has an extraordi- narily high measurement accuracy of +/2 mm with a reproducibility of 0.5 mm, whereby an up-to-date meas- urement value is transmitted every mil- lisecond more precise distance measurement is hardly possible in such applications. Precision in any position the DME 5000 is the right choice for dis- tance measurement in automatic small-parts stores, for vehicle position- ing, and for crane distancing. insightLINK You can obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.nordlandpapier.de Transport line with four capacitive sensors Distance measurement devices on trans- port vehicles insightLINK You can obtain further product informa- tion with the attached card under: INFO 209 or on the Internet at: www.sick.de/insight/en SICK insight 2/2004 The solution: the LUT luminescence scanner for detecting guidance paths 18 Applications Flexible when destinations change On the right path with illuminated guidance >> Unlike expensive inductive guid- ance, or complicated optical naviga- tion systems, this is a reasonably priced flexible solution for free-moving and self-positioning industrial trucks. Follow that light Whether adhesive tape or paint lu- minophores are available in a wide va- Whether in production plants for large-scale machines and systems, or during storage and logistical transport movements within works there are individual cases where the destinations of free-moving industrial trucks are only temporary or used during a specific project, and are therefore often subject to change. In such cases, following removable fluorescent guidance paths with LUT luminescence scanners has proved highly effective. riety of media. They are invisible to the human eye but light up as soon as they are excited by high-wavelength light. LUT luminescence scanners both stimulate luminophores and detect them. The vehicle reliably follows the detected light on the basis of digital signals transmitted to the control sys- tem. Sensor solution for transport systems with heavy loads The leading manufacturer of transform- ers uses so-called air-cushion trans- port systems in its production, inspec- tion and dispatch areas, with loads that at times exceed 500 tonnes. De- pending on the size and type of trans- formers, different transport destina- tions must occasionally be reached via differing routes. Shorter journeys across the works grounds are also an everyday occurrence. The use of fluo- rescent guidance paths together with luminescence scanners provides trans- port systems with the maximum possi- ble degree of freedom, and thus maxi- mum applicability. Thus guidance paths can be individually set up in the inspec- tion area, for example. If narrow areas must be approached, or the vehicle re- quires exact positioning, this is achieved with millimetre accuracy thanks to the devices precise detec- tion of the guidance path. Other sectors also face situations similar to those found during internal works transportation in transformer construction. These include furnace and tank construction; the production of modules for commissioning shelves; rolling stock construction and the pro- duction of diesel and ships engines; the production and assembly of air- craft; or the transport of large-scale tools and machines for metal process- ing. The LUT for detecting guidance paths the flexible and cost-effective solution. Suitable for free-moving industrial trucks with changing destinations: the LUT lu- minescence scanner SICK insight 2/2004 Identification with hand-held and bar code scanners at Swedish recycling works 19 Applications A clean solution for a clean environment Stationary and mobile bar code readers control recycling process >> The works a joint venture between Danish and Swedish companies went into operation in March 2004. It is de- signed for enormous recycling volumes an estimated annual volume of 6,500 trucks loaded with cans and bottles. Whereby cartons with counted amounts of cans and PET bottles, and sacks with uncounted contents from gastronomic sources must be identi- fied, explains Claes Johansson, Man- aging Director of the company Styrlog- ic, which solved the control and identi- fication tasks in the project. Ultima- tely, every customer wants to get their deposits back. Stationary scanners for special containers A special disposable carton, suitable for Europallets, has been developed in order to permit consistent automatic handling inside and outside the factory. A counted number of aluminium cans and PET bottles are delivered within them from the trade. Each carton is Every year, 250 million PET bottles and 850 million aluminium cans are prepared for recycling at Returpacks new recycling works in Norr- kping, Sweden. CLV 450 stationary bar code readers and IT 3870 data-radio scanners identify the incoming consolidated packages in or- der to ensure smooth processing of the financial deposit on the goods. identified by stationary CLV 450 scan- ners, with inductive encoders, checked for its content (aluminium or plastic) and then pushed onto the appropriate conveyor belt to the next process step. The great strength of the CLV 450, says Claes Johansson, is that the de- vices can also reliably read poor-quality bar codes, because not every carton is in a good condition when it arrives at the works from the dealers. Mobile solution for the uncounted material for recycling Returpack receives cans and PET bot- tles from gastronomy and other sources in plastic sacks, for which no individual automated counting can take place. These sacks are distributed to 15 manned stations at the factory. Each sack is identified online with the help of IT 3870 hand-held scanners be- fore its contents are emptied into large bins for counting and further transport. Whats practical about the mobile scanners argues Claes Johansson, is that they offer great freedom of movement after all, the area covered by data radio is about 730 m 2 . Then there is the reading distance of about 0.5 m, which makes it possible to iden- tify the sacks ergonomically. By the way In addition to the scanners mentioned above, a large number of WL 250 pho- toelectric switches are installed along the edges of the conveyor system. insightLINK You can find obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.returpack.se Recycling countless PET bottles and aluminium cans at the new recycling works in Sweden The CLV 450 bar-code scanner The IT 3870 hand-held scanner SICK insight 2/2004 Egg labelling with a variety of SICK sensors 20 Applications Cracking the egg positioning problem SICK sensors control automatic egg labelling EU law stipulates that all class A* eggs must be labelled with a special identification code: a twelve-character producer code. So this is now required in Poland, a new EU member state, as the company Intrex has recognised. Those at Intrex have also recognised that SICK sensors crack the problem of detecting the position of eggs in the labelling system. >> The code on the premium goods should look like an extension of the egg shell. This places two demands on the automatic coding system: the egg must be detected before printing, and must be transported at the right speed during printing. R-egg-ular information Egg detection by light or more pre- cisely with the help of WLL 170 photo- electric fibre-optic switches or VTE 18 cylindrical photoelectric switches. The labelling system is thus reliably in- formed that there is again something there for labelling. L-egg-ibility assured The DRS 60 encoder co-ordinates the speed of egg rotation with the printing speed of the labelling system, thus achieving a cleanly applied and clearly legible print result. Simple adaptation to new b-egg-innings Both the photoelectric switches and the encoders are fit for any southward enlargement of the EU. The ranges of the WLL 170 and the VTE 18 can be adapted; the DRS 60 can be ordered Ex-Works with a variety of pulse num- bers for differing rotation speeds. Thus if Australia should ever join the EU, the labelling of premium ostrich eggs, in line with their new l-egg-islation, would actually not be any problem at all ... insightLINK You can find obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.intrex.pl * Eggs are divided into quality classes A and B. Retailers, however, only offer class A eggs. Class B eggs are second-quality eggs. They can only be delivered to spe- cially approved food companies or the non- food industry. New labelling obligation in the EU An important code for maintaining food quality: where is my breakfast egg from? From January 2004 no one egg is the same as another. Each egg must show where it originated and how the laying hen lives. A uniform code composed of numbers and letters informs consumers about the eggs country of origin, whether it was laid by a hen living outdoors, only on the ground, or in cages, and in which hen-house it was laid. Decoding the code The first two numbers show the type of living con- ditions under which the egg was laid. 0 is organ- ic production, 1 is for living outdoors, 2 is for liv- ing on the ground, 3 means that the hen lives in a cage. The letters are abbreviations for the coun- try of origin. Each egg receives a special ID code in line with EU legislation SICK insight 2/2004 2-D reading devices check medical products 21 Applications insightLINK You can obtain further product informa- tion with the attached card under: INFO 210 or on the Internet at: www.sick.de/insight/en More about the customer: www.ethicon.com Checking 2-D batch numbers with the ICR 850 data matrix reader Seamless identification of sutures >> Ethicon, a 100% subsidiary of the US Johnson & Johnson Group, employs about 2,100 personnel. Every year, in addition to 150 million surgical nee- dles, they also produce 130 m. metres of surgical sutures on the modern pro- duction plant thats three times the length of the Equator. Safety aspects, quality requirements, and the tracking of every production batch necessitate 100% checking of the sutures during the packaging process on the foil lines. Batch numbers in data matrix code During packing, the suture material is laid in a cavity a type of shell. Before the wrapper with the product in- formation is attached, ICR 850 units read the data matrix code on the prod- uct. The coding contains part of the batch number that is now compared with the current order code. If the two codes match, the wrapper with the product information is attached. This check ensures that any product mix-up on the packing line is detected in good time and reliably prevents use of the wrong wrapper. Matchcode, Profibus, visualisation The ICR 850 is not just a reliable solu- tion here, but also a particularly user- friendly one. For example, at the start of a packing order the appropriate or- der matchcode is automatically taught- in at the code reader the ICR 850 is thus promptly ready for operation with maximum flexibility. The devices are connected to the machine PLC via CDM 420 fieldbus gateways with Profibus. The use of this proven func- tional module ensures smooth data ex- change right from the start. During operation, a wide variety of ICR 850 read and process information is dis- played on an industrial PC. Teach-in, matchcodes, read codes, no reads, error messages and numerous evalua- tions can be read by the machine operator in situ. The ICR 850 the seamless identifi- cation solution that is not just for sur- gical suture material. ICR 850 data matrix readers at medical product manufacturer Ethicon, in Norderstedt, ensure that the wrappers match the products and that there are no product mix-ups. The ICR 850 2-D reader checks whether the product and wrappers match Use of numerous magnetic encoders in the pipe-straightening machine Pipes pass through roller segments SICK insight 2/2004 Pipe-straightening machines with absolute encoders in England 22 Applications Magnetic pick-up technology guarantees maximum reliability The ATM 60 absolute encoder: the robust solution for a harsh environment Bronx Taylor/Wilson, English producers of pipe straightening machines, insist on the ATM 60. Several hundred devices have been installed in re- cent years, and none of them have been harmed by the harsh operating conditions. straight it is necessary to process them further typical requirements are a straightness of just 1 mm deviation per 1,500 mm or even 3,000 mm to achieve these tolerances the pipe straightening machines from Bronx Tay- lor/Wilson are used. Pipe diameters of between 15 mm and 600 mm can be processed on them with insertion speeds of up to 3.3 m/s. The pipes pass through several roller segments whose pressure straightens the pipe. The task of the ATM 60 is to regulate the height of the rollers and their angle relative to the pipe. The encoders mul- titurn property is achieved by using several reducing gears with magnets mounted upon them. This enables the absolute position of the rollers to be detected as the drive mechanism moving the rollers turns through multi- ple rotations. Global encoder The highly robust nature of the ATM 60 is ideal for machines that are installed worldwide they prevent unnecessary complaints and service work. They re- liably withstand the impacts and vibra- tions, that go hand-in-hand with this process, for years 24 hours a day, seven days a week, year in and year out, says John Dunn. Moreover, the device also speaks a variety of lan- guages: the communication protocols for Interbus, Profibus DP, CanOpen, De- viceNet and SSI allow the standardised transfer of digital data to the worlds most important fieldbus systems for factory automation. The ATM 60 is the robust rotary meas- urement system for linear travels, an- gles, positions and pipes. insightLINK You can obtain further product informa- tion with the attached card under: INFO 211 or on the Internet at: www.sick.de/insight/en More about the customer: www.btwcorp.com >> Optical encoders have many posi- tive features, but are relatively sensi- tive to vibrations, shocks and impacts as a result of their glass code discs. Magnetic encoders, such as the ATM 60, are sensors whose permanent magnetic elements scan a magnetic scale, and are considerably more robust due to their principle of opera- tion. This was decisive for us, because each machine we manufac- ture is equipped with numerous encoders, says John Dunn, MD of Bronx Taylor/Wilson, a company active worldwide. Regulating heights and angles It is not possible to manufacture weld- ed or seamless pipes to tight toler- ances. If pipes need to be particularly SICK insight 2/2004 Automatic parking system with laser scanners at the Mvenpick Hotel in Berlin 23 Applications The facade of Berlins Mvenpick Hotel Laser scanners prevent damage during parking and retrieval insightLINK You can find obtain further product infor- mation on the Internet at: www.sick.de/insight/en More about the customer: www.woehr.de and www.moevenpick-hotels.com Automatic car park at Berlins Mvenpick Hotel LMS 200 laser measurement systems de- tect projecting car parts >> Berlins Mvenpick Hotel is located in the completely built-up area of a for- mer administration building. Technical reasons made it impossible to build a conventional underground car park. On the other hand, however, the hotel wanted to be able to offer the maxi- mum number of beds while allowing ho- tel guests easy access to their vehi- cles. Whr found the solution in the in- ner courtyard or rather below it. No loss of space through road access or paths According to calculations, the space below the inner courtyard was suffi- cient for the necessary 22 parking spaces but only if there were no road Car park system producer Whr has constructed an automatic car park for hotel guests below the inner courtyard of Berlins Mvenpick Hotel. LMS 200 laser measurement systems ensure that projecting vehicle parts are detected during automatic parking and retrieval to prevent damage. access or paths. For this reason the project was implemented with Whrs automatic Flurparker 570 (corridor parker) parking system. It offers space-saving parking with vehicles be- ing put on pallets and pushed into the parking level lengthways or laterally, de- pending on demand. A vertical convey- or joins the parking level to the sur- face. Safety for vehicles, ease-of-use for hotel guests Hotel guests see nothing of the work- ing behind the Flurparker 570. They use a parking chip to request an empty pallet, park the vehicle on it and off it goes into the depths of the car park. When the vehicle is removed there is no damage resulting from projecting parts because LMS 200 laser scan- ners checked the vehicle contour be- fore it was accepted by the vertical con- veyor. Hotel guests are provided with a message in clear text if the vehicle is incorrectly positioned on the pallet, or an aerial, a wing mirror or a bulky load exceeds the pallet dimensions. But it is not just the dialogue with the parking system that is user-friendly, but the system itself: on collection, integrated rotary equipment automatically makes the vehicle available in the correct di- rection for driving off! Berlin is also worth a visit for its parking technology thanks to the Flurparker 570 and the LMS units it employs. SICK insight 2/2004 Mattress production Swedish shelving system with miniature photoelectric switches 24 Applications Mini-sensor feeds the feeders WL 2S handles auto-filling shelves >> Whether milk, yoghurt, curd cheese or fruit juices its just plain annoying when the shelf is almost empty and one gets cold fingers from having to reach right into the back of the fridge to get an article out. Then some cus- tomers would prefer to take a better po- sitioned product from further forward. But now an economy of scarcity at the refrigerators is a thing of the past with the new generation of self-filling shelves. Small, light and easy to install The Swedish conveyor company Easy- Link AB has developed the new shelves. Particular emphasis was placed on a space-saving design, a low weight, and simple installation in the refrigerated shelves. The WL 2S mini- photoelectric switches exhibit the same preferences. This through-beam photoelectric switch offers a range of 1,000 mm sufficient for the width of the shelves. The housings, produced using extrusion technology, are ultra- light (only 20 g) as well as ultra-small, though they detect objects of almost any size. And they have an enclosure rating of IP 67 so the sensor has no problems when the shelves are cleaned. The WL 2S has its hands full in the shelves during opening times. The light beam of the WL 2S is inter- rupted as soon as a hand reaches out to remove a package from the shelf. A roller shelf floor, powered by com- pressed air, then moves the next pack- age to the front row after waiting about 5 seconds. Better presentation of goods, less time needed The shelves not only autonomously re- fill spaces with goods, they also full- fill the expectations placed upon them regarding product presentation and time-savings. Cautious estimates by re- tailers reckon that about 15 minutes of Off the shelf, onto the shelf with the auto-filling shelf system from Easy-Link AB, WL 2S mini-photoelectric switches detect each removal of goods and immediately initiate the filling process. Self-filling shelf system refilling time is saved per day and shelf. When adjusted for one month, and with an average total of 16 auto-fill- ing shelves per store, this adds up to almost 100 hours. WL 2S the sturdy solution for activat- ing the feed process for the feeders. insightLINK You can find obtain further product information on the Internet at: www.sick.de/insight/en More about the customer: www.easylink.se Dream machine solves nightmare DT 500 laying it on the line for mattresses >> Small or large pores in foam, mattress cores in all colours, scan- ning distances of between 500 mm and 1,600 mm, and reproducible accu- racy of just a few millimetres the DT 500 achieves, with dreamlike relia- bility, what is a nightmare for other po- sition sensors. Eurofoam, in Kremsmnster in Aus- tria, uses the DT 500 on a machine for gluing and then stacking foam mat- tresses. The foam itself has the most varied of properties, depending on how a customer wants to make their beds later. Sensors used in the past caused considerable problems with inaccurate mattress positioning in the machine. The DT 500 does better. Comfortable positioning easily achieved The DT 500 is a distance scanner with a particularly long range and high accu- racy. It generates a measurement value every 250 ms, and transmits it via a 420 mA analogue output or a se- rial RS-422 measurement data inter- face. For mattress positioning this means: comfortable positioning easily achieved. First, a mattress surface is glued onto the mattress core on one side. Then the machine turns the core. The DT 500 now ensures that the ro- tated mattress is correctly positioned and centred so that the mattress sur- face can be attached to the other side. The finished mattresses are then put in the mattress warehouse tidily stacked with the help of more position detection with the DT 500. www.eurofoam.at and www.euro-foam.com Further product information on page 39 N E W S SICK insight 2/2004 GPSG Germanys new device and product safety legislation 25 Standards In force since 1 May 2004 Device and product safety legislation (GPSG) clears up uncertainties insightLINK Further details on the GPSG are available at: www.gpsg.info or on the home page of the Federal Ministry for Economics and Employment: www.bmwa.bund.de or www.bmwi.de. Information on the GPSG (device and product safety legislation) What is the GPSG? Germanys new Gerte- und Produktsicherheitsgesetz (GPSG) device and product safety legislation combines the Gertesicherheitsgesetz (device safe- ty legislation) and the Produktsicherheitsgesetz (product safety legislation), discards oft-criticised multiple regulation, and implements the EU Product Safety Directive of 2001 in national law. Business, authorities and, above all, consumers should profit from the new arrangement. The justification for the legal text states that: In the context of deregulation and de-bureaucratisa- tion, the new GPSG is intended to create comprehensive legislation guaran- teeing health and safety regarding the marketing of technical products. Much has been included from the old laws, some central aspects are new. EU legislation: EU Product Safety Directive 2001/95/EG National law until 30 April 2004: National law since 1 May 2004: Device and product safety legislation (GPSG) Requirement: implementation in national law Device safety legislation (GSG) Product safety legislation (PSG) In force since 1 May 2004: Germanys device and product safety legislation Germanys new Gerte- und Pro- duktsicherheitsgesetz (GPSG) de- vice and product safety legislation came into force on 1 May 2004. It combines the safety legislation for products, that was previously con- tained in the Gertesicherheitsge- setz (device safety legislation) and the Produktsicherheitsgesetz (product safety legislation), and si- multaneously incorporates the EUs Product Safety Directive 2001/95/EG in national law. >> The new GPSG is umbrella legis- lation incorporating the EU Low Voltage Directive, the EU Machine Directive and the EU ATEX Directive, among others; it is also a catch-all regulation in case special regulations, such as building legislation or laws on electromagnetic compatibility, fail to cover individual points. Important changes The most obvious change affects the term device that has been re- placed by the generic term product which distinguishes between techni- cal equipment and consumer prod- ucts. Further modifications affect, among other things, its range of appli- cability (which now also includes used devices or exhibits); the introduction of traceability for all consumer products; self-accusation; and CE-designation. Regarding technical equipment, the new approach in 4 Clause 1 of the GPSG has created an evidentiary privi- lege for manufacturers over the author- ities increasing security for products that have been manufactured in com- pliance with a harmonised standard. Dr. Werner Jansen (left) spoke to Dirk S. Heyden from SICK insight SICK insight 2/2004 In conversation with Dr. Werner Jansen, Manager of the BGFEs Prevention Department (Training) 26 Interview A visit to the Trade Association for Precision Mechanics and Electrical Engineering Safety at work involves technology, knowledge and the right attitude SICK insight: What are the tasks of the BGFE? Dr. Jansen: The Trade Associations have been around since 1885, when Bismarcks social legislation was intro- duced. Trade Associations have been part of the social network since then, though with some special aspects that still apply today. Thus companies that are considered to be in the precision mechanics and electronics sectors au- tomatically become members of the BGFE when they are founded. And they pay 100% of the contribution, not 50% as is the case for national pension or unemployment insurance, for example. The BGFE uses this money to carry out its tasks: compensation payments in cases of industrial illnesses and acci- dents at work; medical, professional and social rehabilitation; accident pre- vention in companies in the form of in- spections by technical supervisory staff; providing safety advice on plants in operation and new product develop- ments; as well as the implementation of comprehensive preventive meas- ures. The BGFE is now responsible for almost 100,000 member firms with about 2.2 million insured personnel. SICK insight: Training is a fundamental part of your preventative work. Who are your courses intended for? Dr. Jansen: A short historical excursion would help answer this question. Peo- ple were already thinking about preven- tion in the 20s. But they were given a decisive boost in the late 50s and ear- ly 60s when strong economic growth unfortunately led to a sharp increase in accidents at work. And the safety at work legislation introduced in 1974 created an enormous need for training. The BGFE soon recognised that safety was more than just technology. Sen- sors and barriers alone do not make machines safe whats needed is a lively belief in safety in the form of atti- tude, behaviour, organisation and lead- ership. This is why the Safety at Work Centre here at the Berghof in Bad Mnstereifel, which was opened in 1962, was deliberately set up as a training centre at that time the first of its type in Germany. The express aim of this organisation was not merely to pass on technical knowledge, but to highlight and propagate safety-oriented behaviour and safer organisation. These ideas are best put over in the factories, by training multipliers throughout the hierarchy to create safe- ty specialists who are also prepared to make use of this material and take re- sponsibility. And it is precisely these people for whom the courses are in- tended: persons on a variety of levels with a range of different functions who are capable of raising safety levels in the factory. SICK insight: With about 100,000 member firms you must have quite a lot to do Dr. Jansen: Without doubt. BGFE train- ing centres in other words, the Berghof and the other meeting places and academies in Linowsee, Dresden and Oberaichen near Stuttgart organ- ise about 1,000 seminars, workshops and such like every year, attended by approximately 16,000 participants. Last year we welcomed our 250,000th participant to the Berghof. Though it must be noted that it is mainly the larg- er companies that send employees to the BGFE, while participants from the 85,000 small and medium-sized com- panies are clearly under-represented. This may have something to do with the amount of work that potential partici- pants face, though it is certainly not because of the costs involved: the seminars are free-of-charge and in- Whether switches or safety fencing, light curtains or laser scanners components alone do not make machines safer. Specialist knowledge and the right attitude towards safety are just as important. Getting this interrelationship across is one of the tasks of the Berufsgenossenschaft der Feinmechanik und Elektrotechnik (BGFE), the German Trade Asso- ciation for Precision Mechanics and Electrical Engineering. SICK insight spoke with Dr. Werner Jansen, Manager of the BGFEs Prevention Department (Training). SICK insight 2/2004 27 Interview clude board and lodging, i.e. the costs are covered by the membership fees. And the BGFE also pays for the travel- ling costs. SICK insight: 1,000 seminars, more than 16,000 participants this all re- quires a lot of organisation. But how do you organise the trainers and spe- cialists necessary for the wide range of topics studied they dont grow on the trees in front of the Berghof, do they? Dr. Jansen: Youre right there even with a lot of shaking weve never har- vested any. To be serious our pool of about 350 trainers comes from many sources. First of all, the BGFE has a to- tal of 20 full-time teachers distributed among the various training sites. Then there are also about 80 technical su- pervisory staff who make regular visits to the works and are very well aware of the real situation in practice. Lawyers from the main administration in Cologne and some of the BGFEs local administrations explain topics that in- volve the legal situation and the conse- quences of safety at work regulations. But most of our work is achieved with external experts from other Trade As- sociations, from universities, from offi- cial factory inspection authorities and particularly from companies. SICK also offers a seminar that has been suc- cessfully run by your Mr Grnemann for many years now. SICK insight: How significant for the BGFE is co-operation with the industry? Dr. Jansen: Co-operation with the in- dustry not only ensures that our teach- ing content is heavily practice-related, but is also important for the BGFE be- cause our specialists are kept up-to- date in technological terms by the early consideration of new product develop- ments. This is particularly important because safety technology is increas- ingly becoming more software-oriented. Electronics is increasingly taking over safety functions whose examination and assessment requires correspon- ding specialist knowledge. One can see at a glance whether a protective door is open or not but whether a particular software activates measure X in case Y requires a more intensive inspection. Only well-founded specialist knowledge is of any assistance when there are al- so safety-relevant, complex communi- cation structures in machines and plants. SICK insight: What status do the new media have for the BGFEs work? Dr. Jansen: When I look back over my more than twenty years with the BGFE I can see that we have developed from a regulatory body to a modern service- provider not least as a result of the new media which we actively exploit. This starts with the intensive use of our Seminar Database on the Internet. Well over half our participants register for courses online. Information of al- most any type can be downloaded at the click of a mouse. A newsletter for subscribers is in development and will hopefully be available soon. Twelve times a year we offer the Topic of the month on our home page and thus achieve greater topicality. And, of course, new media have created ad- vances in the seminars themselves. The latest computer and presentation technologies ensure that our trainers really do get their knowledge across. SICK insight: One last question: Is the co-operative approach of the BGFE still in keeping with the times and fit for the future? Dr. Jansen: One only has to look around at the economic landscape to see that not every change is beneficial. In my opinion, this would also be the case if, as is often brought up in con- versation, the Trade Associations were privatised. The solidarity principle would be replaced by a kind of efficien- cy principle. I dont have anything at all against efficiency, quite the opposite in fact. But safety cannot be reduced to a money matter, i.e. seminars must still be offered even if they do not seem to add up commercially at first glance. Or what would happen to the small Trade Associations or those that are in finan- cial difficulties as a result of the eco- nomic situation in their sector, e.g. in building or mining? How would the soli- darity adjustment currently in use be handled then? I think that the consider- ations that have so far taken place are half-baked because ultimately they fail to ensure the safety of those we insure at the workplace precisely because safe machines cannot be achieved with technology alone, and the passing on of safety competence in a variety of forms is still vital. SICK insight: At least one thing is cer- tain, Dr. Jansen: the idyllic location of your Berghof training centre. Thank you very much for this conversation. insightLINK Further Information on the Internet at: www.bgfe.de The 2003 Annual Report is available. It offers detailed information on the work of the Berufsgenossenschaft der Fein- mechanik und Elektrotechnik (the Ger- man Trade Association for Precision Me- chanics and Electrical Engineering). The report provides up-to-date statistics on accidents, companies and insured mem- bers. It shows how contributions are de- veloping and provides information on compensation, prevention, treatment and professional assistance. The Annual Re- port is automatically sent in printed form to companies with more than 21 insured members. The Annual Report can be downloaded from the Internet as a .PDF version in the Statistics section. The Berghof , the Bad Mnstereifel house for safety at work
Co-operation with the industry [...]
is also important for the BGFE be- cause our specialists are kept up-to- date in technological terms by the early consideration of new product developments. +++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+ SICK insight 2/2004 28 Products Fewer cables, lower costs: with sensor connection boxes Ready-made simplification of field wiring The costs of wiring sensors and actuators in machine and plant construction represent a not inconsider- able component in terms of time and money. SICK of- fers sensor connection boxes for direct field use to provide customers with simple installation in com- pact, robust and proven module technology. >> These connection boxes allow optimum adaptation of your wiring to the particular machine and plant periphery. Robust and versatile The sensor connection boxes are characterised, among oth- er things, by their high enclosure rating of IP 67, compact de- signs with cast plastic housings, and high levels of immunity to impacts and vibrations, as well as withstanding chemical and electrical loads. Interference-free operation is ensured by high-quality, gilt-edged contacts; threaded metal connec- tions; and halogen-free PUR connection cables. SICK offers a wide variety of these sensor connection boxes to adapt to the machine and plant periphery. According to the application, SICK offers 4-plug or 8-plug M12 boxes with 2 signals per slot. The connection of these boxes can be carried out via di- rectly connected halogen-free PUR cables in 5 m and 10 m lengths, or can be achieved using an M23 central plug. The sensors and actuators can be connected with tried-and-test- ed M12/M8 connection cables from SICKs range of connec- tion systems, available with lengths of 0.6 m and 2 m. Use in wet areas in the food industry SICK also offers all the advantages of proven connection technology for wet areas in the food industry. Connection boxes specially designed for this environment are available in high-quality V4A stainless steel with an enclosure rating of IP 69K. The cables between the connection box and the sen- sors have been adapted appropriately. SICK sensor connection boxes practical connection sol- utions for installation and maintenance. With its own GSD file The MLG light grid the new Profibus bus stop SICK is presenting the new MLG Profibus light grid for the first time at SPS/IPC/DRIVES. Its special fea- ture? The bus node is entirely accommodated within the sensor housing. >> Doing without the otherwise usual external gateway makes the cost of driving the Profibus particularly reason- able, as the integrated bus connection saves about 200. Rapidly ready for action Users need not wait long for departure on the MLG Profibus. The universal GSD file ensures speedy system settings. The MLG Profibus has its own PNO number for logging-in the new bus traffic at the machine control system. The corresponding GSD file, that allows the PLC to interpret the sensors signals, can be downloaded at www.profibus.com. All in all, the MLG Profibus is thus ready for action with just a few mouse-clicks. When required, all configuration parameters can be transmitted to a new light grid via Profibus. Object detection by means of parallel beams The MLG light grid is the right automation solution whenever single-beam sensors do not offer the desired reliability. The number of beams and their separation from one another, i.e. the resolution of the MLG, can be assigned task-specifically as can the range of the system. Typical areas of use are height measurement, the detection of lying parts or objects that fall through the light grid, monitoring web slack, or the detection of holes and cracks. Those seeking a professional detection and data transmis- sion solution would do well to choose the MLG Profibus. S P O T L I G H T +++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++ SICK insight 2/2004 29 Products Magnetic cylinder sensor with ATEX approval T-slot talent MZT 6 defies explosion potential Ignitable gases or non-conductive dusts in the oper- ating environment are just the right environment for the new MZT 6 with ATEX approval. >> Right from the start, the MZT 6 proved itself as the mag- netic cylinder sensor for detecting the position of pistons in pneumatic cylinders. The reasons: very user-friendly, im- mune to vibrations, and with high switching accuracy. And from now on secure fixing and reliable function (to sum- marise the experience of many users of the T-slot talent) is also possible in the Ex-Zone. Give ground is what many standard devices have had to do, as they do not conform to the ATEX directive. In almost all cylinder T- slots their place is increasingly being taken by the MZT 6 ATEX. It is approved for Ex-Zone 22, Category 3D/3G, among others. The sensor is not just gaining ground, but often of- fers users better and more reliable switching behaviour than before. This has been made possible by a specially adapted mounting technology, whereby the sensor is first inserted from above saving time. Then the MZT 6 is pressed onto the bottom of the pneumatic cylinder slot over its entire length during fixing. Standard tools are sufficient to carry out rapid and firm screwing of the slotted head or Allen screw into the metal cylinder liner and the sensor cannot be ripped out. Excellent against potential explosions the new MZT 6 ATEX. INFO 212 Growth capacity for capacitive sensors CM family has no succession worries SICK has extended its family of capacitive sensors with further sensor variants. The CM 30 is now avail- able in a 2-wire design for an operating voltage of 250 V AC. >> Increased switching distances of up to 25 mm and op- tions for flush or non-flush installation characterise capaci- tive sensors from SICK the new CM 30 AC too. Moreover, all capacitive sensors share a special highlight: their high level of electromagnetic compatibility. This reliably prevents spurious switching caused by, for example, electrostatically charged granulate in bulk material silos, mobile telephones and radio devices, or from interfering voltages brought about by magnetic valves, relays or frequency converters. CM 18 PTFE: a tough guy with fine discrimination Capacitive sensors are mainly used in applications for which optoelectronic sensors are unsuitable because of the high risk of contamination, for example. Now the CM 18 PTFE goes one step further: the use of PTFE (Polytetrafluoroethyl- ene, also known as Teflon) for the housing and the M18 threaded connections allows the sensor to check the filling levels of aggressive media, e.g. hydrochloric acid, sulphuric acid, phosphoric acid, a variety of alkalis, and numerous solvents. The same applies for object detection in environments in which these materials can be present as gases, steams or vapours. It is also suitable wherever plants require frequent cleaning with chemicals or at high temperatures. INFO 213 See page 17 for an application report. S P O T L I G H T SICK insight 2/2004 The UE 440 and UE 470 safety controllers 30 Products UE 440/470 safety controllers Flexible, compact and reliable >> While safety PLC and open fieldbus systems are becoming increasingly dominant in larger, complex production sites, simple applications are still best solved with safety relays. The UE 440 safety controller the device for com- plex protective applications, and the UE 470 the variant specifically de- signed for presses and rotary attach- ments, with integrated single-break, double-break and protective functions are positioned precisely between the two. Among other features, they offer 15 single-channel inputs, of which six can be connected as two-channel in- puts. There are also two safe connec- tions (Cat. 4, SIL 3) for electro-sensi- Freely programmable Intelliface UE 440/470 safety controllers are the right choice for smaller to medium-sized machines with significant safe- ty requirements. They fill the technological gap between safety relays that require complicated wiring and the safety PLC, whose cost-benefit ratio is unfavourable in this machine segment. tive protective equipment from SICK with internal device interfaces. Eight output pairs, of which two are safe out- put pairs, allow individual control of downstream plant components. The compact alternative UE 440/470 interfaces are charac- terised by low engineering and initial costs per input and output, lower wiring costs, and optimum user-friendliness during operation, troubleshooting or when making modifications. The con- trol systems, accommodated in com- pact housings, also convince with their customer-specific parameterisation and Category 4 compliance with EN 954-1 and SIL 3 according to EN 61508. In combination with electro- sensitive protective equipment from SICK, UE 440/470 interfaces not only cover a wide range of safety functions such as Emergency Stop, Restart, or the monitoring of protective doors there are also interesting expanded functions for users. Intelligent configuration memory Pre-configured ready-to-use C 4000 light curtains often contain a lot of ex- pertise in the form of parameterisation or operating-mode-specific settings such as blanked protective field areas. UE 440/470 interfaces also ensure that these are not lost if a sensor is re- placed. Of course, they autonomously detect the new light curtains and auto- matically configure it with the data of the original device retained in the con- figuration memory. Thus UE 440/470 interfaces are the safe choice whenever flexibility and relay technology wiring costs are limit- ing factors, and use of a safety PLC would be unwarranted. insightLINK You can obtain further product informa- tion with the attached card under: INFO 214 or on the Internet at: www.sick.de/insight/en Protecting hazardous areas and access with the UE 440 When greater safety is required: the UE 440 safety controller SICK insight 2/2004 The W 190L series of laser photoelectric switches 31 Products New W 190L series of laser photoelectric switches Specialists for standard and special applications Externally uniform, but internally with differing laser technology adapted for meeting application requirements this is the new W 190L. The Standard series of this sensor family is designed for uncritical appli- cations. The W 190L High Grade series is intended for demanding appli- cations and provides maximum accuracy and resolution. Numerous features in common As distinctive as the interiors of the individual W 190L sensors can be, they are all similar on the outside. All sensors have a red-light laser in Protection Class 2. As a result, the sensors can be rapidly and accurately aligned on tar- get objects. The rotatable M8 plug or the 2 m cable are just as much device standards as the yellow and green LED display, providing practical assistance during commissioning and operation. The uniform compact plastic housing made of ABS allows use of the devices even under difficult conditions. >> All the sensors have a red-light laser in Protection Class 2, so they can be rapidly and accurately aligned on the target object. For standard use The W 190L Standard series is a com- plete family of photoelectric switches consisting of through-beam and reflex photoelectric switches as well as prox- imity switches with adjustable back- ground suppression. They are reliable, user-friendly and economical sensors, whose basic features and functions are designed for solving conventional appli- cations. High Grade: individually optimised for demanding applications Specialisation is trumps with the W 190 Laser High Grade series. Thus, the CMOS technology of the WTB 190TL scanner offers a very high resolution. This permits reliable detection of ob- jects with highly reflective surfaces, such as foils. With appropriate pro- gramming, the scanner can operate with a choice of background or fore- ground suppression. The WLG 190T glass photoelectric switch is designed for the reliable detection of transparent objects. Whether glass bottles or flat objects, such as discs; whether thin- walled PET plastics or transparent foils the WLG 190T makes even the al- most invisible visible. Both sensors of- fer teach-in programming at the touch of a button or externally via the control cable. This allows simple definition of scanning distances and ranges. Menu navigation takes place on an easily vis- ible numerical display via which, for ex- ample, the type of switching can be programmed and, if necessary, a time delay activated. insightLINK You can obtain further product informa- tion with the attached card under: INFO 215 or on the Internet at: www.sick.de/insight/en The W 190L series consists of Standard and High-grade laser sensors for demand- ing applications SICK insight 2/2004 The programmable IVC-2D smart camera 32 Products >> Vision solutions for factory au- tomation: the introduction of the IVC-2D marks a breakthrough in high- tech image-processing technology for factory automation. This camera com- bines the latest technology with a high- ly flexible and powerful library of image evaluation programs. Quality inspec- tions on assembly lines, robot guid- ance, or checking labels on packaging are just a few of the examples of the wide variety of application possibilities of the IVC-2D in industrial environ- ments. A tool for experts The IVC-2D offers image-processing users a wide range of possibilities. These include approximately 100 soft- ware tools from the program library, with which the most varied of two-di- With its integration of the Swedish image-processing experts IVP last year, SICK has taken a further step in expanding its leading techno- logical position in the area of factory automation. The first result of this combination of competence in sensor technology and specialist know-how in image processing is the new 2-D IVC-2D Industrial Vision Camera, which was presented to interested users at the international VISION trade fair in Stuttgart in October. mensional tasks can be solved. Shapes, geometries, sizes or designs users can make very detailed adjust- ments of the camera via the graphic programming interface to meet the re- quirements of their object detection. The solution is exclusively oriented on the function of the machine without any compromises and thus without im- pairing its performance potential. Dif- insightLINK You can obtain further product informa- tion with the attached card under: INFO 216 or on the Internet at: www.sick.de/insight/en Excellent co-operation the latest joint development with the new SICK IVP logo: the programmable IVC-2D smart camera The smart- camera IVC-2D Setting its sights on the future SICK IVP the new brand in image processing fering pixel resolutions, a shutter for re- ducing the effect of ambient light, in- dustrial housing and connection technology, and immunity to impacts and vibrations guarantee the smart camera a high level of availability in in- dustrial environments. Fieldbus-enabled with Fast Ethernet In addition to three freely programma- ble switching outputs, the IVC-2D offers a Fast Ethernet connection for rapid and uncomplicated construction of a communication network for transferring data and parameters to the machine control system. This also removes any communication restrictions on its use. SICK IVP: from vision sensors for standard applications and optimally programmable solutions to complex camera systems it is needs-oriented image processing that counts. SICK insight 2/2004 The IN 4000 inductive safety system 33 Products Sensor can be connected directly to safe PLC The IN 4000 safety system switches on metal Friction-free, immune to vibrations, easy to install and unaffected by dirt the new inductive IN 4000 safety system fulfils all the requirements for the reliable monitoring of position or protective gates in harsh indus- trial environments. A further highlight: the sensor of the IN 4000 can al- so be connected directly to a safe PLC. >> The basic version of the IN 4000 consists of an inductive sensor in a cu- bic housing for switching distances of 10 to 15 mm, and a relay evaluation unit. The entire system, as well as each of the two individual components, is certified for Category 4 in compli- ance with EN 954-1, making individual safety solutions possible. The direct solution If the control system of the machine or plant to be protected is based on a safe PLC, the IN 4000 sensor can be operated directly. This is possible be- cause the sensors input and output signals are designed to correspond to EN 61131-2 and are thus compatible with the I/O signals of a safe PLC. Con- trol Category 4 according to EN 954-1 is maintained even if the maximum number of 10 sensors is connected in series. The relay solution If there is no safe PLC available, the sensor can be connected to the IN 4000 evaluation unit with relay out- puts. Here, too, connection of up to ten sensors is possible leading to con- siderable cost savings, particularly in the case of complex machines or plants. Three safety-relevant N.O. con- tacts, two N.C. contacts, and integrat- ed external device monitoring also allow flexible integration in the particu- lar machine controller. Monitoring the switching area prevents tampering The sensors inductive operating princi- ple means that no separately coded ac- tuator is required, i.e. the sensor detects the presence or absence of metal directly. In order to meet the re- quirement to prevent simple tamper- ing, the switching area of the sensor is monitored in terms of both time and space. Unauthorised alterations are detected and lead to the machine be- ing safely switched off. The design of the IN 4000 inductive safety system thus offers completely new approaches to the safe monitoring of position and protective gates on ma- chines and plants. The basis version of the IN 4000: relay evaluation unit and inductive sensor insightLINK You can obtain further product informa- tion with the attached card under: INFO 217 or on the Internet at: www.sick.de/insight/en N E W S SICK insight 2/2004 New contrast scanners The IT 3810 hand-held scanner 34 Products Good and reasonably priced The IT 3810 hand-held scanner: bar codes in focus The IT 3810 hand-held scanner has been designed as a good, reasonably priced solution for reading bar codes on documents and low-volume goods. Its reading performance and simple operation is good, its high re- liability and low cost make it reasonably priced, too. >> As a basic model lacking no techno- logical necessities, the IT 3810 rounds out the successful IT 3800 series, of which more than 1,000,000 have been sold. The linear image-capture module generates a clear scanning line on the bar code and reads it at the usual counter distance of between about 100 mm and 150 mm. Thanks to menu options and quick-start instructions, the IT 3810 is easily and quickly pre- pared for operation. A variety of inter- faces, including a keyboard wedge, RS-232 or USB permit connection to mobile terminals as well as stationary computer systems. Robust and user-friendly Typical areas of use for the IT 3810 are fixed and mobile workplaces, at which the bar codes on documents, packag- ing or storage spaces (as in invento- ries) require detection. The robust and shockproof device design ensures ex- traordinary availability; the ergonomic handle, low weight and simple target- ing of the bar codes provide a high lev- el of user-friendliness. Deal yourself a good hand with the bar-code reading advantages of the IT 3810. insightLINK You can obtain further product informa- tion with the attached card under: INFO 219 or on the Internet at: www.sick.de/insight/en Poster for hand-held scanners provides overview Have you got a good grasp of scanning? With or without cable? Radio: yes or no? Bar code or 2-D? Range? Wall-mount- ed receptacle or belt attachment? USB, RS-232 or both? Who can keep a grasp on the scanning possibilities? Become a scanner-grasper with SICKs new hand-held scanner poster. Theoretically, SICKs hand-held scanner family and accessories offer well over 200 potential configurations. Request the scanner poster and any confusion will be brought to an end with a practised grasp of scanners you will imme- diately be able to identify your mobile bar-code or 2-D reader. To receive your poster use the attached card under: INFO 220 Know the devices scan with the right one! The IT 3810 hand-held scanner The KT 3 Laser compact contrast scanner Highly reliable detection of small objects >> The new KT 3 Laser is intended to be a contrast to other scanners. Maximum scanning distances and minimum light spot both features of the new KT 3 Laser allow no con- trasts to escape detection, whether cracks in glass, grooves in metal, or printed marks. Moreover the sensor, in its minia- ture housing, is easily installed even if space is limited. A real giant in performance In terms of device properties, the dwarf in SICKs family of contrast scan- ners is actually a giant. 20 to 60 mm range with a light spot of only 2 mm 2 at a scanning distance of 40 mm, large detection reserves with changing ob- ject distances, switching frequencies of 1.5 kHz, and an enclosure rating of IP 67 are features that ensure high de- tection reliability in a wide variety of ap- plications. Then there is the rapid com- missioning of the KT 3L resulting from static teach-in on the mark and the background a process that can be carried out either on the control panel of the device or via the control cable. If the target object is highly reflective, au- tomatic adaptation of the switching threshold guarantees reliable detec- tion. Thus the KT 3L is dazzlingly pre- pared for e.g. the detection of cracks in glass and narrow grooves on metal- lic surfaces, as well as the detection and precise positioning of small marks and labels. INFO 218 SICK insight 2/2004 NEW: The DKS 40 incremental encoder Ultrasonic sensors 35 Products Predestined for monitoring the rotation of rollers, cylinders and axles The DKS 40 incremental encoder the compact and robust cost-cutter >> Given its application and price seg- ment, the DKS 40 offers unaccus- tomed quality. Its housing consists of solid die-cast zinc and is also extreme- ly compact with a diameter of 50 mm and a height of 42 mm. The user thus saves on valuable installation space. The DKS 40 is extremely robust against impacts and vibrations as a re- sult of using the highly successful mini- disc technology. Whether in a tooling, textile, packaging or timber processing machine conditions can be tough and space limited. The DKS 40 is available with a face-mount flange and 8 mm solid shaft. The device offers all common line numbers up to 1,024 per revolu- tion. There is a choice of electrical interface between Open Collector, TTL/RS-422 and HTL/push-pull. The connection cable is positioned in such a way that it is possible to lay the cable downin a radial or axial direction with- out any excessive bending. With this flexibility, the DKS 40 sets a new stan- dard in its class. Robust, compact, reasonably priced, flexible and rapidly available for use the new star from SICK-STEGMANN can be seen at SPS/IPC/DRIVES. insightLINK You can obtain further product informa- tion with the attached card under: INFO 221 or on the Internet at: www.sick.de/insight/en N E W S Users are increasingly demanding encoders for standard applications, such as monitoring the rotation of rollers, cylinders and other axles, in a robust but nevertheless reasonably priced design. The new DKS 40 was specially developed for these applications. It is not only the compact de- sign and robustness that attracts attention, but also the fact that its extremely attractive price makes it a genuine cost-cutter. New ultrasonic sensors UM 18 when space is limited >> SICK presents the new UM 18 ul- trasonic sensor, specially designed for applications with limited space. The device, in robust M18 fine-thread housings, is available in two variants Standard and High End. The detection of transparent ob- jects (e.g. PET bottles) or checking liquid levels in test tubes are just two of the many applications for the new UM 18. Both device variants offer an operating scanning distance of be- tween 30 mm and 250 mm, as well as teach-in and switching threshold pro- gramming via the control cable. The Standard UM 18 is best suited for those for whom a single switching output is sufficient. The High End version is available for those who require more. More functions and additional switching reliability Externally, the UM 18 High End is dis- tinguished by the two function LEDs and the two switching outputs. Inter- nally, an integrated temperature com- pensation system ensures that the sensors detection accuracy and relia- bility remain constant despite changes in ambient temperature during opera- tion. The possibility of background teach-in is a real highlight. Critical ob- jects can thus be detected with partic- ular reliability, as it is not their often un- defined sonic reflectivity but the inter- ruption of the taught-in background sound reflections that leads to a response from the UM 18. The UM 18 ultrasonic sensor reliable switching made easy. INFO 222 SICK insight 2/2004 The new V 4000 Press Brake Category 4 camera sensor 36 Products Reliable image processing on press brakes The V 4000 Press Brake optimises safety and processes >> Conventional systems for safe- guarding the hazardous closing move- ment on sinking brake presses consist of simple optoelectronic sensors and receivers and are mounted on the top clamping bar and thus move with it. While they detect any hazardous reach- ing into the protective field, they have serious disadvantages for machine productivity. The V 4000 Press Brake offers visionary use The new V 4000 Press Brake corre- sponds to Category 4 in compliance with EN 954-1 and SIL 3 according to EN 61508 and thus offers maximum safety. Machine vision, i.e. image pro- The new V 4000 Press Brake Category 4 camera sensor offers both maximum safety at work and maximum optimisation of folding process- es. This has been made possible by programming a safety field whose evaluation can do more than just monitor a light path. cessing, is the technological approach upon which this electro-sensitive pro- tective equipment is based. A two-di- mensional safety field, co-ordinated with the particular bending process, is active during the downward motion of the die. The height of this field de- creases continuously as the bending die, on which the V 4000 Press Brake is installed, approaches the die plate. This offers a variety of advantages: thick sheet metal, bent metal shapes, and thin plate with side walls are sub- ject to differing protection modes ac- cording to the various bending tasks: Standard for simple one-dimensional bending, Box for bending multi-di- mensional objects such as boxes, and Limit stop to take into account limit stops tight on the object to be bent. The system is exceptionally easy to in- tegrate into the press constructors machine control system. In this way the safety equipment can be switched to the optimum protective mode via se- lection of the bending program. The machine can thus activate the different protection modes appropriate for the bending techniques, one after another and as often as required, for the same object, e.g. first Standard, then Box for a high box side, and finally Limit stop for the low part of a side. Now possible: folding without an intermediate break The features and opportunities of the V 4000 Press Brake provide a very im- portant advantage for the actual bend- ing process. Unlike with conventional systems, the downward movement of the press bar must no longer be SICK insight 2/2004 The KT 5 contrast scanner (with) display 37 Products Bar display for easier use The KT 5 contrast scanner dis- play: a straight back for com- fortable use >> Teach-in and tuning a maximum of two steps to get the contrast scanner ready for use. First, the bar display of the KT 5 Display supports the user dur- ing teach-in, when the sensor is taught the mark and its background, whereby the sensor activates the optimum transmission colour of the three-colour LED according to the contrast. If, in in- dividual cases, even more accurate fine adjustment is necessary, the dis- play permits pixel-precise fine adjust- ment of the current signal level via a tuning button. Its all a question of adjustment So users can now check the current signal level in combination with the cur- rent switching threshold, as well as as- sessing detection accuracy and, if necessary, carry out a manual adapta- tion of the switching threshold. Thus if, for example, the appearance of a label Those who desire maximum ease of use from their contrast scanners should select the new KT 5 Display. Why? The new bar display on the back of the sensor housing now makes teach-in and fine adjustment par- ticularly easy. changes (leading to altered grey values of marks, and the background or reflec- tivity), the KT 5 Display can now be eas- ily re-adjusted during operation. Performance features that re-define the device standard The new KT 5 Display has several per- formance features upon which users place particular value. In addition to the three-colour LED technology and the proven 2-point teach-in, these in- clude a switching frequency of 10 kHz and automatic adaptation of switching thresholds with highly reflective materi- als. Individual alignment and attach- ment possibilities cover a wide variety of mounting situations and ensure both the electrical and mechanical compati- bility of the KT 5 Standard. A winner without drawbacks the KT 5 Display with the new informative back. INFO 224 Bildtext insightLINK Weitere Infos erhalten Sie mit der Karte am Ende des Magazins unter: INFO 200 oder im Internet unter: www.sick.de/insight insightLINK You can obtain further product informa- tion with the attached card under: INFO 223 or on the Internet at: www.sick.de/insight/en N E W S stopped just before folding, with a new approach then being made using a foot switch. The savings in cycle time that this brings about increase machine ca- pacity and thus economic efficiency. Setting new standards in practice The intelligent image processing of the V 4000 Press Brake also sets new standards regarding commissioning and availability. Vibrations typical for presses do not trigger any system re- sponse because the entire camera field, within which the safety-monitored area is programmed, is intelligently evaluated. The monitored area of the safe camera sensor tracks even small changes in alignment. This immunity to any misalignment also makes adjust- ment during first commissioning, and after a change of tools, simpler and quicker than with other passenger systems. The very simple integration in exist- ing control systems is also remarkable, as the V 4000 Press Brake operates with the signals that are anyway used on press brakes. The V 4000 Press Brake press pro- tection that offer users and integrators a real technological lead. Maximum optimisation of bending processes and maximum operating safety with the V 4000 Press Brake camera sensor The bar display informs the user about the detection reliability of the taught-in contrast N E W S Automatic counting of persons at airports, shopping malls or stadiums LD PeCo enables more efficient safety strategies With 11 or 16 beams in a com- pact housing The ELG 1 short range the rea- sonably priced au- tomation light grid >> Simple installation and robustness during operation characterise SICKs automation light grid. With a range of up to 3 m, the ELG 1 is the ideal solu- tion, e.g. for regulating throughput, checking and positioning pallets, de- tecting objects on overhead conveyors, or counting parts. Those who know how difficult it is to create ones own light grid from large numbers of individual sensors appreciate the advantages of the new ELG short range. No more misalign- ment and there is no longer a mess of cables between the sensors and the control system the ELG 1 eliminates many disadvantages that are almost impossible to avoid with multi-beam detection solutions involving individual sensors. Optical synchronisation, optimum object detection ELG 1 options are avail- able with a monitoring height of 150 mm with 16 light beams, or a monitoring height of 100 mm with 11 light beams. Senders and receivers are optically synchronised thus there is no need for the otherwise necessary cable. A detection field with beam separations of 10 mm is generated between the sender and the receiver hous- ings. This fine resolu- tion allows even small parts to be detected. Furthermore, it is even possible to detect flat objects with the help of cross-beam evaluation. The ELG 1 its better to install a single device than improvise with lots of sensors. INFO 225 LD PeCo is a new type of long-range system for counting persons and de- termining the direction in which they are moving. Whether children or adults, individuals or entire groups the non-contact measurement sys- tem reliably detects how many people there are, where they are, and in what direction they are moving. >> The system is particularly suitable for counting people in large buildings, e.g. at airports, shopping centres or stadiums, as it detects the direction of movement and can monitor path widths of up to 26 m. In this way the LD PeCo can, among other things, de- termine the best place for advertising, control air conditioning, or provide im- portant information for security and rescue measures in an emergency. Detection by means of invisible light curtains The LD PeCo is an actively scanning, highly precise laser measurement sys- tem, whose scanner emits two invisi- ble, fan-shaped, parallel light pulses and measures the time until reception of their reflections. Regardless of the size and geometry of a space, room or passage, LD PeCo can be adapted to take any spatial structure into account, e.g. supporting pillars or electronic goods security portals. The time-of- flight of the transmitted light pulses changes as soon as someone walks through the light curtains, and the per- son is counted. When several people, even of different sizes, cross the moni- tored area, they are also reliably de- tected and counted. Simultaneously, the LD PeCo detects which of the two light curtains is interrupted first and calculates the direction the persons are moving in. This quantity and direc- tional information can be transmitted to, for example, the central building control system via RS-232, RS-422 or two digital switching outputs. SICK insight 2/2004 The ELG 1 light grid The LD People Counter laser measurement system 38 Products The LD PeCo provides reliable results even in dense crowds insightLINK You can obtain further product information on the Internet at: www.sick.de/insight/en Can be installed almost anywhere The maintenance-free LD PeCo offers almost no restrictions regarding instal- lation. The system can be installed out- side the aisles or beyond any possible access, thus protecting it against dam- age or tampering. People can be reli- ably counted, even in high arcades in shopping malls, or in arrival and depar- ture halls at airports, thanks to a mounting height of up to 15 m. Unlike cameras, the LD PeCo operates inde- pendently of the light conditions and is effectively protected against strong light or targeted dazzling. The LD PeCo the detection solution that meets numerous requirements in building management. N E W S SICK insight 2/2004 DT 500/DS 500 distance sensors 39 Products >> Numerous users are not distancing themselves from the DT 500 and DS 500 distance scanners on the contrary. Since it was initially intro- duced at the Hanover Industrial Trade Fair 2004 the devices have enjoyed ever-increasing popularity. This is particularly the case in ap- plications such as collision prevention for cranes, distancing for transported objects, or measuring the heights of stacks. The sensors have proved them- selves everywhere as a result of their high accuracy even with pitch-black surfaces. Analogue or digital a choice but no dilemma While the DS 500 has two switching outputs that can be displayed, the DT 500 offers a choice between a 420 mA analogue output and a serial RS-422 measurement data interface. The start and end of the measurement range is freely programmable via the control and display field thus the DT 500 can be ideally adapted to the particular task involved. 3 mm greater inaccuracy is not possible The range of 18 m on a black back- ground with an accuracy of 3 mm pos- sible as a result of the minimised tem- perature drift of just 0.05 mm/K leaves nothing to be desired in terms of detection accuracy. At the same time (the devices provide a measurement value every 250 ms), they also exhibit extremely precise background suppres- sion even if the background material has a light surface. During develop- ment, however, care was not only taken to ensure precision but also user-friend- liness: an integrated display allows sim- ple setting of measurement ranges and switching thresholds, as well as dis- playing the current system function. Better by a long chalk this is the view of users convinced by the perform- ance of the new DT 500 and DS 500 distance sensors. Even suitable for black surfaces DT 500 and DS 500 distance scanners The LD PeCo Black is beautiful! DT 500/DS 500 distance scanners offer long range and great accuracy Tastweite und Genauigkeit insightLINK You can obtain further product informa- tion with the attached card under: INFO 226 or on the Internet at: www.sick.de/insight/en For further reading see page 24 Dream machine solves nightmare DT 500 laying it on the line for mattresses. SICK insight 2/2004 The LD PDS building security laser measurement system 40 Products Recommended by da Vinci, Tizian and Drer LD PDS protects valuables and prevents vandalism >> In many cases laser measurement technology, such as the LD PDS, has proved an economical and technical al- ternative for monitoring buildings, as well as a sensible supplement to CCTV. Reliable detection and precise camera guidance Independent of the lighting conditions in an area, and effectively protected against strong light impingement or de- liberate dazzling, the LD PDS laser measurement system offers maximum detection reliability. The active scanner The LD PDS is a new, non-contact building security laser measurement system for horizontal and vertical 360 all-round monitoring. The Pro- tection and Detection System (PDS) offers versatility and detection re- liability. It is thus ideally suited for security functions in building management. Famous paintings are already protected by the LD PDS. of the measurement system transmits an invisible fan-shaped light pulse and measures the time until reception of its reflection. The time-of-flight of the transmitted light pulse changes as soon as someone reaches into or en- ters the protective field and triggers an alarm signal. As the system not on- ly detects persons as such, but can al- so determine their position in an area, observation cameras can also be ex- tremely accurately aimed and focused on the basis of the information sup- plied by the LD PDS. Maximum flexibility thanks to dual DSP In addition to a first digital signal processor (DSP) for controlling the measurement system, every LD PDS has a second DSP that carries out a programmable application-specific con- version of the measurement values ob- tained, and transmits them via RS-232, RS-422 or two digital switching out- puts. As a result, any security techni- cian, system integrator or user of the measurement system can adapt the monitored area appropriately. If this changes, e.g. as a result of putting up new walls or buildings, or exchanging guarded objects of different sizes, this is also easily taken into account via software in the device. Thus the laser measurement systems allow continued flexible use of spaces or wall areas. Light veils protect Louvre works About 30 LD PDS are in use at the Louvre in Paris, one of Europes oldest and most prestigious museums. As a result of their designs, the devices could be integrated into the walls of the exhibition rooms and protected against sabotage and interference. The veil of light generated by the de- vice does not impair visitors views of works by Leonardo da Vinci, Raphael, Rembrandt, Tizian, Drer and other great masters. The LD PDS insightLINK You can obtain further product information on the Internet at: www.sick.de/insight/en SICK insight 2/2004 The CVS 1 Color Vision Sensor 41 Products >> The CVS 1 Color Vision Sensor checks whether the amount, or number of pixels, of the colour tone in its field of view matches at least the minimum taught-in in principle it therefore functions like a colour scanner with a very large light spot and very long op- erating distance. Industrial design in photoelectric switch format The CVS 1 is used for colour detection in industrial environments. For this rea- son, during development emphasis was placed upon: simple teach-in pro- gramming, direct display of the image captured by the CVS 1 Color Vision Sensor, typical cycle times of just 10 ms, and the storage and immediate retrieval of up to 16 different colour tone inspections. What is special about all these fea- tures is that they have been achieved within the CVS 1 camera sensor itself (only about the size of a photoelectric switch) without any supplementary external control and evaluation unit. There is a separate monitor and control panel that can be connected to the camera sensor for use in mounting lo- cations where its own display cannot be seen. Great performance low price The CVS 1 offers highly versatile use from monitoring the browning of meat- balls, and checking the presence of bottle tops and lids, to detecting logos and checking labels in packaging ma- chines. Here, for example, labels with defective designs can be detected al- most impossible with point-based sen- sor detection. The CVS 1 also detects colour in applications such as checking the completeness of crates or carrier systems, checking the presence of en- closed instructions, differentiating be- tween objects on the basis of colour, and checking the filling levels of trans- parent containers. Given all these ad- vantages, one can hardly believe the price of the CVS 1 the device is the only one in its performance class avail- able for less than 1,000! Whether price or performance the CVS is a fantastic solution from any point of view. The intelligent small-scale CVS 1 Color Vision Sensor: a photoelectric switch for detecting colour in industrial environements insightLINK You can obtain further product informa- tion with the attached card under: INFO 227 or on the Internet at: www.sick.de/insight/en Large-format colour detection with the CVS 1 Color Vision Sensor Suitable for meatballs, bottle tops and packaging A large detection field, integrated illumination, long operating distances, a colour monitor for simple operation, a teach-in button and extremely short evaluation times. A single device, the CVS 1, offers all these fea- tures normally requiring expensive camera and computer equipment. SICK insight 2/2004 Standardised sensor teach-in Bluetooth 42 Know- how Maximum simplicity for users SICK supports standardised teach-in >> Intuitive operation without a manu- al, simple and rapid commissioning, prevention of unintentional triggering, and clear visual indication of device states on the sensor or in response to remote querying this is how users want to commission and operate their optoelectronic and ultrasonic sensors. So the leading suppliers of standard sensors are working towards the goal of formulating uniform teach-in philoso- phies for customers and producers, and deriving shared features from them. Uniform features Participants in the workgroup have dis- cussed uniform sensor features based on the requirements of customers and the solutions already implemented indi- vidually by producers. Among other things, this affects the use of buttons; operating modes and their visualisa- tion by means of LEDs; automatic ac- ceptance of teach-in values; indication In partnership with other producers, SICK is working on the rapid imple- mentation of a producer-independent standard teach-in process in the Standardisation of sensor teach-in processes workgroup in the Ger- man Trade Association for Electronic Components and Systems (ZVEI). of error states; and time locks in the teach-in process intended to prevent unintentional operation. Icons have al- so been defined for uniformly labelling teach-in buttons for: p single-value teach-in: only set on one object, and p two-value teach-in: setting takes place on one object and one back- ground. Draft standard handed in to CENELEC* A draft for standardising the teach-in process of standard sensors has been presented to CENELEC for European standardisation as an appendix to EN 60947-5-2: the IEC 60947-5-2 Annex G Draft. Parallel to this, SICK has integrated the latest generation of optoelectronic switching circuits (so- called opto-ASICs), that are in com- plete conformity with the agreed draft standard, in its latest optical sensors for automation, including the WT 9-2, WT 14-2 and WT 18-3, among others. All producers a single goal: straight forward teach-in without com- plicated operating instructions. www.zvei.org and www.stafuco.org * CENELEC is the European Electrotechnical Standardisation Committee The DME 5000 distance measuring device: teach-in by mobile phone Parameterisation and diagnosis via Bluetooth >> Replacement of the serial in- terfaces of sensors such as the DME 5000 laser distance measuring device is particularly attractive. With the help of a Bluetooth-enabled laptop, service technicians can communicate with the sensor on the high bay stacker from a distance, without having to en- ter a blocked aisle of shelving. This is considerably simpler and more com- fortable than via cable. And it is also secure, as Bluetooth not only encodes the radio signal, but also changes its transmission frequency up to 1,600 times per second. Greater mobility and comfort drive the standard Cable-free connections, mobility of end- devices, and online communication over short and medium ranges are the reasons why Bluetooth is well on the way towards becoming the standard in the cable-free IT environment. Numer- ous end-devices are already equipped with this radio interface. So its hardly surprising that the DME 5000 with the Bluetooth interface attracts great interest whenever it is presented. insightLINK Comprehensive information on Blue- tooth is available in six languages at www.bluetooth.com the official Bluetooth web site. Away with the cables this trend is becoming increasingly common among modern automation components. Whether parameterisation or diagnosis cable-free data transmission via Bluetooth simplifies work in situ, e.g. in high-bay warehouses. Teach-in button labels Single-value teach-in without background/ target differentiation Two-value teach-in Optional Target Background SICK insight 2/2004 Autoworld in Brussels, Belgium 43 Museum >> Several hundred cars can be seen lovingly restored and looked after. Horse-drawn vehicles are just as much a part of the museum as are the first real cars and their successors: state carriages, luxury limousines, convert- ibles, coups as well as buses and trucks. Motorcycles are a further area of interest. A variety of collections embedded in their time Several private contributors have lent their collections to the museum over the decades. The Mahy Collection shows extraordinary and prestigious vehicles, the Thiry Marcel Collection concentrates on two-wheeled vehicles, while buses and transport vehicles of One of Europes most interesting automobile museums is accommodat- ed in the Palais du Cinquantenaire: the Brussels Autoworld. It tells of times long past, while also stimulating a critical consideration of the car in todays social environment. all types are to be seen in the Gallery Pierre dIeteren. There is also a replica of the 1902 Motor Show, and a depart- ment for the history of car design. Looking at the exhibits conjures up in ones minds eye the history of the last century. The Belle poque of the 20s, two world wars, the limousine era and the revolutions of the 50s and 60s, as well as the last three decades during which the car finally developed into a commodity for the masses. Goods for the masses = good for the masses? In addition to its purely expositional aims, the Brussels Autoworld also fol- lows technical and social education aims. Children and young adults are of- fered a variety of visitor programmes that, in addition to the automobile as technology, also consider how the car has influenced the appearance of the world, the development of societies, and the attitudes and ways of life of mankind and families. Whether the car, as a good for the masses was, and is, always good for the masses the visitor must come to their own conclusion. Whatever the case, the Brussels Autoworld provides a richness of stimuli here. 100 years of automotive history at the Autoworld Museum in Brussels insightLINK You can obtain further information about the Brussels Autoworld on the Internet at: www.autoworld.be A vehicular journeythrough time Turkish subsidiary for south-east Europe SICK founds S.I.C.K. >> As of now, S.I.C.K. (Sensrler ve Ileri Cihazler Kontrol Sanayi Ticaret) A.S. has exclusive rights to sell the en- tire range of products in Turkey, and will later also distribute them in a variety of neighbouring countries. 10-year history of success Onur Mhendislik was founded in 1994. While just six staff were em- ployed during the first two years, meet- ing all the needs of sensor sales in As part of its strategy of expanding its market position in south-east Eu- rope, SICK has integrated its former Turkish sales representative in Istanbul, Onur Mhendislik, into its worldwide sales network as a new subsidiary. Turkey, Onur achieved continuous growth during the following years de- spite the difficult economic conditions. A total of 22 personnel are now em- ployed by the new SICK subsidiary, up- on whose specialist knowledge numerous customers and users rely including major press producers, auto- motive suppliers and logistical compa- nies that use sensors, safety systems and bar-code readers. SICK insight 2/2004 Company founded in Turkey Results of the safety co-operation 44 SICK Tour Safety co-operation: Omron + Rockwell + SICK DeviceNet Safety on the march >> SICK sees DeviceNet Safety as a technology on a par with Profisafe and AS-Interface Safety at Work, and has deliberately integrated a lot of expert- ise in the development of products. The UE 4470 is one of the first exam- ples of this. For consistent machine safe- guarding concepts Any combination of safety sensors and actuators can be integrated locally and decentrally in DeviceNet Safety net- works with the UE 4470 Safety Con- troller. Status, diagnostic and error messages can be detected and processed in situ or via the network. In- tegrated and certified basic and appli- cation function blocks (such as automatic reset, enabling switches or two-hand control units) permit the solu- tion of simple and more complex safety tasks, allowing the realisation of con- sistent machine protection concepts, In October 2002 the companies Rockwell Automation, Omron and SICK presented the Open DeviceNet Vendor Association (ODVA), the safety co- operation they had founded. The aim of this collaboration was and remains the development of hardware and software components that use De- viceNet Safety, the safety extension of DeviceNet, as their protocol. The UE 4470 Safety Controller is one of the first results. such as those relevant for packaging machines or machine tools, robot cells and conveyor systems. Equal partners with differing emphases With Rockwell Automation, Omron and SICK, three partners that are leaders in their market segments with leading market positions in the USA, Asia and Europe, have united in a safety co-op- eration. Each company contributes specific expertise: Rockwell Automa- tion and Omron provide control system, programming and network technolo- gies, while SICK provides expertise in safety applications and technology. Flexible safety automation with De- viceNet Safety SICK actively supports the dialogue on distributed logic in networks. INFO 228 www.odva.org key words: CIP Safety The UE 4450 safe bus node and the UE 4470 safety con- troller (right) 10 years SICK Hong Kong >> Danny Chan, the current Managing Director, and three other employees, were the original team at SICK Hong Kong in 1994. The company developed as dynamically as the market: after a first office in Guangzhou, a branch was opened in the metropolis itself one year later. With further offices in Bei- jing and Shanghai, SICK China now has a presence in the most important ar- eas of the nation. The company pro- vides support to all the key industries in China: automobile construction and the electronics industry, steel works, machine tool manufacturers, the print- ing and packaging industries, food and drinks producers, as well as compa- nies involved in material handling. Congratulations for the last ten years and all the best for the new decade. SICK insight 2/2004 Finding products in the eCatalog Hong Kong celebrates tenth anniversary 45 SICK Tour In September 2004, almost 60 staff celebrated the founding of SICK Hong Kong ten years ago. The company formed the core of the SICK Op- tic-Electronic Co. Ltd., Guangzhou China which came into being in 2003. Hong Kong at a glance: Official name: Hong Kong Special Administrative Region of the Peo- ples Republic of China, since 01.07.1997 Area: 1,092 km 2 about the size of Martinique c.f. China with 9,597,995 km 2 = almost as large as the USA or approx. 27 times the size of Germany Population: approx. 7.3 m. about as many people as in all Switzerland estimated total population of China is almost 1.3 bn. Population density: 6,771 persons per km 2 c.f. 387 on Martinique Exchange rate: 1 Hong Kong dollar (HKD) = ca. 0.10 EUR; 1 EUR = 9.66 HKD (in October 2004) Sources: Homepage Spiegel / Lnderlexikon The Team of SICK Hong Kong The Product Finder offers you the opportunity to enter parameters to se- lect the products that potentially meet your needs. You can narrow down the search results as desired and therefore influence the number of products se- lected. You can thus rapidly and com- prehensibly obtain information on our products. You can obtain detailed product da- ta such as the data sheet, connection diagrams, accessories, etc. by clicking within your search results. To the product via the Application Finder The Application Finder guides you from the application to the product. By se- lecting the task, sector and products used one rapidly reaches an appropri- ate application description and links that take you to the products used in the application. Thus your search al- ways results in a solution. And you can find mounting sets, plugs, lenses, etc. in the Accessory Finder. Please note: As a result of the enor- mous range of products not all products are available in the Finder pages during the transition period. SICK Product Finder eCatalog on the Internet ecatalog.sick.com Find sensors online >> Find dont seek. Click and stay up-to- date. Its never been easier with SICKs Prod- uct Finder eCatalog. A complete range of automation sen- sors; industrial safety systems; and trail-blazing material flow, identification and handling systems the Product Finder eCatalog invites online research for SICK products (currently in three lan- guages). SICK insight 2/2004 P6 SICK Rundschau Eat that frog by Brian Tracy 46 Book Corner >> When I picked up this book I thought: Well, it looks funny enough, the frog on the cover, looking at me in that way with its big froggy eyes but Im supposed to eat that? No thanks!!! OK, even I quickly grasped that it was just a bit of imagery for something uncomfortable, something that I really dont want to do, which I may even find disgusting. And there are a few things that spring to mind which I would take the trouble to think of 1,000 excuses to keep putting off. But what effects does that have on my life? Either pri- vate or professional. So lets see what tips and tricks Brian Tracy can offer me to conquer my weaker self. Right at the start he impresses up- on us the importance of not starting the day with the easier tasks, as we hu- mans are wont to do. So the first job is to clearly define what the biggest frog is. Its helpful to plan the day properly. A range of rules and various lists are very helpful here. It is also very important to consider the repercussions of doing or not doing something. This can become a key fac- tor in the long-term perspective of life. Whereby one also determines the next frog what more could one want? Eat that Frog 21 great ways to stop procrastinating and get more done in less time The 21 steps to success build upon one another logically and are compre- hensibly structured with key words and sub-headings. Many of the steps also offer exercises that help me put the theory into practice. Summary: A very stimulating book that I would recommend. It made me think about my long-term aims in life and about how I can achieve them most effectively, if I really want to. Book Corner by Ingrid Rathfelder, Editor SICK insight e-mail newsletter Eat that frog is available from Berrett Publishers, Inc., ISBN 1-57675-198-8 Another significant tip: set priorities and never start a B, C, or D task before the A task has been completed. Concentration on key areas, such as planning, organisation, job place- ments, delegation, inspection, meas- urement and reporting, is the next ma- jor factor, particularly in management. In this context it is important to contin- uously improve oneself. Here Tracy rec- ommends, among other things, keep- ing the working environment clean and tidy. Oh dear, looking at my desk is so awfully depressing! How well I succeed in taking my special talents into account, what can prove to be important impediments, how I can motivate myself to take ac- tion, how I can put pressure on myself, when matters are critical, what the Salami Tactic or Swiss Cheese Method are, and much else besides, are covered in the remaining third of the book. A well organised summary at the end provides assistance in again clarifying that eating the biggest frog in the morn- ing is both satisfying and motivating, and that I will then find the other tasks much easier to deal with. The rule is that you should never do a B task when there is an A task left undone Rule: Long-term thinking improves short-term decision making The key to the success of this method of working in specific time segments is for you to plan your day in advance and specifi- cally schedule a fixed time period for a particular activity or task insightLINK Weitere Infos erhalten Sie mit der Karte am Ende des Magazins unter: INFO 121 insightSERVICE Trade fair dates Imprint Contacts 47 Info Central Sales, Germany SICK AG Schiess-Strae 56 40549 Dsseldorf Germany Phone +49 211 53 01-0 Fax +49 211 53 01-100 e-mail vzdinfo@sick.de Company Headquarters SICK AG Sebastian-Kneipp-Str. 1 79183 Waldkirch Germany Phone +49 7681 202-0 Fax +49 7681 202-38 63 e-mail info@sick.de Trade fair dates Germany Trade fair Location Date 2004/2005 SPS/IPC/DRIVES Nuremberg 23.11.25.11.2004 i+e Freiburg 27.01.29.01.2005 LogiMAT Stuttgart 01.02.03.02.2005 HANNOVER MESSE Hanover 11.04.15.04.2005 SEMICON Europa Munich 12.04.14.04.2005 interpack Dsseldorf 21.04.27.04.2005 Trade fair dates Europe Trade fair Location Date 2004/2005 Elektro Vakbeurs Hardenberg, NL 07.12.09.12.2004 elec Paris, F 09.12.13.12.2004 DRIVES AND CONTROL Danzig, PL 09.02.11.02.2005 AIDC Papendal, NL 08.03.09.03.2005 CFIA Rennes, F 08.03.10.03.2005 MOCON s-Hertogenbosch, NL 30.03.31.03.2005 AUTOMATICON Warsaw, PL 05.04.08.04 2005 Swiss Sensor Market Zurich, CH 07.06.09.06.2005 VISION SOLUTIONS Nijmegen, NL 15.06.16.06.2005 SAWO Posen, PL 20.06.23.06.2005 ELEKTROTECHNIEK Utrecht, NL 26.09.30.09.2005 Trade fair dates worldwide Trade fair Location Date 2004/2005 PRO MAT Chicago, Illinois, USA 10.01.13.01.2005 METALFORM Rosemont, Illinois, USA 20.03.23.03.2005 FIE Anhembi, So Paulo, BR 25.04.29.04.2005 Subsidiaries Australia Phone +61 3 9497 4100 +1800 3 3480 2 toll free sales@sick.com.au Austria Phone +43 22 36 62 28 8-0 office@sick.at Belgium/Luxembourg Phone +32 2 466 55 66 info@sick.be Brazil Phone +55 11 5091 4900 sac@sick.com.br China Phone +85 2 2763 6966 ghk@sick.com.hk Czech Republic Phone +420 2 57 91 18 50 sick@sick.cz Denmark Phone +45 45 82 64 00 sick@sick.dk Finland Phone +358 9-25 15 800 sick@sick.fi France Phone +33 1 64 62 35 00 info@sick.fr Great Britain Phone +44 17 27-83 11 21 info@sick.co.uk Italy Phone +39 02 27 40 93 19 ced@sick.it Japan Phone +81 3 3358 1341 info@sick.jp Korea Phone +82 2 786 6321/4 kang@sickkorea.net Netherlands Phone +31 30 229 25 44 info@sick.nl Norway Phone +47 67 81 50 00 austefjord@sick.no Poland Phone +48 22 837 40 50 info@sick.pl Singapore Phone +65 6744 3732 admin@sicksgp.com.sg Spain Phone +34 93 4 80 31 00 info@sick.es Sweden Phone +46 8-680 64 50 info@sick.se Switzerland Phone +41 41 619 29 39 contact@sick.ch Taiwan Phone +886 2 2365 6292 sickgrc@ms6.hinet.net Turkey Phone +90 216 388 95 90 pbx info@sick.com.tr USA Phone +1 (952) 941 6780 info@sickusa.com More representatives and sales offices in all major industrial nations at www.sick.com Imprint Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com Phone +49 7681 202-0 Fax +49 7681 202-3863 info@sick.de Co-ordination: Anette Hippach Customer Magazine Project Manager, SICK AG Anette.Hippach@sick.de Specialist editors: TOP MEDIA Dirk S. Heyden 69469 Weinheim info@topmedia-weinheim.de Conception/layout: johnson][braun Direktwerbung 76133 Karlsruhe jb@johnsonbraun.de Translator: Richard Dennis 79194 Grundelfingen richarddennis@t-online.de Printing: Druckerei Furtwngler 79211 Denzlingen info@druckerei-furtwaengler.de Pictures: SICK AG, Getty Images, Autoworld Brussels, BGFE, Roland Krieg Fotodesign Individual contributions may be reproduced after prior consent. Please contact us at: Phone +49 211 5301 0 Errors excepted Subject to technical change