SICK Magazine

02 2006 www.sick.
com
Volkswagen Brussels
New logic module for new
logistics centre
Page 13
Direct or indirect?
2-D reading technology
and direct part marking
Page 29
Controllers darling
Automatic format adjustment via
PROFIBUS-DP Hub
Page 34
S I C K S C U S T O M E R M A G A Z I N E
320 %
safetyPLUS: safety and added value in one package
Page 30
Better safe than sorry
Better safe than sorry
: Editorial
insightTELEGRAM
++ SICK celebrates its 60th jubilee
the town of Waldkirch renamed
Sebastian-Kneipp-Strasse as Erwin-Sick-
Strasse in memory of the companys
founder, Dr. Erwin Sick Anne-Kathrin
Deutrich, Spokesperson of the Executive
Board, went into retirement during the
festivities ++ The new exhibit concept
with touchscreens, which provide all-
round information on products and their
varied application, was very well received
at the Hanover Industrial Trade Fair (HMI)
the concept has been modified and
expanded for SPS/IPC/Drives ++ SICK
optimises delivery accuracy targeted
control of all internal processes for rapid
product availability: the right goods,
quality and quantity at the right time
and at the right place for measurable
dependability. ++
Networking competences, offer-
ing added value worldwide
Dear Reader
We would like to introduce ourselves to you in this new issue
of the SICK insight customer magazine. Since 1 July 2006
we have been responsible in the Executive Board of SICK
AG for the areas of Factory Automation and for Finances,
Personnel and IT. This transition has loomed large in recent
months because the Spokesperson of the Executive Board
for many years, Anne-Kathrin Deutrich, went into well-earned
retirement on 30 September 2006.
The last quarter also gave us an opportunity to get to know the company SICK,
meanwhile celebrating 60 years existence, from your point of view, the view of
our worldwide customers and business partners. As a result, we have realised
how important it is for you to obtain intelligent and complete sensor and control
solutions from a single source. Which is why we intend to continue providing
added value by concentrating more on OEM and end-customer advantages, and
the networking of technical core competences with an international presence, as
SICK already does uniquely in many cases, e.g. with the safetyPLUS safety
concept (please see Page 30).
Check it out for yourself: many of the applications presented in this issue of SICK
insight show what we mean by solutions, and what added value customers re-
ceive as a result. We would like to thank our customers for their support and col-
laboration. At the same time, we would also like to persuade new users to report
on their SICK sensor and control solutions in one of the future issues please
contact us.
But first, have a good read. With best wishes from Waldkirch
2/2006 03
Markus Vatter, Executive Board
Responsible for Finances, Personnel, IT
Markus Paschmann, Executive Board
Responsible for Factory Automation
: Contents
2/2006
04
Three dimensional measurement
of channel systems
17
safetyPLUS: safety solutions throughout
the entire machine life cycle
30
The worlds fastest camera system for
contour measurement
36
In conversation with Anne-Kathrin Deutrich
looking back, and to the future
46
:

T
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T
L
E

T
O
P
I
C
: safetyPLUS .................... 30
: Products
Product News ...................................... 32
Automatic format adjustment
via the PROFIBUS-DP Hub .................. 34
Magnetic cylinder sensors
with two switching points ................... 35
Worlds fastest camera for
3-D measurement ............................... 36
Evolution of multiple
lightbeam safety devices .................... 37
ASIC technology provides
increased performance ...................... 38
MM12 greater functional and
reliability reserves ............................... 38
Mobile identification of DPM codes ... 39
Masterly motor feedback solution ..... 40
Magnetic positioning system .............. 41
Laser photoelectric switch with small
optics and great intelligence ............... 41
Wire-draw encoder now with
HIPERFACE
interface ......................... 42
High-end reading system
for bar codes and data matrix ........... 43
Maximum switching accuracy through
2-D magnetic field evaluation ............ 44
: Museum
The Granville Museums in Vancouver
offer miniature Technology ................ 45
: Interview
In conversation with Anne-Kathrin
Deutrich, Spokesperson of the
Executive Board of SICK ..................... 46
: SICK Tour
Safety technology for Stankins
training centre ..................................... 48
Training & Education 2007 ................ 48
SICK celebrates its 60th birthday ...... 49
SICK supports Manchester
Metropolitan University ....................... 49
SICK Poland receives Gold Medal ....... 49
: Book Corner
The Travels of a T-Shirt in the
Global Economy by Pietra Rivoli ......... 50
: Info
Imprint/Service ................................... 51
Trade fair dates ................................... 51
: Editorial ............................... 03
: SICK Complete
Unbreakable position determination
for 12-tonners ..................................... 06
Blue is in at BONITA ......................... 07
Bar-code readers at WMF ................... 08
: Applications
-precise inspection of weld seams .. 09
Protecting rotary stations and lifts ..... 10
Fully automatic format adjustment for
the worlds first metal laminating plant 11
Through Lausanne
by laser measurement ........................ 12
New logic module at new Logistics
Centre for Volkswagen Brussels ........ 13
A dazzling solution .............................. 14
Collision prevention at Volvo .............. 15
Checking type and installation
of ventilator drives .............................. 15
Safety sensors at BMW ...................... 16
Three-dimensional
measurement of shaft caverns .......... 17
CLV490 bar-code scanners at VIKING 18
Multifunctional interfaces with
multiple opportunities ......................... 19
Tunnel contour measurement
with the DMT10 ................................... 19
ImageTeam hand-held
scanners at Bell .................................... 20
Compact photoelectric proximity
switches for better window frames .... 20
Zero-pulse assignment
at the press of a button ...................... 21
Safe production at
John Deere in Brazil ............................ 22
Industrial chains inspected
by 2-D smart camera .......................... 23
More safety for heavy traffic .............. 24
Robot guidance for meat processing 25
Intelligently organised safety .............. 25
Laser measurement
technology for coal heaps ................... 26
Training in a safe and
ergonomic environment ...................... 27
: Know-how
Automation with laser
photoelectric switches ........................ 28
Safe sensors and controllers ............. 28
2-D reading technology
and direct part marking ...................... 29
insightBOOK CORNER
Visit us at the SPS/IPC/DRIVES trade fair
SPS/IPC/DRIVES 2006
in Nuremberg from 2830 November 2006
Stand 7A-310 Hall 7A
www.mesago.de/sps
Take the opportunity at SPS
safetyPLUS the PLUS in information for you:
pExperts answer your questions on the new standards, applications, etc. at our
stand. Arrange an appointment now.
p Practical focus: companies present their safety applications at the VDMA stand
(Hall 6 - 236). Wed. 12.00, Thur. 11.00
Further information at: www.sick-safetyplus.com
: News
>> SICK has supplemented its series of
compact, light and low-current safety la-
ser scanners with the S200. Tasks that
require Category 2 protection in com-
pliance with EN 954 can now be imple-
mented even more economically.
Safety laser scanner for horizontal and vertical use
Now also for Category 2!
With a 270 scanning angle and a pro-
tective field radius of 1.5 m, the latest
addition to the new generation of scan-
ners covers a protective area of over
5 m
2
. Numerous integrated functions
and a 7-segment indicator for rapid
commissioning, diagnosis and mainte-
nance are the most important features
of the new S200. Object resolutions of
70, 50, 40 or 30 mm are available, pro-
viding reliable leg, arm or hand detec-
tion. Whether for horizontal or vertical
protection of hazardous points-of-op-
eration and areas, vehicle approach
protection, or monitoring distance
the S200 is the right solution for nu-
merous stationary or mobile tasks in
which cost-effectiveness and Category
2 safety are required.
05
Pietra Rivoli
The travels of a T-shirt
A T-shirt on a journey. What path does a T-shirt
take until its sale in a shop? Read for yourself
on Page 50.
>> Those logging in at www.2d-code.
com can profit doubly once from the
detailed information on the topic of
2-D codes and their identification, and
a second time by winning an ICR840
2-D code reader.
Several thousand interested visitors
have logged in at www.2d-code.com
within a short period. All have found out
about labelling and reading technologies
and some have even won a prize.
The lively interest shows the impor-
tance of the topic of 2-D in many sec-
tors. And SICK is providing one ICR840
2-D code reader each month in order to
ensure that at least one visitor can also
implement in practice the theoretical
knowledge gained via the Internet.
Maybe you will be the next winner...
Now one ICR840 code
reader each month
Win at
www.2d-code.com
Series of articles on safety tech-
nology in the specialist press
Finale in November
>> SICKs five-part series of articles cov-
ering all aspects of safety technology
ends with the publication of the article
Protective equipment for machines
protected but still unsafe? in Issue
12/2006 of the specialist magazine
Sicherheit & Management.
Over the year, Sicherheit & Manage-
ment (only available in German) and the
periodical :K reported on all aspects of
machine safety in five articles:
1. Why Europe made machines safer
2. The Machine Directive and safety:
from the standard to the norm
3. Safe construction, integrated safety
systems, circulation without defects
4. Triggering a stop, preventing a start,
safe operation
5. Protective equipment for machines
protected but still unsafe?
The overwhelming response to the arti-
cles shows that they offered the right an-
swers to resolve the questions and lack
of clarity existing in many places.
Those who missed one or other of the
articles can download them from the
Internet at www.sick.com/insight/en
2/2006
Positioning system : SICK Complete
06
Unbreakable position determination for 12-tonners
Undercover length measurement
>> Pfleiderer AG is one of the leading
system suppliers for wood materials,
surface treatment and laminated floors,
among other things. Typical Pfleiderer
products include untreated chipboard,
flooring and decorative panels, laminat-
ed panels or work surfaces. Gtersloh is
one of 19 production sites in Europe and
North America. At Works III the surface
treatment plant several thousand chip-
board panels are coated per shift.
Expanded production affects
transport concept
This transport system for stacked 11 m
2
panels was equipped with new vehicles
after the last production expansion in
2005. The 12-tonne transfer vehicles
are extremely well equipped: an on-
board control system with visualisation
and operation, energy and data trans-
mission by PROFIBUS via an inductive
system in the floor, and S3000 safety
laser scanners from SICK to monitor the
170-metre-long drive path shared by the
vehicles. A robust and precise solution
for absolute vehicle position determina-
tion was all that was still needed to fin-
ish off the concept. Most of the potential
solutions were discarded because they
were not sufficiently immune to damage
and misalignment.
Pomux KH53 by far the
best solution
The Pomux KH53 magnetic positioning
system proved to be the best solution. The
sensor unit determines the actual position
by means of non-contact scanning of ref-
erence marks (with integrated permanent
magnets) mounted along the drive path,
whose distance to one another represents
a fixed position coding and which are iden-
tified by magneto-resistive sensors. As a
result of the non-contact technology, the
system operates completely free of wear.
And thanks to absolute position determi-
nation, no reference run is required when
a transfer vehicle starts up. Users particu-
larly appreciate the superaccuracy. No
wonder with a resolution of 0.1 mm, re-
peat accuracy of 300 m, and a scanning
speed of 0.8 ms.
Active underground
to prevent damage
With fork-lift traffic and transfer stations
on both sides of the drive path, the risks
of damage or misalignment are ever-
present and discouraged mounting of
the reference marks along the side of the
drive path. Best stick them in the floor,
was the decision at Pfleiderer. A groove
was cut into the floor along the drive
path and levelled with non-absorbant
sand, the reference marks were installed
and the whole thing was then sealed at
floor level with cast resin. This solution
was ultimately also possible because the
Pomux KH53 offers a reading range of
25 mm and thus reliably detects the per-
manent magnets in the floor.
Pole position in costs comparison
The two transport vehicles of the intial
expansion phase have been in operation
since December 2005. They carry out
more than 300 transports per day and
have never lost their position. And the
costs side also works out well: compared
to the purchasing and operating costs of
other solutions, the Pomux KH53 paid
for itself within half a year.
The wood material system supplier Pfleiderer in Gtersloh was looking for
a robust and precise solution for determining the positions of four transfer
vehicles active in five halls but using only a single drive path Seli, the com-
plete solution supplier and systems partner of SICK Vertriebs-GmbH, found
the right solution with the Pomux KH53 linear length measurement system.
insightLINK
You can obtain further product
information with the attached card under:
INFO 201
or on the internet at:
www.sick.com/insight/en
More about the customer
www.pfleiderer.com
The S3000 safety laser scanner and the KH53 positioning system protect the drive
path and determine the positions of transfer vehicles
: SICK Complete Textile industry
07
>> Its not the CLV420 compact bar-code
scanners for the identification of boxes,
the CLV490 high-end scanners for read-
ing the labels on the goods on clothes
hangers, or the WL9-2 series photo-
electric switches on the roller conveyor
systems. No, the WT18-3 is the most
fashionable for the automation of the
BONITA distribution centre.
Universal genius
The sensor is used on the transport sys-
tem for the goods on clothes hangers and
is a universal genius, is how Paul Mess,
Managing Director of msm automations
gmbh & co. kg, describes his experience
with the device. It offers a scanning
range of 1,000 mm, can detect even
black clothes hangers or textiles with
maximum reliability, and is not at all sen-
sitive to the many and varied sources of
interference near the conveyor systems,
storage buffers and sorting plants.
BONITA: feeling for
combination fashion
Bonita has been selling ladies wear
for demanding and fashion-conscious
women under its Spanish name since
1986. With its combinable fashion col-
When automation follows fashion
Blue is in
At BONITA, specialists in ladies wear, it is not only the collections that
match perfectly in colour and style, but also the sensors at the distribu-
tion centre in Hamminkeln near Bocholt, Germany. More than 8,000 I/O
point photoelectric switches and bar-code readers in uniform blue attire
dominate here.
lections, BONITA has developed into the
leading ladies wear chain in Germany
and Austria: the range is currently sold in
more than 600 branches. The construc-
tion of the new distribution centre was
therefore intended to ensure the smooth
initial stocking of branches with new col-
lections, to provide 24-hour availability
of goods to meet customer wishes, and
to meet future logistical needs.
Fit for 50,000 units
The dynamic warehouse for goods on
clothes hangers, automated by msm,
forms the heart of the distribution cen-
tre. Up to 50,000 units in the 28 stor-
age buffers, and up to 6,000 storage or
retrieval actions per hour do not permit
any unnecessary plant downtimes not
if BONITA wants to guarantee the smooth
filling of orders, says Paul Mess. Which
is why he chose to use the WT18-3 pho-
toelectric proximity switch for object
detection on the suspension conveyor
systems, so often susceptible to critical
environmental conditions.
Dazzling sensor availability
The reason why the WT18-3 was se-
lected is because the differing colours of
insightLINK
INFO 202
www.bonita.de
the textiles, and the varying surfaces of
the clothes hangers, generate an assort-
ment of reflectivity signals for a scanner
that can persistently affect scanning re-
sults. Not only this, but persons, trans-
ported goods, and light or dazzling ef-
fects can cause a variety of interfering
pulses in the storage buffers and sorting
systems, and on the conveyor belts po-
tentially leading to spurious switching or
false positives if conventional scanners
are used. Not so with the WT18-3. Light,
dark, patterned or interwoven articles of
clothing are always reliably detected.
Clothes hangers with optically differing
appearances are also no problem, con-
firms Paul Mess. In addition, passive
or active interference of any type in the
operating area is electronically identi-
fied, suppressed and thus reliably cut
out ensuring the high availability of the
plant.
Top for ladies wear: the WT18-3
makes a considerable contribution to-
wards assuring the proper supply of
BONITA branches.
The WT18-3 photoelectric proximity switch detects clothes hangers
or textiles with maximum reliability
Reading labels on goods on clothes hang-
ers with the CLV490 high-end scanner
2/2006
Logistics : SICK Complete
08
Bar-code readers in warehouse modernisation
More reading stations greater
logistical performance
Bar codes, not reflectors was the motto during the modernisation of
WMFs central warehouse in Geislingen, Germany. viastore systems, the
general contractor, chose WL9 photoelectric switches and C4000 safety
light curtains from SICK, in addition to numerous CLV bar-code reading
systems.
>> The modernisation of high-bay ware-
houses is in on the one hand because
the material flow and control technology
of first-generation warehouses are age-
ing and, on the other hand, because
modernisation is often the most efficient
solution for space or licensing reasons.
These were also the reasons why Wrt-
tembergische Metallfabrik (WMF) decid-
ed on a comprehensive modernisation.
WMF hired viastore systems to carry out
the planning and restructuring of all in-
tralogistical processes. This involved
modernisation of the high-bay stackers,
the conveyor technology, and the ware-
house administration software, as well
as standardisation of the computer and
control structures, and replacement of
the reading technology.
More scanners offer greater func-
tionality for material flow computer
One focus of the modernisation work
was thus on reading technology. The old
reflector system was replaced by the use
of bar-code labelling. At the same time,
the reliable bar-code scanners of the
CLV420 and CLV430 series were chosen
the latter with oscillating mirror tech-
nology. These bar-code readers offer in-
dustrially proven technology with which
the reading stations could be economi-
insightLINK
INFO 203
www.wmf.de and www.viastore.de
High-bay stackers equipped with bar-code scanners and safety light curtains
cally set up. Thus each decision-making
location in the material flow of the new
WMF warehouse is equipped with a CLV.
This not only results in greater process
reliability, but the material flow compu-
ter can also control the flow of material
quantities more efficiently.
Leading table and kitchen products
As an internationally leading product and
service supplier specialising in table and
kitchen products, WMF is particularly de-
pendent on logistics that function well
in order to promptly meet the needs of
retailers (and thus consumers), as well
as hoteliers and customers in gastrono-
my. Availability, flexibility, upgradeability
all aspects of the old warehouse solu-
tion were running up against their limits.
Which is why viastore systems modern-
ised 17 high-bay stackers and installed
15 new units. The entire stationary con-
veyor technology, including its control
components, and material flow and con-
trol computer, was transformed.
The performance capability of WMFs
central warehouse could correspondingly
be increased to up to 30,000 individual
product picks per day to process delivery
orders while simultaneously shorten-
ing order throughput times.
WL9 photoelectric switches
small and powerful
: Applications Steel industry
09
>> Displacement sensors with CMOS
technology, like the OD Max, measure in
the -range. They monitor the presence
and position of objects, measure profiles
and diameter, regulate processes and
handle other quality inspection func-
tions. At the automotive sub-contractor
Tailored Blank Gent, which specialises
in welded and formed parts, the task is
to check that the weld seams on steel
sheets welded to one another are per-
fect. At the same time it was necessary
to install the highly precise sensor we
needed in the smallest of spaces, says
Patrick De Coninck, responsible for the
automation line at Tailored Blank Gent.
OD Max the maximum solution
Tailored Blank Gent decided on the OD
Max for various reasons. The 30 mm
version provides a measurement range
from 25 to 35 mm and an accuracy of
10 m. It thus fulfils the applications
-precise inspection of weld seams
5 million inspections per year
Tailored Blank Gent, a member of the Luxembourg-based Arcelor Group,
has found the perfect solution for inspecting about 5 million weld seams
per year with the OD Max displacement sensor.
distance and precision demands. Thanks
to its CMOS technology, the OD Max
measures with -accuracy and extreme
reliability even with reflective sheet and
weld seam surfaces. The concept of a
separate sensor and evaluation with an
LC display is characterised by space-sav-
ing installation, as well as simple com-
missioning and operation. With four ana-
logue outputs, five switching outputs and
an RS-232 interface, this displacement
sensor offers all the important methods
of data output.
Its not the looks but the profile
that counts
We produce about 13 m. weld seams
a year; of which 5 m. are inspected with
the OD Max, says Patrick De Coninck.
Whereby 100% inspection is indispensa-
ble. If a weld seam in a weight-bearing
part of a car chassis is poor (we call this
an irregular weld seam) it could be cat-
insightLINK
INFO 204
www.arcelor.com
The OD Max displacement sensor meas-
ures sheet and weld seam
surfaces with -accuracy
even in the tightest of spaces
astrophic for the driver, explains Patrick
De Coninck. Although the defective weld
seam may appear optically perfect, the
OD Max detects it as defective on the ba-
sis of it not reaching the defined height
difference between the sheet and the
weld bead.
Successful start at Arcelor
The positive experiences that Tailored
Blank Gent have had with the OD Max
have got around the Arcelor Group. A
variety of other Group companies have
adopted the inspection system with the
OD Max, for comparable production en-
vironments.
: Applications
10 2/2006
>> In addition to toilet paper and kitchen
rolls, WEPA Mainz GmbH also produces
damp hygiene tissues on a total of five
processing lines. The production capac-
ity is approximately 58,000 tonnes with
a processing capacity of about 30,000
tonnes of tissue per year a volume
that also requires intralogistical trans-
port between Production, the ware-
house and Despatch. The use of the
C4000 Palletiser ensures that persons
in the vicinity of equipment, or machines
and pallets, do not get in the way during
automatic material transport.
Pattern-based monitoring
The C4000 Palletiser safety light curtain
is electro-sensitive protective equipment
in the highest possible safety category:
Type 4 in compliance with IEC 61496
and SIL3 according to IEC 61508. It is
also an intelligent sensor system that
operates on the principle of self-learned
pattern recognition, and can thus de-
pendably differentiate between persons
insightLINK
INFO 205
www.wepa.de
Protecting rotary stations and lifts
Safety for automatic tissue transport
C4000 Palletiser safety light curtains at the Mainz works of tissue paper
producer WEPA protect rotary stations and lifts on the pallet conveyor
sections between Production, the warehouse and Despatch.
and pallets providing reliable protec-
tion of feed openings for automatic
material transport in hazardous areas.
At the same time, pattern recognition
means that no supplementary muting
sensors, indicator lamps, fencing and
barriers, or swing flaps are required,
minimising potential problems and opti-
mising availability of the entire plant.
Collision-free tissue transport
even with differing pallet types
In addition to other stations at which
WEPA already employs proven mut-
ing solutions from SICK, a safety-criti-
cal access to rotary stations and lifts
was recently equipped with the C4000
Palletiser safety light curtain. Pattern
recognition for pallets is already deliv-
ered in an activated state and simply
requires installation. The monitoring
function remains active when the sys-
tem recognises the foot pattern of the
Europallets used, so that the pallet can
pass through the protective field without
stopping the plant. The hazardous move-
ment stops if the pattern deviates from
the programmed limit values or the pat-
tern changes during transport. This even
happens if a person walks along behind
or alongside the pallet. In this case, too,
a pattern is recognised and evaluated
by the C4000 Palletiser with a not in
order signal. The automatic learning
process takes place with each pallet. It
is thus possible to use a mixture of pal-
lets. The direction of movement can also
be defined in the program. So access
against the direction of movement also
triggers a safe stop.
In many cases the safety, availabil-
ity, supplementary functions, or savings
resulting from lower installation costs
make the C4000 Palletiser the right so-
lution for automatic material transport in
protected areas.
The C4000 Palletiser safety light
curtain can reliably differentiate be-
tween persons and pallets no sup-
plementary protective equipment is
required on feed openings
Pallet transport
11
>> The automation concept of the NO-
VUS 1200 employs automatic format
adjustment with the integrated HIPER-
DRIVE
positioning drive throughout.

The motor, drive, absolute measure-
ment system, and performance and
Fully automatic format adjustment for the
worlds first metal laminating plant
Fantastic flexibility
The NOVUS 1200 from the Nuremberg-based company Billhfer is the
worlds first laminating plant for metal packaging. During implementa-
tion of this revolutionary coating concept, e.g. for bottle tops, stoppers,
containers, tins or lids, the decision was also made to use equally revo-
lutionary format adjustment with the fully automatic HIPERDRIVE posi-
tioning drive.
regulatory electronics are accommodat-
ed in a compact housing. The absolute
determination of orientation offers an
unambiguous positional value for each
axle position no reference run is nec-
essary when the laminating machine is
insightLINK
INFO 206
www.billhoefer.de
Billhfer has taken a totally new route with the NOVUS 1200. The production
of surface-treated sheets takes place through lamination of the raw substrate
with a protective foil within, as well as lamination with a previously printed foil
on the outside. This completely does away with the spraying and drying stati-
ons necessary for the conventional process. The raw substrate, with thick-
nesses of between 0.1 and 0.4 mm, e.g. metal sheets, are de-stacked in the
automatic sheet feed unit and then cleaned in a Corona unit, and provided
with the surface charge necessary for the lamination process. The foil, with
a thickness of between 12 and 23 m, is coated with glue in an application
system straight off the roll and without contact and then joined to the
metal sheet in the laminating unit with an application force of 6 tonnes.
>> Metal lamination
started up. In terms of construction, the
compact devices also fit perfectly into
the tight spaces of the NOVUS 1200.
Integration of the positioning drives in
the PLC machine controller takes place
by means of a PROFIBUS-DP plug-in
module that is inserted and screwed
in directly onto the standardised basis
drive with plug & play.
HIPERDRIVE for all important axles
The limit stops in the feed unit, the knife
for cutting the foil edges, the width ad-
justment for the application of glue,
the positioning of the edge detection
sensors, or the width and length ad-
justments of the receiving system all
the format-relevant axles are equipped
with HIPERDRIVE positioning drives.
They allow adjustment of any panel for-
mat between 500 x 500 mm to 1,200
x 1,200 mm, and any web width of be-
tween 100 mm and 400 mm at the
press of a button and in the shortest
of times.
Format advantages
The end-users find this quite fantastic,
as the positioning drives offer them
flexibility and time savings. Adjustment
at the press of a button is a simple
formality and is very rapid: Billhfer
estimates that there is a 66% cut in for-
mat adjustment time. Several product
and batch changes per day, economi-
cal laminating of both large and small
batches, reduced need for personnel
around the machine, just one format
adjustment for frequently recurring
orders, and documentation of the ma-
chine parameters for quality control are
the advantages most frequently cited
by customers.
Regardless of the end-product, au-
tomated format adjustment with HIPER-
DRIVE makes a decisive contribution
towards each user being able to exploit
the new technology of metal lamination
for their tasks economically and with
maximum flexibility.
Positioning drives on laminating plants offer flexibility and save time
: Applications Laminating metals
: Applications
12 2/2006
insightLINK
INFO 207
www.serpentine.ch
>> Tomorrows urban mobility requires
new approaches that take into account
the wishes and requirements of local traf-
fic suppliers and potential passengers,
says Bernard Saugy, Managing Director
of CN Serpentine SA in Lausanne. In
classic local public transport, aims such
as minimised emissions, savings in
energy and costs, no accidents, rapid
progress in traffic without wasting time
in traffic jams, frequent and preferably
individual departure times, comfortable
transport, and an acceptable price-per-
formance relationship often contradict
one another. This is not the case with
Serpentine. Which is why he is sure that
his company is on the right path with this
concept. Numerous international prizes
appear to confirm this view.
To the conference or
caf by capsule
Externally, the Serpentine local transport
system consists of a variable number of
autonomous vehicles depending on the
number of passengers. In addition to
the capsules, there is the MagnetoGlis-
seur magnetic vehicle guidance system
along the drive path (which is also re-
sponsible for the transfer of energy and
information) as well as the central HB
Traffic Manager, that administrates the
vehicles, monitors the direction of trans-
port of the capsules, manages the tick-
eting, and is responsible for the safety
of the entire system. Each vehicle is in
use 20 hours a day and only consumes
300 W of energy that is 1/30 of the
energy requirement of a car for the same
distance, says Bernard Saugy. The cap-
sules on the drive path, along the banks
of Lake Geneva in Lausannes Ouchy
district, can be called up individually by
SMS or e-mail. This simple availability
at any time made a major contribution to
Driverless and risk-free Serpentines
Through Lausanne by
laser measurement
Public but individual Serpentine, a new autonomous system for trans-
porting persons in local traffic, has been successfully tested in Switzer-
lands Lausanne. The heart of the solution concept, driverless personal
capsules for up to five passengers, can be called up by e-mail or SMS.
LMS Laser Measurement Systems support the vehicles safety systems by
monitoring the drive path and thus preventing collisions.
their positive acceptance by users, says
Guy de Pourtals of CN Serpentine SA
and head of the Lausanne project. But
the fact that the passengers felt safe in
the capsules, which travel at about 15
km/h, was the decisive factor. Towards
which the LMS Laser Measurement Sys-
tems make a considerable contribution.
Drive path monitoring and
collision prevention through
laser measurement
Serpentine takes care of the safety of pas-
sengers with numerous safety features
The LMS is mounted for forward vision
so that the actual safety technology is only
actually used in an emergency. It was the
only system with which the geometries of
the monitored fields could be taught-in
path-specifically, Guy de Pourtals em-
phasises. Several signalling areas can
be defined within the monitored field.
This allows graduated responses. Per-
sons who are far away are warned acous-
tically, and if they continue approaching
the capsule it goes into crawl mode until
it reaches the defined safety distance and
automatically stops and only continues
moving when the person has moved out
of the way.
Our concept is the right one for the
future, says Bernard Saugy. Which may
have already started the company is
currently carrying out other interesting
projects, e.g. in Geneva, between the air-
port and the city centre.
prevention of wedging during entry and
exit and during opening and closing of the
doors, or emergency stop buttons for ac-
tive interruption of the drive. Each vehicle
is supported in this by a LMS Laser Meas-
urement System. It checks the drive path
over the entire width and detects persons
or obstacles at distances of up to 10 m.
Collision-free travel for driverless personal transport capsules supported
by the LMS Laser Measurement System
Transport and traffic
: Applications
13
insightLINK
INFO 208
www.volkswagen.com
>> The ZLM1 logic module, containing
the logic for the accumulating roller
conveyor and the magnetic valve, thus
increases the flexibility of accumulating
roller conveyors. As a result, the most
varied of applications can be solved
economically and with technical sophis-
tication. The module can be combined
with the most varied of optical or induc-
tive SICK sensors even with the clas-
sic WTR1 accumulating roller sensor.
Increased flexibility for
accumulating roller conveyors
The automatic small parts store at
Volkswagens Logistics Centre in Brus-
New logic module at new Logistics
Centre for Volkswagen Brussels
Greater flexibility for accu-
mulating roller conveyors
Varying container sizes are no longer a problem for modern accumulat-
ing conveyor systems such as those at Volkswagen in Brussels: contain-
ers of differing sizes in any position on the conveyor section are reliably
detected, accumulated and removed with the ZLM1 logic module and the
MHL15 compact photoelectric switch.
sels was commissioned in January 2006
by EISENMANN, the general contractor.
What is special about this accumulat-
ing roller system is that goods of differ-
ing dimensions (from 800 x 400 mm
2

to 200 x 300 mm
2
) are transported on
the same system. Two MHL15 units are
located on each conveyor segment and
connected to the ZLM1 logic module
with an OR linkage, whereby the logic
component and the magnetic valve form
a space-saving unit. This achieves the
targeted deceleration of both large and
small containers. While the latter could
theoretically be detected by using only
a single photoelectric switch, it would
be stopped too late due to the braking
arrangement necessary for the over-
all system. The result: the light path of
the photoelectric switch would be free
again and the small container would
logically be transported onwards.
Control of the accumulation and start
functions in the accumulating roller con-
veyor system takes place autonomously
thanks to the logic module, which con-
tains the most frequently used logic func-
tions: single feed, single removal and
block removal. This reduces the wiring
effort required by the user compared to
a star-shaped wiring concept, as well as
the corresponding programming required
in the connected external controller.
MHL15 short and flush, ideal for
conveyor systems
The MHL15 photoelectric switch sim-
plifes installation in or above a lateral
branch as a result of its new type of
mounting concept with a flush cover
ring and fixing nut also providing a
simple means of protecting the photo-
electric switch from damage. The MH15
is also available as an energetic photo-
electric proximity switch and a through-
beam photoelectric switch.
Varying container sizes are no problem with the MHL15
compact photoelectric switch
The logic unit and the magnetic
valve form a space-saving unit
with the ZLM1 logic module
Automotive
: Applications
14 2/2006
A dazzling solution
Photoelectric proximity switches
for satellite protection
Mobile working platforms from Swedish producer MaxMove are very
popular in the airplane industry. WT18-3 series photoelectric proximity
switches ensure that the platforms also simplify everyday work in the
space industry, e.g. at Boeing Satellites.
>> Gran Eckestrm, the active partner
and Marketing Manager of MaxMove, of-
ten travelled from the northern Swedish
town of Umea to the American west coast
to convince Boeing Satellites of the appli-
cability of his mobile working platforms.
In the end he succeeded ultimately be-
cause he could also offer a solution for
detecting highly reflective black satellite
surfaces and their solar cells.
Preventing floor collisions
The manoeuvrable working platforms
from MaxMove are used for bringing and
readying materials and tools in the imme-
diate vicinity of the satellites. They also
prevent the use of step constructions or
ladders on the satellites, which may be
several metres tall. Of course the very
mobility of the platforms represents a
risk of collisions with the satellites under
insightLINK
construction, which are spread out all
over the works hall, Gran Eckestrm
describes the problem. It was not pos-
sible to use conventional photoelectric
proximity switches to detect the extreme-
ly sensitive, black, highly reflective outer
skins of the satellites and the solar cells
mounted on them. So its a good thing
that SICK Sweden could present the new
WT18-3.
Sensors dazzle
suppression is dazzling
Dazzle is one of the most common types
of passive interference for opto-electronic
sensors in industrial use. With the WT18-
3, a scanner is available that eliminates
precisely these interfering factors. It is
the first device of its type to exploit a chip
technology specially developed for scan-
ners. The scanning distance and scan-
ning range can be adjusted with extreme
accuracy and reproducibility. At the same
time, dazzle and reflections are electroni-
cally suppressed, and thus reliably cut
out. With their total of 18 photoelectric
proximity switches each, the mobile plat-
forms soon detect when they approach
too near a satellite and respond by gen-
erating an alarm signal.
We really scored a bulls eye with the
WT18-3, Gran Eckestrm is pleased to
say. And Boeing profits from the fact that
the sensors light beams are the only
form of contact between the working
platform and the satellites.
A view of the works hall of Boeing Satellites
Object detection
INFO 209
www.sick.com/insight
More about the customer:
www.maxmove.se and
www.boeing.com
: Applications
15
insightLINK
INFO 210
>> Several gantry cranes share the same
rails in Volvos works hall, e.g. between
the laser cutting plant, manual welding
stations and the welding robot cells. The
task was to reliably prevent collisions
both between the cranes themselves,
and between the cranes and the hall
walls. We needed a collision prevention
system that guaranteed the safety of our
employees and met the demands of au-
thorities, says Tom Ericsson, a Mainte-
nance Engineer at Volvo.
S3000 the suitable sensor
In sensor terms, the task was solved with
the S3000 Standard safety laser scan-
ner. The device is mounted at the top of
the gantry crane and vertically aligned.
The protective fields must be very long
because of the crane operators insuf-
ficient overview, says Tom Ericsson.
Which is why we measured the brak-
ing distance of the crane and then knew
what protective field length the S3000
had to cover.
UE440 and UE48 the suitable
control components
The UE440 safety controller handles the
separate evaluation of the protective
fields allowing monitoring of the direc-
Collision prevention at Volvo
Flexible drive path protection
for gantry cranes
Whether forwards or backwards the combination of a safety laser scan-
ner and the UE440 safety controller prevents collisions in both directions.
The UE440 safety controller evaluates the protective and warning fields;
type UE48 safety relays generate the switching signal for the crane con-
troller. A solution that is currently only available in this form from SICK.
tion of movement and the safe speed, as
well as collision prevention. It receives
the S3000s safety-relevant signals via
the enhanced function interface (EFI).
A total of four UE48 safety relays are
connected to the UE440. Two of them
process the signals of the configurable
signalling application diagnostic outputs
(ADOs), providing detection of obstacles
in the direction of movement. The two
other UE48s receive their signals via
the two output signal switching devices
(OSSDs), with which the speed of the
crane is reduced, or an emergency stop
of the entire crane is initiated.
A safety laser scanner with protective
fields that can be separately evaluated,
which protects gantry cranes in both di-
rections of movement without directional
and speed information this solution is
currently only available from SICK.
>> The Czech single-purpose machine
builder ADAX spol. s.r.o. has designed
an installation inspection station for a
producer of car air-conditioning systems,
in which the CVS3 camera sensor differ-
entiates between two types of ventilator
drives while also ensuring correct instal-
lation.
The CVS3 Contour Vision Sensor is a
compact and user-friendly camera sen-
sor with integrated illumination. Versions
are available with operating ranges of 30
mm to 40 mm, and from 90 mm to 150
mm, depending on the task. The device
detects the presence of objects, their
shape, size and orientation and allows
mounting processes, for example, to be
designed efficiently and with a high level
of availability.
The side view is decisive
This inspection task could be ideally
solved with the help of the CVS3. The
device detects the ventilator drive from
the side and can reliably differentiate
between the two types on the basis of
characteristic features. The PNP output
switches if an incorrect part is detected.
If the ventilator type is in order, the cam-
era sensor determines the correct angle
of orientation before insertion of the ven-
tilator. ADAX was very enthusiastic about
the simple and rapid implementation of
the solution as well as the camera sen-
sors compact housing and reliability.
CVS3 when its the contour that
counts. INFO 211
Checking type and installation
of ventilator drives
Getting the in-car
climate right
Everything in view with the S3000 safety laser scanner vertically
: Applications
16 2/2006
insightLINK
INFO 212
www.bmw.de
>> Construction of the BMW vehicle works
in North Leipzig meant creating one of the
worlds most modern automobile facto-
ries. The 3-Series has been rolling off the
lines here since spring 2005. Up to 650
vehicles are to be produced each day in
Integration and monitoring of decentralised
safety functions at BMW in Leipzig
Safety sensors with the best
of contacts to PROFIsafe
The BMW works in Leipzig is one of the most modern production sites
of its type. This is not only visible in the plant technology, but also in the
safety technology. Electro-sensitive protective equipment directly con-
nected to PROFIsafe increases availability in final assembly and improves
the productivity of automobile production.
the medium term. Whether shell construc-
tion, the paint shop or assembly during
planning of the works, particular attention
was paid to ensuring flexible and expand-
able communication structures which
were not to be impaired by the safety sys-
tems employed.
Intelligent interfaces for
in-situ safety communication
These demands could be solved with the
help of SICK UE4120 and UE4150 safety
modules which have two extra connec-
tors for intelligent SICK safety compo-
nents, e.g. the S3000 without the need
for long cable connections between sen-
sors and controllers. The interface mod-
ules have eight field signal inputs for the
connection of active and passive, single-
or dual-channel safety components up to
control Category 4. The sensor connec-
tions and system functions can be config-
ured offline, i.e. without connection of a
failsafe PLC. CDS configuration software,
as used for SICK safety sensors, offers us-
ers a familiar look and feel. In operation,
the UE modules provide maximum system
transparency: all connected devices can
be contacted, analysed and visualised
directly via PROFIBUS. A sensors stored
parameter data can automatically be
transferred to the new device if the re-
sults of remote diagnosis indicate that a
replacement is necessary, minimising im-
pairment of plant availability.
UE possibilities also for the X5
four-wheel drive vehicle
These interface modules allowed, among
other things, the numerous S3000 safety
laser scanners and MSL-Z multibeam
photoelectric safety switches in the final
assembly at BMW in Leipzig to be di-
rectly integrated in the works PROFIsafe
communication structures. In addition to
reducing interface hardware and instal-
lation costs, the integration and monitor-
ing of remote safety functions increased
process efficiency, in particular. The sys-
tem is also open for plant expansions or
structural modifications.
BMW has exploited these advantages of
intelligent interface technology again at
its US works in Spartanburg for produc-
tion of the X5.
Final assembly at BMW in Leipzig equipped with electro-sensitive protective equipment from SICK
Intelligent interfaces for safe
in-situ communication
Automotive
: Applications
17
insightLINK
INFO 213
www.eth.ch
>> Steep descents through vertical
shafts, dampness, dirt and unforeseen
conditions not many people enjoy en-
tering shaft caverns. And it will also no
longer be necessary thanks to the Cav-
ern Measurement System (CMS) devel-
oped by ETH Zurich to the relief of em-
ployees at civil engineering authorities or
engineering and surveying companies.
For renovating channels, and water and sewage pipe systems
Three-dimensional measurement of
shaft caverns without entering them
The Institute for Geodesy and Photogrammetry at the ETH in Zurich (Chair
of Geodetic Metrology and Engineering Geodesy, geomETH) has devel-
oped a prototype of a new measurement system, based on the LMS Laser
Measurement System, for determining the dimensions of shaft caverns.
The solution is more precise and safer for personnel than conventional
manual measurement.
Head first into the depths
Mounted on a rotary table, the LMS200
goes head first into the depths on a tel-
escope support. When it reaches the
bottom, it is turned through 360 to
make the measurement. During the
measurement, the measurement data of
the LMS200 and the current position of
the rotary table compared to the origin
(zero point) are registered on a hard disk.
Darkness, dark walls or damp concrete
surfaces nothing impairs the operation
of this 3-D measurement system, en-
thuses Hans-Martin Zogg of the Institute
for Geodesy and Photogrammetry at the
ETH in Zurich. The practically relevant
measurement range lies between 1 m
and 30 m. The result of a roughly three-
minute all-round scan by the LMS200 is
a cloud of points consisting of more than
one million individual measurement
points. The level of detail of the cloud
of points depends on the resolution of
the 3-D measurement system. Vertical
resolution is fixed at 0.25, while the
horizontal resolution is infinitely variable.
Thus even the smallest of channels, or
the rungs on the entry ladder, are clearly
visible in the cloud of points. The evalua-
tion software of the CMS then provides a
3-D model of the shaft cavern.
The CMS has remained within its
tight budget, not least because of the
LMS200, making it interesting for poten-
tial purchasers such as civil engineering
authorities, city departments of works, or
surveying companies.
Head-over-heels into the depths the
LMS200 laser scanner measures shaft
caverns with 360 scanning
Civil engineering
: Applications
18 2/2006
insightLINK
INFO 214
www.viking.at
>> VIKING, a member of the Stihl Group,
produces and sells lawnmowers, ride-on
mowers, garden shredders, lawn trim-
mers, hedge trimmers, garden shears
and motorised tillers of the highest qual-
ity. We wanted to achieve the same
high level in the logistical chain to end-
customers, says engineer Harald Gan-
ster, responsible for logistics at VIKING.
Therefore, in collaboration with SICK
and the Steininger technical office, we
have implemented a fully automatic out-
going pallet inspection that is integrated
in our SAP system.
Automatic identification with
real-time comparison
The identification and checking of
packed garden tools takes place fully
automatically using two CLV490 bar-
code scanners. The scanners identify
the despatched devices on the basis
of their EAN numbers and serial num-
bers, and also check completeness on
the pallet. The pallet, with its goods
and their EAN and serial numbers, is
turned through 360 on a rotary table
Delivery quality is also a product property
Ensuring that garden tools
reach retailers in good time
In order to optimise the flow of goods and prevent incorrect deliveries, the
Austrian gardening tool producer VIKING relies on automatic inspections
of outgoing goods with CLV490 bar-code scanners.
and scanned on all four sides. After all
the data has been read-in and sent to
the control system they are compared
with the production and delivery data.
Whereby the first EAN numbers deter-
mine the type of goods and the assigned
maximum pallet quantity and these are
shown on a display. An error message
is displayed if the EAN number does
not match the data at the industrial ter-
minal, and further processing can only
take place after physical correction on
the pallet and a new scanning process.
The pallet stretch wrapping equipment
is activated if all serial numbers tally
with the values expected by the system.
At the same time, the data are sent to
a PC for further processing, from where
they are transferred to the SAP system.
This procedure reliably prevents incom-
plete or incorrect consignments while
ensuring gap-free traceability.
As Harald Ganster sums up: 100%
tracking of all machine numbers and a
gap-free quality chain to our end-custom-
ers is now possible with the inspection
capabilities of the CLV490. The identi-
fication solution from SICK is therefore
now an important component in our
quality management.
Fully automatic outgoing pallet inspection ensures a complete quality
chain all the way to end-customers
The CLV490 bar-code scanner in use
Material handling
: Applications
19
>> Checking access, monitoring internal
spaces or emergency stop are functions
that minimise the risk of dangers on
presses. The UE470 safety multifunc-
tional interface maximises the benefits
users gain from the central control and
monitoring of safety functions.
Central monitoring and control of complex safety functions on presses
Multifunctional interfaces with multiple opportunities
Machines and plants can be flexibly and
efficiently protected with the UE470 pro-
grammable safety multifunctional inter-
face which is Category 4 in compliance
with EN 954-1 and SIL3 according to
EN 61508. A total of seven dual-chan-
nel inputs, eight outputs four of which
can be used as safe output pairs and
bypass functions offer wide-ranging pos-
sibilities of use. The menu-guided CDS
configuration and diagnostic software
supports users in the parameterisation
of the UE470, and thus in the implemen-
tation of complex safety functions, e.g.
on the presses produced by Meyer.
UE470 multifunctional interfaces
combine safety functions
Large presses work with forces of 10,000
kN, sometimes even more. Depend-
ing on the workpiece, the tables of the
presses may have dimensions of several
square metres. This shows that both the
access to presses and presence in the
area of the table, e.g. while changing
tools, must be protected. C4000 safety
Scanning distance sensor used for measurement
Tunnel vision
light curtains are proven for protecting
access, while internal monitoring is a
typical domain of the S3000 safety la-
ser scanner. Finally, the emergency stop
button allows the operator to switch off
the machine directly when he or she
detects a risk or a problem. When the
press is switched on it needs safe logic
to evaluate, for example, the Reset sig-
nal initiated by the operator, or to bridge
protective equipment in a safe operating
state. The UE470 offers all the possibili-
ties of receiving signals, processing them
safely and according to the press cycle,
and switching off the press in an emer-
gency via the two output signal switching
devices (OSSDs). Whereby the OSSDs on
the Meyer presses are contacted in dif-
ferent ways either jointly, via the elec-
tro-sensitive protective equipment and
the emergency stop button, or via the
emergency stop button alone.
The central monitoring and control of
complex safety functions on presses no
problem with the UE470. INFO 215
>> Whether the correct location for bore-
holes for explosives, or the thickness of
the air-placed concrete applied the
DMT10 provides highly accurate data as
a sensor for a 3-D tunnel profile meas-
urement system.
The Bever 3D Profiler is a system so-
lution from the Norwegian company Bever
Control. It is installed directly on the tunnel
drilling vehicle, and carries out both point
measurements at the current vehicle lo-
cation as well as simultaneous scans of
a tunnel section several metres long. The
DMT10 is mounted on an arm that pivots
through all axes. Its measurement data is
processed in a computer system that the
company developed itself, and is visual-
ised by the user as a 3-D graphic.
Precise, robust and economical
Both technical and economic arguments
supported use of the DMT10. The de-
vice offers a practical scanning range
of 20-40 m even with dark rock layers.
It is also very precise, allowing the 3D
Profiler to generate a picture of the tun-
nel accurate to within a few millimetres,
says Thorvald Wetlesen, Managing Direc-
tor of Bever Control. He is also convinced
about the costs side of the solution: The
DMT10 is an industrially proven stand-
ard device that we can exchange rapidly
and easily if it becomes necessary.
New DMT version offers
new opportunities
The development engineers of Bever Con-
trol already have the next improvements
of their 3D Profiler in their sights and
thus also a further developed version of
the DMT10. There is a new type of elec-
tronic reflectivity adaptation, allowing re-
al measurements within a time frame of
1 ms. This will make our measurement
system considerably faster and provide
users with an even more detailed tunnel
profile, Thorvald Wetlesen described
the advantages provided for him and his
customers.
Best by a long way tunnel contour
measurement with the DMT10.
INFO 216
The distance to the tunnel wall is
precisely measured with the DMT10
: Applications
20 2/2006
>> The Swiss meat processor Bell uses
mobile ImageTeam hand-held scanners
from SICK for the identification of animal
cadavers and batches of meat to provide
the legally stipulated traceability in the in-
coming goods area and during processing.
The individual tasks at Bell were solved
within the framework of batch identifica-
tion with differing hand-held scanners. The
advantages were that the application ben-
efits of the devices balanced one another,
and that the scanners could be purchased
from a single source.
Versatile ITelligence for the iden-
tification of animal cadavers with
PDF417 codes
Moving cadavers (transported on the over-
head suspension conveyor system), vary-
ing reading distances, differing attachment
locations of the PDF417 labels, and harsh
conditions resulting from the carving and
cleaning operations Bell decided to use
a variety of IT hand-held scanners to meet
the particular demands made by the vari-
ous processes.
The IT3800 hand-held scanner is
used for identification during the thin-
Traceability of meat products at Bell
ITelligently solved with ImageTeam hand-held scanners
ning out process and, to some extent,
packaging. Its ergonomic design, com-
fortably shaped handle, and convenient
trigger provide user-friendly handling.
The IT3800, inserted into its adjustable
retainer, operates in self-triggering Pres-
entation Mode at some work stations,
where the operator needs to have both
hands free.
The robust IT5800 hand-held scan-
ner is also appreciated at Bell. As a re-
sult of its long reading range of more
than 2 m the device offers a high level
of ergonomy, because large objects can
also be identified on the roller conveyor
feed station from longer distances.
The reading-in of PDF417 codes, e.g.
on delivery of animal cadavers, takes
place with the IT4800. Omnidirectional
detection capability, enhanced reading
distance, and an improved depth-of-field
permit more comfortable work with the
device.
Bell uses the IT5620 with its Blue-
tooth module wherever the length of the
spiral cable on the device is insufficient,
or interferes with the work. This data ra-
dio option allows the device to be used
Mobile IT hand-held scanners from SICK
within about 10 m of the basis station,
and the reading information is trans-
ferred online to the batch identification
system. A high level of user-friendliness
is achieved with a reading distance of 90
cm, a depth-of-field of 56 cm, and a wide
reading window of up to 17.8 cm.
Traceability by means of PDF417 ITelli-
gently solved at Bell with mobile identifica-
tion technology from a single source.
INFO 217
>> Strtz Maschinenbau has integrated
an effective tool-break detection system in
its plastic window frame production plants
with the help of the WTB190T compact
photoelectric proximity switch. The sensor
detects even small drill bit diameters, but
Compact photoelectric proximity switches for better window frames
Youll be sorry if the tool breaks ...
is unimpressed by heavy background in-
terference.
The small, precise red light spot that
the photoelectric proximity switch gener-
ates on the drilling or milling machine,
and its accurate background suppres-
sion, are the prerequisites for detecting
drill bits, even with diameters of only 3
mm. During in-house tests and on-site
commissioning, Strtz employees profit
from particularly simple parameterisa-
tion of the device thanks to mode selec-
tion, teach-in and button operation sup-
ported by a menu display.
No screwing-in
without drilled holes
Insertion, sawing, drilling, reinforcement,
seal shaping, welding, hinge and handle
assembly there are numerous auto-
mated processes before a window frame
has been produced from plastic profiles.
If there were a hold-up in one area of the
processing station, e.g. because a drill bit
or milling machine is broken, there would
be a problem at some other point in the
processing, e.g. during screwing-in of the
reinforcements, because the drilled holes
would be missing. The result: congestion
in the production process, repair work, and
sometimes even complaints from builders
or end-customers. Now, however, the tool-
break detection of the WTB190T provides
the right overview. The photoelectric prox-
imity switch signals a broken drill bit to
the machine controller. The drilling station
stops, the tool is replaced and the drilling
process continues. This ensures that the
profiles have all the holes needed by the
screwing-in station.
Tool-break detection provides the
customers of Strtz Maschinenbau with
greater process and product quality. Thus
the WTB190T ultimately ensures more
economical window production.
INFO 218
: Applications
21
Zero-pulse assignment at the press of a button
Speedier diesel
engine inspections
The British diesel engine producer Cummins Engine Company is speed-
ing up its engine inspections. Thanks to the DRS60, alignment of an
engines top dead centre with the zero-pulse of the incremental encoder
no longer takes up to 30 minutes, but is now a matter of seconds.
>> The Cummins Engine Company
is one of the worlds largest manufac-
turers of diesel engines. In 2005 alone,
the company delivered about 3,000
engines with 12, 16 or 18 cylinders.
They are used as drive systems for gen-
erators, locomotives, heavy vehicles
and ships.
Inspection centre modernised
The engines undergo comprehensive
function tests as early as the construc-
tion and development phase. Cummins
runs three inspection cells for this
purpose. Their technical equipment
including couplings, support brack-
ets and encoders has recently been
modernised. A solution was sought for
the rotative encoders, in particular,
which would allow the top dead centre
(TDC) of the cylinder to be aligned with
the zero-pulse (reference) position of
the inspection equipment more rapidly,
easier and more accurately.
DRS60 ensures
alignment in seconds
The test engineer used to have to turn
the engine to the TDC, adjust the built-
in encoder manually until the precise
zero-pulse was found, and then put it
Simple electronic zero-pulse assign-
ment at the touch of a button with the
DRS60 encoder
on the testing equipment without any
rotation of the shaft. The task was not
only difficult, but also extremely time-
consuming: it sometimes took more
than half an hour to get the test rig
ready. So its no wonder that Cummins
was very interested when they found
out about the DRS60 and its zero-pulse
alignment at the press of a button while
installed. Because, as explained above,
while with most incremental encoders
this is a complicated process, with the
DRS60 the zero-pulse is simply aligned
by pressing a button. The mechanical
loosening and turning of the encoder
that is otherwise necessary and thus
the risk of unintentional rotation is
no longer required. Of decisive impor-
tance, however, is the zero-pulse align-
ment: from 30 minutes adjustment to
just a few seconds. All the test engineer
has to do now is turn the engine to the
TDC, mount the encoder, and press a
button to align the zero-pulse.
Save time at the press of a button:
zero-pulse assignment with the DRS60.
insightLINK
INFO 219
www.cummins.com
Diesel engines from Cummins undergo
wide-ranging functional tests
Drive systems
: Applications
22 2/2006
insightLINK
INFO 220
www.deere.com
>> Deere & Company employ 38,700
employees worldwide. Their products in-
clude agricultural, construction and for-
estry machines, community technology,
as well as equipment for the upkeep of
lawns, grounds and golf courses. Deere
& Co. have customers in more than 160
countries, with eleven production works
worldwide including Horizontina in
Brazil. In 1998, for legal and safety at
work reasons, the company faced the
task of protecting the mechanical and
hydraulic presses, press brakes and
punching presses, as well as other pow-
er-driven machinery used here, against
the risk of accidents. As the company
did not have any in-house safety spe-
cialists they were obtained externally:
from ACAO and SICK.
Greater safety, step-by-step
One mechanical and one hydraulic press,
as well as a press brake, were initially
equipped with safety technology in a first
Safe production at John Deere in Brazil
From the first safety project
to a solid safety partnership
SICK, together with ACAO, its Brazilian sales partner, has implemented a
variety of safety projects at John Deere Brazil during the last eight years.
Good technical and economic advice, and professional implementation,
have made close partners out of project participants.
joint project. Right from the start, the
idea of combining safety functions with
automation functions to support produc-
tion was taken into consideration. One
of the solutions was floating blanking,
i.e. the variable cutting out of individual
beams of the FGS safety light curtain at
the moment when a work-piece is jutting
into the protective field during process-
ing. What at that time was still only possi-
ble with a separate LCUP evaluation unit
is now handled by an integrated compo-
nent, e.g. in the C4000 safety light cur-
tain. The project was concluded to the
complete satisfaction of John Deere.
In the second project, too, in 2001,
John Deere again employed the compe-
tent partners ACAO and SICK of course,
we already had first-class in-house refer-
ences. Now it was more than 20 presses
and machines that had to be given state-
of-the-art safety treatment. This time,
operating experience from the machines
originally equipped could be taken into
account, alongside the internal safety
expertise that had developed at John
Deere.
The logical consequence of this
was a third project, in 2004, with over
35 machines using the same proven
partnership and the latest safety tech-
nologies, e.g. the C4000, S3000, and a
control solution in the form of various
safety relays from the Intelliface product
family.
Competent advice, professional im-
plementation, continuous support and
100% commitment to the customer
have been the keys to success for ACAO
and SICK at John Deere over the years.
John Deere sells agricultural machines in more than 160 nations worldwide
Presses equipped with the latest sensor
technology from SICK
Machine safety
23
>> Rexnord Kette GmbH in Betzdorf, Ger-
many, produces drive, conveyor and flyer
chains in the most varied of designs. We
produce almost 50 different chain sizes
for flyers and rollers alone as endless
material or as lengths of chain, explains
Stefan Zimmermann from Rexnord Kette.
As any chain is only as strong as its weak-
est link, however, the company sought a
robust, low-maintenance and user-friend-
ly solution for 100% inspections of every
chain to reliably detect defective links.
Further requirements included automatic
detection of differing chain types, as well
as image and data output via Ethernet.
IVC-2D: the smart camera solution
The system integrator given the job of
solving this task, AKL-tec (specialists in
demanding solutions involving image
processing and laser measurement tech-
nology, among other things) decided on
optical inspection with the IVC-2D smart
camera. The system offers a wide-rang-
ing software library that simplifies pro-
gramming. The camera is designed for
industrial use, its simple to operate,
and has on-board Ethernet interfaces for
rapid transfer of signal and image data,
Industrial chains inspected by 2-D smart camera
No weak links in the chain
Rexnord Kette, a company that produces chains for industrial use, has
done away with weak links. The IVC-2D smart camera embedded within a
complete inspection system from AKL-tec knows no compromise when it
comes to inspections.
says Rdiger Elben from AKL-tec. More-
over, background suppression can easily
be connected to the smart camera via
M12 plug-in connectors and the illumina-
tion time is controlled via the cameras
step program.
From the feasibility study...
After carrying out the feasibility study,
AKL-tec developed the right mechani-
cal inspection system, integrated the
system components smart camera,
illumination, PC, display and PLC and
adapted the camera and PC software to
the inspection program. Thanks to the
simple user interface of the IVC-2D it only
took three days development time to get
the first version operating, says Rdiger
Elben. During inspection, the chain is
fed into the inspection station and the
chain type is automatically detected by
the smart camera. Then each link of the
chain is tested for different features, e.g.
the presence of individual parts, height,
parallelity, and the distance between the
bolt and the plate. The feeding process
for the automatic inspection machine
stops when a defective chain link is de-
tected. The operator replaces the defec-
insightLINK
INFO 221
www.rexnord.de and www.akl-tec.de
tive component and re-checks this area.
There is no way that he or she can get
around this inspection, says Stefan Zim-
mermann. After this process, the images
captured and the statistical information
on the chain are transferred to a higher-
ranking embedded PC via FTP & TCP/IP
protocol.
... to the chain reaction
Not a single defective chain link has
been delivered to customers since the
inspection table was commissioned,
Stefan Zimmermann cites one of the rea-
sons for the somewhat different type of
chain reaction there are now more
than a dozen of these systems in use.
The entire inspection process has been
revolutionised, he sums up. The in-
spection table offers a range of possibili-
ties that were simply not available to us
before. And with the information gained
from archiving when the equipment has
switched off we can not only determine
where there might be potential plant de-
fects, but also optimise the production of
individual parts.
Whether industrial or process chains
both profit from the IVC-2D smart camera.
The checking of industrial chains at Rexnord Kette was solved by a
new inspection system with an integrated smart camera
: Applications
Happy about the revolutionary
inspection process: Frank Kesseler from
Rexnord Kette, Ralf Zller from AKL-tec
and Christoph Brinkmann from SICK
(from left to right)
Inspecting industrial chains
: Applications
24 2/2006
insightLINK
INFO 222
www.ectn.com
>> Those driving southwards towards
the Gotthard tunnel along the A2 mo-
torway in Switzerland pass the Erstfeld
heavy transport measurement station a
few kilometres before the tunnel. ECTN
from Buochs has set up a profile meas-
urement system for trucks at the existing
weighing and inspection station, after
receiving an order from Uri cantons civil
engineering authorities and the respon-
sible federal road authorities ASTRA. Its
task is to measure, detect and evaluate
unauthorised height, width or length de-
viations as the vehicles pass by slowly on
their way to the static weighing system,
in order to increase safety in the tunnel,
explains Richard Arnold, head of Uris
traffic police.
Three scanners for profile and
length measurements
The truck measurement system consists
of two laser scanners on a gantry set up
in front of the vehicle weighing system,
with a third Laser Measurement System
installed on a mast with a jib directly
behind the weighing equipment. As a
result of their weatherproof outdoor de-
sign they are suitable for use outside,
and are also immune to extreme outdoor
temperatures. The truck can drive into
the plant as soon as the signalling sys-
tem switches to green. The synchronised
gantry scanners, each monitoring the
entire drive path width, measure the left
and right halves of the vehicle simulta-
neously. The evaluation computer of the
truck measurement system determines
the actual vehicle width from these data.
At the same time, the scanners generate
the sectional profile information (height,
width) that are evaluated and checked
against pre-programmed tolerance val-
ues. The third scanner (on the mast) de-
tects the vehicle length while the truck
More safety for heavy traffic with LMS
Laser Measurement Systems
Too long, too wide, too tall? Truck
profile measurement plants from
ECTN AG with outdoor laser meas-
urement scanners from SICK de-
tect, without contact, whether
vehicles conform to standard di-
mensions or not.
drives through the measurement system.
With the length information, the system
can classify the truck automatically, de-
tect over-lengths and localise any exces-
sive profiles. The measurement data for
the profile measurement are already
available by the time the vehicle stops
on the weighing system. When the truck
has left the profile measurement system
the signalling system switches to green
again for the next vehicle.
Successful practical operation
The truck profile measurement system has
proved its efficacy in practice. Uri cantons
police report that dangerous over-widths
and over-heights, in particular, which are
difficult to determine (because they can
only be measured in point form) have again
and again come to light and are always fol-
lowed up and punished with fines.
Outdoor laser scanners on the truck profile measurement system detect whether
the vehicles dimensions conform to legal stipulations
Traffic
: Applications
>> The English machine constructor TS
Converting had to protect three hazard-
ous points-of-operations on a particular
machine. Two systems a C4000 safety
light curtain and a S3000 safety laser
Three monitoring areas, two safety systems, one safety controller
Intelligently organised safety
scanner proved to be the right sensors.
A UE440 configurable safety controller
brings everything together to create a
unique solution.
While the C4000 monitors the back
of the machine, the S3000 is used to
ensure safety on both the feed system
and at the front of the machine, where
power-driven shafts and cutting tools
are located. The special feature here:
because only the feed system or only the
processing machine is active at any one
time, the S3000 can alternately monitor
both functions with two separate protec-
tive fields.
Protective field activation and
signal evaluation by the UE440
The UE440 safety controller supplies
the necessary information on which of
the protective fields is to be activated. It
also evaluates all the signals including
those of the C4000, and the three emer-
gency stop buttons and a safety interlock
that also contribute to the machines
safety concept. Two supplementary func-
tions of the UE440 are of significance to
TS Converting. The Bypass function per-
mits employees to approach the slow-
running machine from the front or from
the back during Setup Mode, without it
being switched off by the safety equip-
ment. The integrated Override function
only affects the laser scanner at the
front. Its switch-off signal is suppressed
when an employee has to work in the im-
mediate vicinity of the hazardous point-
of-operation in Setup or Quality Inspec-
tion Mode.
The solution bears the
signature of safetyPLUS
The development, implementation and
future-orientation of the solution devel-
oped with TS Converting bear the signa-
ture of safetyPLUS. With the safetyPLUS
strategy (see also P. 30), SICK is extend-
ing its approach of integrated safety
thinking and safety activity. Early involve-
ment in the machine project allowed
greater integration of safety technology
aspects. The consequence: greater func-
tionality through the optimum combina-
tion of the individual functions and op-
portunities offered by sensors, control
systems and service performance. The
plus for users: greater security regard-
ing the technology, the overall solution,
future capability, and their investment.
TS Converting is as shown by the above-
mentioned application satisfied with
the one-stop safety shopping concept.
INFO 224
The S3000 can monitor two
functions alternately with two
separate protective fields
25
>> The slaughter and conveyor technol-
ogy producer BANSS has automated the
processing of cadavers with LMS400 La-
ser Measurement Systems.
The 2-D measurement values of two
LMS400s, supplemented by the speed
of the conveyor system, allows three-di-
mensional measurement and display of
the entire body surface of animal cadav-
ers. The PC evaluation software of the
cutting line then transfers the data to the
robots in the cutting plant. From these
measurement values, the robots control-
lers generate the optimum vertical robot
movement for each animal, e.g. to cut the
rectum free or to open the abdomen and
Robot guidance for meat processing
Laser measurement provides cutting
data for animal cadavers
breastbone. Up to 600 animals per hour
can thus be processed efficiently.
High precision, rapid processing
of measurement values
The high precision of the LMS400 is im-
portant for use in the cutting plant. The
large aperture angle of 70, the fine an-
gular grid of 0.1, and the high distance
resolution within the 3-metre range
provide precise contour data on the ani-
mals body and thus equally precise
control data for the robots. Furthermore,
the data are quickly available as a result
of rapid measurement value processing
and real-time transfer.
The LMS400 is thus an efficient solu-
tion for the automation of cutting lines in
meat processing. INFO 223
: Applications
26 2/2006
>> The LD-LRS Long Range Scanner from
SICK AG is a laser scanner that scans its
surroundings with laser pulses and gen-
erates a profile with distance and angu-
lar data. Thanks to its Ethernet interface,
this data can be further processed in
real time as is the case at the power
station. The device can really exploit its
strengths when the detection of dark ob-
jects over long distances is involved, and
high-resolution results are required.
Laser measurement provides
information on the location of
particular coal types
The coal for the power station is deliv-
ered by train, temporarily stored in the
coal bunker, and fed into the power sta-
tion boilers via a rotary bucket excavator.
Coal types of differing qualities are used
Coal heap measurement at an
RWE Power brown-coal-fired power station
Laser measurement
technology for coal heaps
At a brown-coal-fired power station belonging to RWE Power AG a meas-
urement solution has been developed with the LD-LRS laser scanner for
the coal bunker, precisely detecting each heap of coal without the de-
vice costing a heap.
in order to ensure an optimum burning
process. As the unloading of the train
wagons is a manual process, it is nec-
essary to determine exactly where the
particular types of coal have been de-
posited. In the case of certain problem
coals this knowledge is particularly im-
portant for the subsequent burning proc-
ess. This is where the LD-LRS comes in.
It measures the entire 250-metre-long
heap after each delivery. For this pur-
pose, a rail-borne measurement wagon
(developed by ABB Automation GmbH
in Cottbus, Germany) with an integrated
LD-LRS travels along its section of the
heaps and determines the current bulk
material profile. The resultant 3-D and
2-D models of the heaps calculated
using software from Berlins AUCOTEAM
GmbH show the locations of the coals
insightLINK
INFO 225
www.rwe.de and www.abb.de
or www.aucoteam.de
in the bunker. The total volume is also
calculated from this both to enable
re-orders to be made in good time, and
to track the coal quality and quantity
through the rotary bucket excavator and
coal conveyor belts until it reaches the
final burning process.
Maximum operating
reliability due to long range
The scanner and data transfer wagon
can be driven at a safe distance to the
coal thanks to the long range of the LD-
LRS (80 m with only about 10% reflec-
tivity of the bulk material surface). This
makes a decisive contribution towards
the high availability of the heap meas-
urement system because the system is
subjected to considerably less vibration
and damage from flying shards of coal,
or extreme contamination from the coal
dust or other environmental effects.
In addition to profile measurement,
the LD-LRS offers a collision prevention
function for particular applications if it
can be mounted directly on a coal exca-
vator real added value that really pays.
A rail-borne measurement wagon with integrated laser scanner
detects coal stocks at Neurath power station
Used at a safe distance to the coal:
the LD-LRS Long Range Scanner
Power stations
: Applications
27
insightLINK
INFO 226
www.sew-eurodrive.de
>> With DriveAcademy, SEW-EURODRIVE
has built a modern training institute that
is intended to provide a stimulating learn-
ing atmosphere not least with its ar-
chitecture, which resembles a ship. As
a supplier of knowledge, DriveAcademy
places great value on practical training,
i.e. learning on and with the drives, safe
drive systems, servo-linear motors, con-
trollers and field distributors, Johannes
Beck, Manager of the DriveAcademy, de-
scribes its philosophy. One of the largest
of the 14 training rooms has thus been
equipped with a wide range of plant tech-
nology driven and controlled by SEW com-
ponents, including conveyor belts, rotary
Training in a safe and ergonomic environment
SEW-EURODRIVEs DriveAcademy
relies on SICK safety technology
Just in time for the companys 75th anniversary, SEW-EURODRIVE will
soon open the new DriveAcademy training institute in Bruchsal, Germany.
C2000 light curtains and S3000 laser scanners from SICK, together with
MOVISAFE 100 A safety monitors from SEW-EURODRIVE provide protec-
tion for the up to 200 employees and customers a day undergoing practi-
cal training on the drives and the plant technology.
tables, elevating shearing tables, gantries
and converters. Here, practical knowledge
is applied live, i.e. programming, commis-
sioning, equipment tests and simulations
of problems. There is always something
going on, there is almost always someone
working on (or in) the equipment, ex-
plains Oliver Jger, Manager of Functional
Safety at SEW-EURODRIVE. We therefore
had to ensure safety during training, with-
out complicating access to the equipment
with, say, barriers.
Flexi- yes, Plexi- no
Instead of fences or Plexiglas walls with
doors or flaps, it is C2000 safety light
curtains, S3000 safety laser scanners,
and MOVISAFE 100 A safety monitors
that protect the roughly 200 trainees a
day at the DriveAcademy, as well as the
approximately 25 trainers. At the same
time, they allow flexible and unhindered
access to drive systems and equipment
parts that are reliably monitored by
MOVISAFE 100 A units. In this way, the
DriveAcademy offers the ideal prerequi-
sites for imparting and applying theoreti-
cal and practical knowledge regarding
drive technology in general, and drive
safety technology in particular.
Technological knowledge has a half-
life of about four years. The DriveAcad-
emy therefore offers high-quality training,
ensuring that employees and custom-
ers are always kept up to date with the
state-of-the-art in drive and automation
technology. Safety equipment from SICK
and safe drive systems from SEW-EURO-
DRIVE thus work hand-in-hand to ensure
a protected and ergonomic environment.
Safe training environment: the plants of the DriveAcademy
equipped with safety technology from SICK
Oliver Jger from SEW-EURODRIVE and
Volker Neuenhaus from SICK
Plant technology
28 2/2006
: Know-how
For small objects:
Automation with laser photoelectric switches
Whether in standard applications or those that make special demands
of the sensors laser photoelectric switches allow the reliable and eco-
nomical solution of automation tasks in many situations.
Laser the special light source
Unlike LED sensors, lasers largely gen-
erate parallel light. This results in con-
siderably longer photoelectric switch
ranges, even with small housings. The
narrow beam path also allows objects to
be detected through tight openings in a
machine. Finally, the sensors generate
an extremely small, easily visible light
spot on the target object, even over long
distances so that even the smallest of
objects and features can be detected.
The laser packaging
must suit the application
Sensors must be available in application-
oriented housings to exploit the advan-
tages of laser technology. With a total of
eight series, SICK offers an appropriate
housing to cover all installation and envi-
ronmental conditions. Read more at
>> The smallest of objects or features,
easily visible light spot, long ranges on
reflectors, and tight optical openings in
the machine the laser photoelectric
switches or laser scanners of the eight
different SICK series offer decisive ad-
vantages wherever these conditions and
requirements exist.
Laser expertise has led to advantag-
es with SICK for over 15 years, and not
just in photoelectric switches. Our laser
competence is also exploited to the full
in other sensor systems: such as those
for highly accurate distance and profile
measurement, electro-sensitive protec-
tive equipment, sensors for detecting
contrasts, and readers for the identifica-
tion of bar codes and 2-D codes.
Safe sensors and controllers
Think in terms of open solutions
Whether simple machines or complex production plants safety is no
longer simply a question of the sensors themselves, particularly in times
of decentralised automation and network solutions. Control technology
is increasingly the centre of attention and with it, the demand for plat-
form-independent and application-oriented complete solutions from a
single source.
>> Standards are becoming more com-
plex, technologies more demanding, the
supplementary automation advantages
of safety solutions have to be more ver-
satile, but also individual this back-
ground, and the merging of safety tech-
nology with standard automation, pose
new challenges for machine producers.
Today, the dominant trend is the desire
for a safe complete solution. The basic
prerequisite here is the comprehensive
safety-application expertise and special-
ist knowledge of solution suppliers. This
is if only for historical reasons often
considerably more likely to exist at pro-
ducers of safety sensors than at pure
control suppliers. Thus during the last
60 years SICK has developed a suitable
sensor solution for almost every task,
including interface components for ma-
chine integration.
The targeted development of the first
safe control solutions by companies that
were originally pure control producers is,
in contrast, relatively new. They almost
always follow a proprietary approach, i.e.
the control philosophy of the particular
producer. The consequence: decisions
are not made on the basis of the best
possible application solution for the task
but are, instead, dominated by the pro-
ducers own control environment. The
resulting system is inevitably often not
the most technically or economically
suitable solution.
As a result of these experiences, SICK
decided to define safety as open for dif-
fering control technologies, as well as an
application- and customer-oriented solu-
tion package. This safetyPLUS approach
offers users one of the widest portfolios
of safety sensors, with open control so-
lutions for differing levels of integration
and networking, based on decades of
application and sector experience.
Read more at
29
: Know-how
>> There are many reasons for the in-
creasing spread of 2-D technology in
many cases at the expense of the clas-
sic bar code. While bar codes are a hori-
zontal or vertical sequence of bars and
spaces, 2-D codes can store information
in both directions. They are therefore able
to achieve a higher density of informa-
tion or provide identification in a smaller
2-D reading technology and direct part marking
Direct or indirect
that is the question
Electronics production, automobile construction, medical and pharmaceu-
tical technology, or document handling the use of 2-D codes such as Data
Matrix for object identification is continuing to gain ground. Direct part
marking (DPM), i.e. the direct application of the code on the object itself,
is particularly popular as a result of its robustness. The differing marking
technologies, however, result in particular conditions of use.
space. A further advantage of 2-D codes
is their high data reliability. The symbology
integrates redundant data for correcting
errors and for data reconstruction. This
makes it almost impossible to read out
incorrect data unlike during the identifi-
cation of one-dimensional bar codes. This
can be of vital significance: just consider
the identification of blood plasma bags.
Important in many
processes: omnidirectionality
A further property is of decisive impor-
tance in many situations: omnidirectional
readability. The reason: 2-D codes have
a matrix-like structure. Correspondingly,
a two-dimensional identification unit is
required to read them. In most cases,
this is provided by a camera with an inte-
grated area sensor (CCD or CMOS chip).
Thus an image of the code can be cap-
tured in any orientation. The reading de-
vice knows where which data is located
thanks to the so-called finder patterns
integrated in the 2-D codes. These align-
ment aids may be concentric circles,
specially designed corner markings, or
particular edge designs. Objects there-
fore no longer require manual position-
ing or turning the code will be detected
if it is present in the read window.
Marking technology influences
reading technology
As versatile as the identification possi-
bilities of 2-D codes are the labelling
technology used has a major influence
on the identifiability, e.g. of data matrix.
Read more at
2-D codes: a lot of info in a little space
SICK offers powerful solutions for effi-
cient 2-D code detection
: safetyPLUS
Those who speak of safety are less and less thinking of just the individual
products that make equipment and machines safe. Safety is now a com-
prehensive concept, as is sensor, control and application competence: i.e.
safetyPLUS the safety concept from SICK.
>> The world of safety is complex and
dynamic: directives and standards in-
teract with one another; technological
progress offers new solution approach-
es; new concepts are created on the
basis of new demands which, in turn,
can have normative or technological
effects. Staying on top of all this, and
offering safe system solutions while
helping design innovative processes, can
only be achieved by those who, like SICK,
have offered practical safe sensor and
control technology for about 60 years.
Safety means knowing
where one is going
Six decades at the cutting edge of safety
developments make SICK a competent
contact for customers, users, standardi-
sation committees and inspection organ-
isations. Based on intensive dialogue,
SICK offers:
p effective, complete solutions from a
single source,
p seamless integration in all open
system worlds,
p the most versatile sensor and switch
portfolio worldwide,
p uniform software for configuration
and project planning,
p innovative safety control technology,
p the worlds first safety controller with
an enclosure rating of IP 67,
p a dense global competence network
of application engineers with first-
class qualifications,
p worldwide service throughout the
entire machine life cycle.
Tomorrows safety is thus called
safetyPLUS.
Safe robot cells: greater integra-
tion and greater functionality right
from the start
safetyPLUS is available to both system
integrators and end-customers. Austrias
Roboter-Anlagen-Technik GmbH (rob-an-
tec) in Linz exploited safetyPLUS in their
latest project.
The task was to ensure accident-free
working processes during the produc-
Complete safety solutions for the entire life cycle
safetyPLUS safety and added value in a single package
30 2/2006
safetyPLUS was fully exploited for a recently implemented project at Austrias Roboter-Anlagen-Technik GmbH in Linz
safetyPLUS the decisive PLUS in
the safety: We support you during
all phases of the machine life cycle
of your machines and plants from
project planning to modernisation.
insightLINK
INFO 227
or on the Internet at:
www.sick-safetyplus.com
SICK believes that safety technology means integrated safety thinking and
safety activity. For one thing, greater integration means always keeping an eye
on all safety-relevant aspects from the very first planning step to the ultimate
modernisation of a machine: the risk analysis and safety concept, project
planning and CE-certification with Safexpert software, commissioning and
inspection, repair and modernisation. For another thing, greater integration in
the form of comprehensive sensor, control and service solutions from a single
source leads to more economical and future-oriented solutions because
greater integration also always means greater functionality. With its compre-
hensive portfolio of products and services, SICK ultimately offers OEMs or
users greater safety through one-stop safety shopping:
p advice on all safety-relevant topics,
p the right solution for the current task,
p any machine downtimes are rapidly and efficiently handled,
p upgrading to meet the new demands of the future,
p open solutions provide independence regarding suppliers,
technologies and systems,
p competent support available worldwide at short notice, and thus ...
p ... confidence in having made the right decision with safetyPLUS.
>> safetyPLUS: greater integration = greater functionality = greater safety
tion of automobile fuel tanks on folding
and welding robots at the end-customer
Magna Steyr Fahrzeugtechnik AG. The
two new robots, neighbouring one an-
other, had interlinked processes. We
had already made contact with SICK
during the initial planning phase so that
we could achieve as efficient a safety
solution as possible right from the start,
says Bernhard Eiber, Managing Director
of rob-an-tec. Building on a risk analysis,
we worked out and assessed a variety of
safety concepts together with SICK. Be-
cause of the technical process conditions,
a C4000 safety light curtain proved to be
the best solution on the welding robot
while, in addition to another C4000, the
cell of the bending robot was equipped
with an S3000 safety laser scanner to
monitor the internal space. Furthermore,
a variety of working and end positions
could be detected in the two cells with
the help of non-contact safety switches,
and this information passed on and used
for controlling the protective equipment.
The flexible UE4400 safety controller sys-
tem was used to provide effective evalu-
ation of the sensors data and for simple
conversion of the safety logic. Together
with SICK, we developed an approach for
the integration of all the safety systems
in the control technology. The early engi-
Complete safety solutions for the entire life cycle
safetyPLUS safety and added value in a single package
neering, programming and advance trials
of the complex functions allowed a con-
siderable reduction in the commissioning
time at the location near the new Peugeot
works in Slovakias Trnava. And now the
early consideration of sensor and control
solutions from SICK has really paid off.
The UE44x7 series from SICK permits,
for the first time, remote safety automa-
tion without a control cabinet in situ in the
field. The field controls can either be run in
stand-alone operation without any other
safety controls or together with other
controllers in a combined network.
The Fast shut-off function with its ex-
tremely rapid reaction times of under 8 ms
even in a combined network combines
the rapid reaction time of the individual
controllers with the flexibility of networked
solutions. This minimises the safety dis-
tance between the protective equipment
and the hazardous point-of-operation. The
Safety enable function allows a standard
controller to regulate the safety outputs of
the UE44x7 without using a safety con-
troller in the application.
: safetyPLUS
31
The project also demonstrates how im-
portant a dense international network
of competence is, because the servic-
ing work and the plant modifications
that can be expected during the plants
operating lives can be carried out or
supported by SICK personnel on site. As
a result of the early collaboration with
SICK as experts in sensors, control sys-
tems and services, we can implement an
intelligently integrated overall solution
whose openness and range of functions
now guarantee the end-customers a high
level of safety at work, and a high last-
ing level of investment safety, Bernhard
Eiber sums up. That is exactly what we
mean by safety, and what SICK means
by safetyPLUS.
Those who speak of safety are think-
ing of the combination of sensor, control
and service competence. Safe system so-
lutions from SICK safetyPLUS for users.
UE44x7 the worlds first compact safety
controller in IP67 technology
32 2/2006
: Products
>> This has been made possible by us-
ing a suitable resolution of 2 mm that
is uniquely not only applicable for
Letters, mailings and very flat or only slightly protruding objects the new
HLG light grid is the right solution when its important to reliably detect
such flat objects on a conveyor belt or in an ejector chute.
>> As a result, users can parameterise
devices in the above-mentioned series
on the familiar PLC program interface.
The advantages offered by the previ-
ous version remain: trouble-free data
exchange between the CLV and the PLC,
integration of additional signals from, for
example, photoelectric switches via the
four digital inputs and outputs, as well
Detection of flat objects in rapid movement
Light grid performs precision work
The possibility of parameterising
the CMF400 PROFIBUS module in
the CDM420 connection module
by means of a GSD file now makes
it even more flexible. The bar-code
scanners of the CLV420 to CLV450
series profit from this update.
as clock-pulsing of the reading device via
the fieldbus.
Two new pre-assembled
CDM420 variants
Externally, two new variants of the CDM420
are evident. The user can chose between
a 9-pin D-sub plug or two M12 connectors
for the PROFIBUS connection. Both CDM
variants are available pre-assembled as
ready-for-use devices with integrated pa-
rameter cloning module and PROFIBUS
module. The advantage: easier ordering
and installation for the customer.
By the way: only SICK allows integra-
tion of its hand-held scanners directly in
PROFIBUS-DP. INFO 228
Software update for bar-code scanners and CMF400 PROFIBUS module
Parameterisation using GSD file
Product News
:
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a very low switching hysteresis and the
currently fastest response time offered
by such systems just 3 ms impor-
tant for rapid postal sorting systems
or packaging machines with a high
throughput rate.
26 beams with an installation
height of just 50 mm
The HLG High-resolution Light Grid
offers a fixed detection height of max.
50 mm. Each of the two robust metal
housings accommodate 26 transmitter
or receiver elements. The teach-in of
objects supported by three indicator
LEDs and the synchronisation of the
transmitter and receiver by cable guar-
antee rapid commissioning and maxi-
mum stability of the taught-in switching
threshold. Apropos rapid: objects can
be closely packed onto the conveyor belt
in the goods distribution centre thanks
to the extremely short response time.
The HLG only needs the smallest of gaps
(just a few millimetres) between the
individual objects at a transport speed
of 120 m/minute for the reliable detec-
tion of the front edges. The switching
signal can then be transmitted via either
NPN or PNP.
High detection reliability for flat objects
the HLG is the right choice.
a small exclusive section but is con-
stant over the entire detection area.
This high resolution is accompanied by
33
: Products
>> Whether electronics production, au-
tomobile construction or other industrial
sectors the two-dimensional Data Matrix
code for the identification of components
and assemblies enjoys widespread use.
The machines, and the reading demands
that must be met, are as varied as the ob-
jects themselves.
Suitable for long ranges and a vari-
ety of marking technologies
The most important conditions are the
range and the identification technology
used. The ICR860 is characterised by high
flexibility in both cases. Data Matrix codes
can be just as reliably read over short dis-
tances as over long distances regard-
less of whether code labels or direct part
Reading distances of between 0.2 and 2 m are the strength of the new
ICR860 2-D reading device. Thanks to interchangeable lenses, compre-
hensive illumination solutions, and the familiar user-friendly interface the
sensor can be rapidly adapted to any task without additional software in-
tegration.
marking (printed by needle, laser or inkjet)
are used. Commissioning is user-friendly
and takes place by means of Webserver
technology. Calibration of the code reader
has a familiar look and feel to it thanks
to software based on CLV Setup. The
program automatically determines the
optimum reading field size and code reso-
lution when the object distance and the
focal point of the lens used are entered.
As an option, the laser device can be inte-
grated via an RS-485 or Ethernet interface
for data transmission during operation.
Apropos resolution: those for whom
the 640 x 480 VGA pixels of the ICR860
are insufficient can use the XGA reading
device of the ICR862 with 1,024 x 768
pixels. INFO 229
>> Encoders with a HIPERFACE interface
are used in drive technology as motor
feedback systems. As a result of their spe-
cial design for drive technology they have
a high temperature range, are often very
small, and are also available in a variety
of mechanical housings. The use of these
encoders in automation technology would
thus be extremely interesting for many
customers if a suitable interface is avail-
able. An appropriate interface conversion
is necessary in order to allow the encoder
data to be transmitted in a suitable form
for SSI or PROFIBUS.
Adapters ensure appropriate
connection
The HIPERFACE SSI Adapter and HIPER-
FACE PROFIBUS Adapter integrate mo-
tor feedback encoders (as well as other
Interface adapter modules provide flexibility
Converting HIPERFACE to SSI or PROFIBUS
Whether rotative or linear all path measurement or position determina-
tion systems with a HIPERFACE interface can now be flexibly connected
to SSI or PROFIBUS with the help of the appropriate adapter module.
CANOpen and DeviceNet versions are to follow soon.
path and position determination systems
with a HIPERFACE interface) into the par-
ticular industrial interface or fieldbus
environment via M12 connectors. The
advantage: the actual encoder remains
compact, the device version remains
unchanged and, in particular, flange or
housing solutions can be achieved more
rapidly and more economically.
Interpolation increases resolution
An extremely high resolution of greater
than 200,000 increments per revolu-
tion is achieved because there is an
evaluation of the encoders digital and
analogue signals during the transition
from HIPERFACE to SSI or PROFIBUS. It
is therefore now possible to meet almost
every application-specific demand.
The conversion modules for SSI and
PROFIBUS are already available from
stock. Further variants for CANopen and
DeviceNet will follow shortly.
Far-sighted reading of Data Matrix
The long-range specialist
Product News
:
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34 2/2006
: Products
Eight axles with a single hub
Automatic format adjustment
via the PROFIBUS-DP Hub
The hub concept of the HIPERDRIVE
automatic format adjustment

drive offers reduced operating costs, lower wiring effort, optimised DP
addresses in PROFIBUS, and space savings on the machine and in the
control cabinet.
>> Precision, repeat accuracy, time
savings and batch-related automation
are the most important arguments for
converting format adjustment from
handwheels to automatic HIPERDRIVE

drives. At the same time, the entire proc-
ess of axle positioning can be document-
ed and becomes more comprehensible.
The new HIPERDRIVE
Hub adds further

cost and data benefits to this list. Apart
from the lower wiring effort, the system
costs in particular are reduced by more
than 40%, depending on the configura-
tion, because up to eight HIPERDRIVE

units can be integrated in a PROFIBUS
environment via a single hub. Simulta-
neously, the hubs Bus Interface & Con-
trol Electronics (BICE) allows all eight
HIPERDRIVE
units to be contacted via

a single DP address.
Practical experience shows:
a drive seldom comes alone
A drive seldom comes alone this was
the decisive realisation that led to the de-
velopment of the HIPERDRIVE
Hub. And
it was the basis for a particular packaging
machine producers requirement to inte-
grate up to 70 format adjustment drives
in the machines. In this case, conven-
tional PROFIBUS connection technology
would have looked like this: 139 plug con-
nections for the PROFIBUS and 70 DP ad-
dresses for the drives and the PROFIBUS
DP repeaters required to maintain signal
quality. Together with other participants,
139 DP addresses would have been
required. In addition to the high space
requirement and the enormous wiring
effort, the other problem would have been
that a maximum of only 125 participants
can be addressed via PROFIBUS-DP.
HIPERDRIVE
Hub: performance
distribution and data management
in PROFIBUS-DP
The task can now be solved with the
HIPERDRIVE
Hub because the entire

format adjustment requires only 9 DP ad-
dresses instead of the original 70. This is
possible because each hub handles the
performance distribution and data man-
agement for up to eight HIPERDRIVE

format adjustment drives but only re-
quires a single address within the PROFI-
BUS topography. Signal and communica-
tion management takes place in such a
way that the automation system knows
the state of every single positioning drive
and can also contact them individually.
No re-programming of the control system
is necessary to connect the hub a sim-
ple reconfiguration of the hardware is
sufficient. Now only one cable is required
to connect a drive instead of three. As a
result, its plug-in module is considerably
smaller and the unit is correspondingly
more compact. The total length of the ca-
ble laid is also shorter because the hub
is installed directly on the machine and
not in a remote switch box.
Up to eight HIPERDRIVE drives can be integrated in a PROFIBUS
environment with the new HIPERDRIVE Hub
Format adjustment drive
35
: Products
insightLINK
INFO 230
Cost controllers darling
Not only are commissioning engineers
and constructors enthusiastic about
HIPERDRIVE
Hub, but also cost control-

lers. Because the comparison between
HIPERDRIVE
with and without the hub

shows a savings potential of about 30%
in the purchasing of, for example, five
drives including cable. If one compares
the HIPERDRIVE
Hub solution with other

offers on the market, the cost controller
can even relish the prospect of purchas-
ing cost cuts of 40%, depending on the
configuration.
Magnetic cylinder sensors
with two switching points
Teach me twice!
>> The new MZ2Q cylinder sensor, with
two switching points and many advan-
tages, does a convincing job wherever
two sensors were required in the past.
Two freely adjustable switching
points in one sensor that means
occupying just one slot, lower installation
costs, and less wiring on the pneumatic
cylinder. And the switching points are
easily taught-in the sensor is therefore
rapidly ready for action. The compact
sensor housing is also advantageous:
it permits completely sunken, and thus
protected, installation in the slot. Also
helpful: the short housing, which even
allows the solving of miniature applica-
tions in very short cylinders.
Position determination and
object detection
An important target application of the
MZ2Q is object detection on grippers,
clamps or presses in which a pneumat-
ic cylinder with an extension of up to
50 mm acts as an actuator. Here the
sensor allows both end positions to be
reliably queried. Moreover, the MZ2Q is
also suitable for applications in which the
second switching points means a signifi-
cant improvement in functional reliability.
An advance signal can be used for target-
ed reduction of piston speed before, for
example, a piston reaches its final posi-
tion: switching point 1 decelerates the
movement, switching point 2 confirms
that the end position has been reached.
MZ2Q: once mounted, twice taught-in,
infinitely often switched. INFO 231
Summary: in constructive terms, HIPER-
DRIVE drives are even more suitable
when space is limited; in communication
terms, even better when DP address lists
are limited and in cost terms, even bet-
ter when budgets are limited!
>> HIPERDRIVE the highly integrated mechatronic drive system
for rapid and precise upgrading tasks
With torques of up to 20 Nm and
drive rotations of up to 280 min
-1
,
these drives are precisely aligned for
meeting sector-specifc requirements.
Intelligence is integrated in the drive
housing and relieves the higher-ranking
PLC or control computer.
p The highly compact HIPERDRIVE

format adjustment drive is predestined
for all tasks in which, in addition to
mechanical strength and a high en-
closure rating of IP 65, a wide-ranging
functionality and high precision are
also required. These positioning units
do not replace all classic servo-drives,
but can nevertheless be economically
used to replace them for the absolute
positioning of individual axles. These
drives can exploit their special advan-
tages to the full when high operational
reliability is required. Decentralised
and intelligent drive concepts such as
HIPERDRIVE
simplify the system

structure of a plant and drastically
reduce the equipping and restart
times of a production process, particu-
larly in the case of packaging machi-
nes, as well as in general machine
construction.
During the setting up and equipping of
machines the limit stops, rollers, tools
and fxtures in all felds of machine and
plant construction are mostly regulated
by means of manual adjustment with
the help of mechanical or electronic
counters. With more and more demands
on the part of the user regarding fexi-
bility, smaller batch sizes and shorter
delivery times, the equipping time
of a machine or plant is increasingly
becoming a major cost factor during the
corresponding product changes.
p With HIPERDRIVE
, a powerful
and compact positioning drive is
available to users in machine and
plant construction. It represents an
ideal solution in terms of housing size,
functionality, accuracy, mechanical
and electrical installation conditions,
simplicity of commissioning, servicing,
and costs.
p The HIPERDRIVE
positioning drive
contains the performance drive, the
brush-free DC motor, the absolute
value encoder, and the regulatory and
performance electronics completely
integrated in the smallest of spaces.
Performance
distribution and
data management
in PROFIBUS-DP
36 2/2006
: Products
insightLINK
INFO 232
>> Ranger E opens up new areas of use
for three-dimensional in-line inspection
with up to 35,000 profiles per second,
and more than 1,500 highly precise piec-
es of 3-D data per profile. The MultiScan
function of the Ranger E allows several
different object features to be measured
and evaluated simultaneously, e.g. grey
value, dazzle, 3-D and laser scatter.
35,000 contour profiles/second, over 1,500
pieces of 3-D contour data per profile
The worlds fastest camera for 3-D
contour measurement
The Ranger E camera system sets new standards in industrial 3-D contour
measurement with the worlds fastest measurement speed, extremely
high accuracy, integrated 3-D data evaluation and the Gigabit Ethernet in-
terface for rapid data transfer.
Rapid and reliable
standard interfaces
The Ranger E has a Gigabit Ethernet in-
terface to permit the 3-D co-ordinates cal-
culated in the camera to be transferred
to an evaluation PC in real time. Ranger
E is the central component in an image
processing system and can be integrated
in the users analysis and inspection en-
Almost all applications proft from the Ranger Es rapid and highly accurate
3-D contour measurement or its MultiScan function:
p checking components in pick & place processes, examining soldering
paste, or inspecting circuit boards in the electronics industry,
p robot guidance, unloading of trading units, and automatic
palletising in robotics,
p checking tyres, surface inspections of tiles,
p portioning meat, fsh, or vegetables, assessing the quality of fruit or ba-
ked goods in the food industry.
>> Ranger E for in-line inspections:
vironment via the iCon API software com-
ponent supplied. The RS-422 interface al-
lows connection of an encoder for precise
detection of the speed of the object in the
measurement field.
Equipped to meet a
variety of demands
With five different versions, the Ranger
E can be used for a variety of tasks. The
image-processing sensors 3-D measure-
ment system is available with two differ-
ent resolutions, an optional high-resolu-
tion line or two different infrared versions.
All Ranger E devices have a robust metal
housing and high immunity to ambient
light features that are important for in-
dustrial use.
Further Ranger variants
The Ranger family also contains two other
variants. Ranger C offers the same per-
formance features as Ranger E, but has
an additional interface for connecting a
camera. Ranger D is a brand new camera
with which standard applications can be
solved economically.
The Ranger Es features offer new oppor-
tunities for in-line inspection systems in
the most varied of sectors.
The Ranger E camera system
detects damaged elements
during blister inspection
3-D camera
37
: Products
insightLINK
INFO 233
>> The M4000 series is available as
Standard, Advanced, or Area versions,
depending on the functions required.
The new M4000 Advanced Curtain com-
Evolution of multiple light beam safety devices
Greater resolution =
lower safety distance
The M4000 series of multiple light beam safety devices has grown: there
are two new Advanced Curtain variants with resolutions of 14 mm and
30 mm. These systems are mounted even closer to the hazardous area.
This is especially advantageous for decentralised muting solutions in ma-
chine environments with limited space.
bines the functions of the multiple light
beams of the Advanced version with a
multibeam concept offering consider-
ably improved resolution.
The advantage: decentralised
muting with the UE403 on the
machine itself
The basic function of the two M4000
Advanced Curtains is to protect access.
Functions such as an RS-232 configura-
tion interface on the device, beam cod-
ing, restart interlock, external device
monitoring, and SDL interface (Safety
Data Link) for network or fieldbus inte-
gration increase supplementary automa-
tion advantages in many applications.
The UE403 muting switching device
(which can be mounted on the multiple
light beam safety device itself) is used if
the actual application requires reliable
differentiation between persons and ma-
terials during automatic material trans-
port. With an M4000 Advanced Curtain
it is now possible to set up an even more
space-saving muting station, e.g. if one
hazardous area closely follows another,
or a hazardous machine is installed di-
rectly behind a curve in the conveyor sys-
tem. The higher resolution has the effect
that a person is detected sooner and the
switching signal is thus transmitted ear-
lier. Hence the M4000 can be installed
correspondingly closer to the hazardous
area shortening the muting station.
With the M4000 Advanced Curtain
the protective system moves nearer
the machine advantageous wherever
installation space for muting stations is
limited.
Access protection
The M4000 Advanced Curtain multiple light beam safety device together with the
UE403 switching device form an efficient solution for decentralised, conventional
muting applications with automatic material transport
38 2/2006
: Products
>> Compared to conventional magnetic
proximity sensors, these series have
a switching accuracy considerably im-
proved (given constant environmental
conditions) and a precisely set hyster-
esis. Thus magnets can now be detect-
ed with a hitherto impossible precision
New short housing for magnetic proximity sensors
ASIC technology provides increased performance
Apart from their reduced length, the new short housing variants of
the MM08, MM12 and MM18 series of magnetic proximity sensors
offer a number of other improvements thanks to the use of new ASIC
technology.
Magnetic proximity sensors are used to detect magnets. They are particular-
ly suitable for use in harsh environments and for detection through non-
magnetisable materials. They are mainly used wherever inductive sensors
reach their technological limits, for example when long switching distances
are involved.
>> Magnetic proximity sensors
Greater functional and reliability reserves
Better switching by far
The Advanced series from SICK expands the range of uses for magnetic
proximity sensors thanks to hitherto impossible switching distances.
>> The switching distance of the Ad-
vanced series MM12 on standard mag-
nets has been increased from 60 mm
to 90 mm, while the MM18 series now
offers an enormous 120 mm in addition
to the former 70 mm a hitherto impos-
sible value in this sensor segment! And
distances considerably greater than
120 mm can be achieved if stronger
magnets are used.
This has three effects on potential uses
for magnetic proximity sensors:
1. Magnetic objects can now be detect-
ed over greater distances.
2. The detection of moving targets, or
those that have up to now been con-
sidered critical, now takes place with
greater reserves of reliability.
3. Smaller magnets can be used at hith-
erto classic switching distances,
allowing the solution of new tasks.
INFO 234
wherever maximum switching point ac-
curacy is required. Further highlights are
improved electromagnetic compatibility
(EMC) and the possibility of meeting cus-
tomer-specific requirements by adapting
impulse length, switching point and hys-
teresis. INFO 234
Magnetic sensors
39
: Products
insightLINK
INFO 235
>> Omnidirectional reading, high resolu-
tion, good ergonomy and robustness are
the basic demands for the industrial use
of hand-held scanners. Both devices
meet these demands in full. The reading
of DPM codes, however, makes special
demands of the laser technology: differ-
ing surfaces, small codes, various mark-
ing techniques, and highly reflective or
weakly contrasting backgrounds are
typical conditions that turn the identifi-
cation of objects from a task into a chal-
lenge.
Maximum performance required
The reading of DPM codes requires maxi-
mum optical and decoding performance.
The devices therefore have a high-reso-
lution CMOS chip with which even small
codes can be reliably read. The applica-
tion-specific optics and special illumina-
tion concept ensure optimum conditions
during the reading of DPM codes. The il-
lumination can be individually adapted
to the application. It is therefore possi-
ble to use dark-field illumination, for ex-
ample often required for the reading
of needle- or laser-printed codes. On the
other hand, the integrated diffuser al-
lows the reliable identification of codes
even if they are located on highly reflec-
tive surfaces.
Cable or radio connection?
The DPM hand-held scanner is available
with a cable or as a cable-free variant
with a Bluetooth radio module and a
range of 10 m providing flexibility and
allowing equally good solution of both
stationary and mobile applications.
Mobile identification of DPM codes
Handy advantages
Production control, labelling tests, traceability, counterfeit prevention
the two mobile 2-D hand-held scanners of the IT6300 DPM series of-
fer handy advantages wherever objects with direct part marking (DPM)
require identification.
Whether bar code or 2-D code there are basically two types of marking
techniques for object identifcation: indirect marking of objects by means of
an attached label and direct marking by inkjet, laser marking, needle pres-
sure or chemical etching.
Indirect marking is generally less durable and no permanent fxing of the
label to the object can be guaranteed. Its advantage: it is quicker and can,
in most cases, be read without diffculty because even the smallest of labels
produced using thermo-printers and thermo-transfer printers generate
standard-compliant code contrasts and contours.
The advantage of direct part marking (DPM) is that the code becomes a
fxed constituent of the object thus marked. Unlike a standard label, the
directly marked codes are thus far more resistant to external infuences.
However inkjet, laser marks or needle prints sometimes have a property that
makes reading more diffcult: instead of the rectangular data cells defned
in, say, the Data Matrix standard, these marking techniques often generate
cells with round contours. Their contrast strengths vary far more that those
of standard labels. This means that one must work with a wide range of
code qualities.
Code quality, refections, contrast strength reading systems like the
IT6300 DPM series used in industry are designed to meet all these condi-
tions, and allow even diffcult cases to be reliably mastered.
>> Whats special about DPM?
The hand-held scanners of the IT6300 series open up a wide area of use wherever
the identification of directly marked objects is required
2-D hand-held scanners
40 2/2006
: Products
>> Mini-disk technology with optical
code disk, compact circuit board in
chip-on-board technology, HIPERFACE

interface and electronic type label the
stand-alone versions have taken over
the technical components, and thus the
fundamental performance features, of
their installation brothers.
Equipped for direct installation
The SKS36 and SKM36 direct installa-
tion versions with their robust IP 65 zinc
die-cast housings, 6 mm full shaft, and
servo face-mount flange offer all the
prerequisites for mechanical connec-
tion to a machine shaft. The same is true
of the electrical connection technology:
the choice of cable or M12 plug permits
simple connection for energy supply and
data transmission.
High performance and
tough as nails
High operating speeds of 12,000 or
9,000 r.p.m., a maximum angular accel-
eration of 5 x 105 rad/s
2
, and total incre-
ment counts of 4,096 for the SKS36 or
4,096
2
for the SKM36 demonstrate the
devices powerful performance. But they
can also take a lot. They can be used
at ambient operating temperatures of
100C, as well as on axles where par-
ticularly high immunity to impacts and
vibrations is required, e.g. on presses,
rolling mills or cutting machines for
structural steel.
Support the technological
trends of drive producers
The stand-alone concept meets the
connection requests of innovative drive
producers for use on master axles very
well, because drives increasingly have
a second HIPERFACE
interface (in-
stead of an expensive SSI plug-in card)
for the connection of a control or path
insightLINK
INFO 236
Installation version for harsh operating conditions
Masterly motor feedback solution
for master axles
They look like encoders but are complete motor feedback systems for
installation: the SKS36 and SKM36. Whether the single or multiturn
version both stand-alone options are suitable for use as robust and
temperature-resistant path and command encoders for the master axles
of machines.
encoder. The new SKS36 and SKM36
offer this interface standard serially
and are thus ideally suited for control-
ling the machine drive automation solu-
tions of the future.
Incidentally, and perhaps of interest
to all those for whom encoder features
are sufficient: the SKM36 is also one of
the worlds smallest multiturn encod-
ers with an integrated drive and thus
ideally suited for tasks in which space is
limited and conditions harsh.
Motor feedback systems
41
: Products
>> The POMUX KH53 is an extremely
precise, linear position determination
system for cranes in handling and ware-
housing systems or for rail-borne vehi-
cles. The sensor unit determines the ab-
solute actual position with great repeat
accuracy by means of non-contact scan-
ning of reference marks mounted along
the drive path. These consist of alumin-
ium profiles with integrated permanent
magnets, whose distance to one another
represents a fixed position coding iden-
tified by magneto-resistive sensors. The
system operates without any friction due
to the non-contact technology employed.
Moreover, no reference run is necessary
on start-up thanks to the absolute posi-
tion determination.
Improved positional tolerance
Magnetic positioning system
fit for rough treatment
The KH53 absolute linear encoder system in the new Advanced design is
now also fit for applications in which the distance between the reading
head and the reference marks is subject to large fluctuations.
Advanced version with improved
positional tolerance
With the new POMUX KH53 Advanced, a
system is now available whose positional
tolerance has been increased to 20 mm.
Thus the reference marks mounted along
the drive path are also reliably detected
even with relatively large positional tol-
erances. Both the reading head and the
reference marks of the proven POMUX
technology were appropriately modified
for this purpose. The Advanced version
is available in two varieties: for measure-
ment paths up to 54 m and up to 548 m.
These cover most tasks in indoor and
outdoor use.
The POMUX KH53 Advanced opens
up new possibilities for crane position-
ing. A suitable system price, lack of
maintenance, lack of mechanical wear,
and its high reliability and availability
even under adverse environmental con-
ditions also make the system interesting
for upgrading equipment. INFO 237
Separate optics and evaluation. Analogue and digital outputs can be combined
Laser photoelectric switch with small optics and great intelligence
>> The precise detection of small parts is
one of the strengths of the new W130L
series of laser photoelectric switches.
They solve demanding detection tasks
even in hard-to-reach locations or where
space is limited thanks to small read-
ing heads and intelligent configuration
possibilities. An analogue output and a
special optical head that generates a
laser line with parallel light also allow
sorting and regulatory tasks to be reli-
ably solved.
The W130L provides the flexibility re-
quired to allow users to put together their
own specific combination of evaluation
unit and optics. The series consists of an
energetic scanner (WT130L), a photo-
electric reflex switch (WL130L) and two
through-beam systems (WS/WE130).
The latter are differentiated by their
laser optics: while the Spot variant
generates a minute laser spot on the
object, and can thus precisely detect
even the smallest of parts, the Line
version offers a 30-mm-wide laser line
with parallel light. Combination with the
evaluation unit, which has both switch-
ing and analogue outputs, opens up
interesting possibilities, e.g. the detec-
tion of small, inaccurately transported
parts; the evaluation of parts; or their
sorting according to size; as well as the
regulation of web edges.
Evaluation units open up many
configuration possibilities
The W130L series offers two different
evaluation units users can choose
between either one switching output or
the combination of switching and ana-
logue output. Objects can be taught into
the device very easily, despite the wide-
ranging configuration possibilities, e.g.
light/dark switching or switch-on/switch-
off delay. And it is also possible to teach-
in the device externally via the control
wire. Depending on the task, the switch-
ing frequency can be set to the optimum
balance of accuracy and speed.
The W130L series thus offers an oppor-
tunity to cover a wide spectrum of appli-
cations with a single device family.
INFO 238
42 2/2006
: Products
>> The new XKS is aimed at applications
in which mounting space must be saved,
a robust complete unit is necessary, and
short-to-medium measurement lengths
are the rule. Typical areas of use for this
device are presses, stamping and spay-
ing machines, wood and metal process-
ing machines, apparatus construction or
medical technology.
Replaces expensive
supplementary interface
The XKS is used like a rotative stand-
alone encoder for determining position.
Thanks to HIPERFACE
, the XKS removes

the need to implement a further interface
in plants in which several drives with
HIPERFACE encoders are already used
for regulation. If the XKS is to be inte-
grated in a fieldbus environment, this
can be achieved with the help of inter-
face conversion modules for PROFIBUS,
and soon for CANopen and DeviceNet.
Whether SSI, TTL or HIPERFACE
the se-
ries of compact wire-draw encoders meets
every communication requirement.
Compact solution for positioning and path detection
Wire-draw encoder now with
HIPERFACE
interface
HIPERFACE
is an asynchronous semi-duplex interface that physically

corresponds to the EIA RS 485 specification. It is now used by more than
70 drive producers from A (as in ABB) to Z (as in Ziehl-Abegg) and has
therefore become established as a standard on the market. Power is
supplied to the encoder via two of the total of eight wires. Two further
wires are required for the bi-directional, bus-enabled parameter channel
via which, among other things, the absolute position data of, for example,
an XKS is transmitted to the regulator in digitalised form. The two remaining
pairs of wires provide the real-time process data channels. Sinus-shaped
incremental signals are transmitted in analogue form via these wires
and interpolated in the regulator. This non-digital process allows a high
resolution to be achieved even at high r.p.m. rates. Thanks to HIPERFACE
,
an interface standard is available for all common drives covering all
applications with just one type of signal cable.
>> Standard HIPERFACE
interface the interface standard

insightLINK
With the new XKS, the HIPERFACE interface standard enters the series
of compact, robust and precise absolute wire-draw encoders for measure-
ment lengths of up to 5 m.
New wire-draw encoders
43
: Products
insightLINK
INFO 239
>> Integration and modularity deter-
mine the structure of the ICR890. Thus
the system has an LED illumination
module, real-time focal control, and a
high-performance decoder. The reading
field covers conveyor belt widths of up to
1 m, at transport speeds of up to 4.8 m/s,
depending on the resolution used. The
depth of field lies between 600 mm at
a resolution of 250 DPI and 1,600 mm
at a resolution of 170 DPI, depending on
the application and type of installation.
Top image quality and reading
performance
The ICR890 is designed for maximum im-
age quality under all operational condi-
tions. The omnidirectional system offers
particular advantages, especially for:
p small bar codes that must be read at
high speeds,
p dirty or weakly contrasting codes,
p bar codes with highly variable module
widths, and
p the identification of codes under foil.
Moreover, the ICR890 allows image cap-
ture for OCR and video-coding applica-
tions. The transmission of image data
takes place in real time via the 2 Gbit
Ethernet interface, so no special image-
processing components (e.g. a frame
grabber) are necessary.
High availability through modularity
The individual illumination and camera
system groups are integrated in the en-
tire system as modules, allowing rapid
exchange. The ICR890 stores its param-
eters on an SD card which has proven
itself as a compact, upgradeable and
rapidly available storage medium for
digital cameras. The previously stored
parameters can be back-loaded from
With 2 GBit image data transmission
High-end reading system for
bar codes and Data Matrix
Objects require flexible, rapid and reliable identification in the distribu-
tion centres of postal and package service providers, of mail order com-
panies, and in the retail trade. The ICR890 high-end camera system sets
new standards here. It solves even the most difficult of tasks and can be
networked, e.g. with supplementary scanners or a volume measurement
system, to create a complete identification system.
the ICR890s SD card to the new mod-
ule should replacement be required.
Remote monitoring and diagnosis, allow-
ing the further optimisation of system
availability, is possible during operation
with the help of the RDT400 software
tool. No external PC is required for
decoding the bar codes because the
ICR890 has an integrated decoder in the
camera. This leads to significantly great-
er system reliability.
Suitable for complete ID systems
The ICR890 can be networked with
other sensor systems via its CAN-Bus
interface. Complete ID systems can be
configured by connecting further scan-
ners (e.g. for reading from the side) or
a volume measurement system. These,
then, only require a single interface to
the host system an important advan-
tage for many users.
The new ICR890 offers almost endless
possibilities wherever high-end code-
reading demands must be met.
The ICR890 high-end CCD camera system for reading 1-D and 2-D codes,
and for image output for OCR and video coding applications
High-end camera system
44 2/2006
: Products
>> The MZT6 magnetic cylinder sensor
is used for detecting the position of pis-
tons in pneumatic cylinders and offers
considerably better switching accuracy,
in addition to greater user-friendliness,
and improved EMC and immunity to vi-
brations.
Precise switching behaviour
This has been made possible by so-called
2-D magnetic field evaluation which, for
the first time, allows areas beside the
switching range to be reliably cut out dur-
ing signal evaluation. There is therefore
Maximum switching accuracy through 2-D magnetic field evaluation
Magnetic cylinder sensor with no
scattering of switching points
no multiple switching with the MZT6.
Moreover, the MZT6 achieves a consid-
erably more exact switching behaviour
and a greatly minimised hysteresis: its
switching point scattering of +/5% is
five times lower than is common with
other cylinder sensors regardless of
the cylinder type and the field strength of
the piston magnets. This also results in
almost scatter-free hysteresis between
the switching points. Applications with
short and precise cylinder movements,
in particular, profit from this improved
accuracy.
Expanded temperature range,
high enclosure rating
In addition to its reliable switching be-
haviour, the MZT6 is characterised by its
great robustness. The sensor can be op-
erated within an expanded temperature
range of from 30C to +80C because
its very low power uptake minimises its
own warming. Supplemented by special
extrusion technology, the new MZT6 also
offers maximum tightness up to IP 69K,
as well as immunity to temperature
shocks.
Proven benefits retained
In other respects, the new MZT6 exploits
the mounting and application advantag-
es of its predecessor. It fits all common
T-slots, can be inserted into the slot from
above, and is reliably fixed without any
special tools. During operation, its firm
fixing ensures that the switching points
remain exactly where they have been
taught-in.
At the 2006 Hanover Industrial Trade Fair (HMI) SICK presented sen-
sors with a completely new type of chip technology which, among other
things, provide hitherto impossibly precise switching behaviour. The MZT6
magnetic cylinder sensor is the latest example.
insightLINK
INFO 240
Particularly precise and robust: The new MZT6 magnetic cylinder sensor
Magnetic sensors
: Museum
>> Whether with a virtual tour or video
visitors can prepare themselves in ad-
vance for the highlights awaiting them in
the museums.
Largest public collection of
model railways
The Model Railway Museum on Gran-
ville Island houses the worlds largest
collection of model railways and toys on
public exhibition. Among other things on
The Granville Museums in Vancouver
offer model ships and railways
Fans of model railways and faith-
fully scaled models of ships will cer-
tainly get their moneys worth at the
Granville Museums in Vancouver,
Canada.
view are several historical locomotives
and trains of differing gauge (gauge 0,
gauge G, standard gauge, etc.) as well
as numerous photo and diorama shows.
The impressive range of model railway
systems, and their detail, give an idea of
the incredible patience involved in con-
structing the five-line networks.
An Eldorado for aficionados
of model ships
The Model Ship Museum is right next
door. It accommodates an impressive
international collection of model ships,
submarines, warships, aircraft carri-
ers, freighters, tugs, yachts and toys.
The Ship Museum exhibits classic ships
such as HMS Bounty, Admiral Nelsons
HMS Victoria or the German destroyer
Bismarck as scale models. The star of
the Museum is undoubtedly the 350 kg
4-metre model of the British battleship
HMS Hood from the Second World War.
It took model constructor Rodney Hen-
driksen more than 20 years to build.
Miniature technology
45
en miniature
TECHNOLOGY
[ ]
International guests are welcome
With their model ships and railways, the
museums present technology in mini-
ature from all parts of the world. So they
are correspondingly prepared for inter-
national guests especially on the home
pages www.modelshipsmuseum.ca and
www.modeltrainsmuseum.ca available
in 15 languages.
46 2/2006
: Interview
Retain the proven, weigh up the new, think long term
Continuity and innovation the right mix determines success
30 September 2006, the day of the companys 60th anniversary, was also
the last working day for Anne-Kathrin Deutrich, Spokesperson of the Ex-
ecutive Board of SICK AG. In conversation with SICK insight she reviews
how the small Black Forest company became a global player in sensor
technology.
SICK insight: What did you think of SICK
when you joined it in early 1992?
Anne-Kathrin Deutrich: I came to SICK
as the successor to the Commercial
Manager during an exciting time. The
then Managing Director and later Execu-
tive Board member, Volker Reiche, had
initiated a new strategic alignment that
SICK insight in conversation with Anne-Kathrin Deutrich
Spokesperson of the Executive Board of SICK AG until 30 September, 2006
was intended to create a company with
professional internal and external struc-
tures from the family business Erwin Sick
GmbH. Improvements everywhere was
the aim particularly regarding greater
market share in the core sectors, ac-
cess to new fields of application, greater
closeness to the customer, and being
more innovative than the competition.
SICK insight: What measures did SICK
take at the time to re-align itself?
Anne-Kathrin Deutrich: We identified
the importance of research and develop-
ment as well as the creation of a mar-
ket- and customer-focused corporate
organisation as long-term factors for
success. The budget for R&D was con-
sequently greatly increased. This was
not so straightforward during the 1993
recession but looking back, this step
provided the technological basis for
SICKs subsequent success. The PLS
safety laser scanner is just one of the
many examples worthy of mention. At
the same time, we expressed our new
type of customer focus in automation,
safety, environmental and identification
technology. As a result, we were better
able to implement customer wishes, and
could also better take into account the
special aspects of the particular areas of
business with short-term component
business here, and long-term project
business there. Further key actions were
the introduction of comprehensive proc-
ess controlling, the evaluation of results,
the creation of new work processes, and
the qualification of our employees.
SICK insight: What significance did in-
ternational business and the topic of
acquisitions have for the development of
the company?
Over 70% of
Group sales take
place abroad
Anne-Kathrin Deutrich: Without the in-
ternationalisation introduced at the time
we would undoubtedly not be a global
player in sensor technology now. We are
in leading positions in the world markets
of Europe, America, and Asia through-
out all our fields of business. Over 70%
of Group sales take place abroad. This
all started with the founding of the first
subsidiaries initially in Europe, then
overseas. We are now represented by
over 40 subsidiaries or participations in
47
: Interview
Retain the proven, weigh up the new, think long term
Continuity and innovation the right mix determines success
more than 40 countries. SICK then be-
gan making acquisitions in the late 90s.
In addition to purchasing brands, we
paid particular attention to the sensible
rounding out of technologies that would
advance our cause in our core areas of
business. This, too, has paid dividends
consider, for example, the rotative
sensors of SICK STEGMANN, the laser
technology of SICK IBEO, the extractive
gas analysers of Maihak or the camera
expertise of SICK IVP. These successes
were possible because we remained true
to our long-term thinking, i.e. aiming for
substantive returns on investment and
not merely quick profits.
SICK insight: You mentioned technology.
Technologies also depend on having the
right technologists, i.e. employees. What
makes SICK interesting for qualified em-
ployees?
Anne-Kathrin Deutrich: The improve-
ment of personnel work was one of the
most important tools in the re-alignment
of SICK, and still is. We rely on the per-
manent qualification of our employees,
while at the same time also require
new colleagues who bring new topics
and technologies to the company. Its
easier to find such people nowadays
than it was ten years ago. This is partly
because of the attractive, modern work-
places that SICK offers just look at
all the new buildings that we have put
up in recent years. We can be proud of
our modern management culture that
encourages employees while also chal-
lenging them. Then there is a new qual-
ity of life that seems to make the region
around Freiburg more attractive to many
applicants and their families than some
urban centres of population without any
real leisure value. Moreover, we under-
take projects that support families in
the company and in the region, e.g. the
youth centre, or afternoon homework
assistance for our employees children.
Finally, SICK as an Aktiengesellschaft
(a form of private limited company) has
also become an open, well-known com-
pany, whose solid and innovative reputa-
tion is an important, even decisive, factor
for some new employees and for many
customers too, by the way. On looking
back, it is apparent that we succeeded
in converting a supposed locational dis-
advantage into an actual locational ad-
vantage.
SICK insight: Where do SICKs future
challenges lie, and what is the recipe for
success in the future?
Anne-Kathrin Deutrich: The challenges
are varied and we are already facing
them. Take the example of complete
solutions. The trend is clearly away from
component business. It will always be
necessary, of course, but the increasing-
ly complex demands of OEMs and end-
customers require intelligent complete
solutions consisting of sensors, control
technology and services. Thanks to our
internal structures, our technological
competence, and our worldwide pres-
ence, SICK is already very well placed
as, for example, the Automotive Sector
Management shows. Competition
particularly internationally will become
increasingly harsh. We have observed
this, but also see that we can decisively
help shape competitive processes by
implementing our corporate mission
statement Independence, Innovation,
Leadership. Technological change
is taking place in ever-shorter cycles,
which means that the importance that
we attach to R&D also in terms of the
percentage of profits re-invested will
increase further, especially considering
that sensor, control and service technol-
ogy is becoming increasingly software-
dependent. Meeting the challenges with
new solutions will thus be an important
part of the recipe for future success. An-
other aspect of this I am quite sure is
to maintain our technological lead. It will
all depend on an appropriate mix of the
proven and the innovative.
SICK insight: Ms Deutrich, thank you for
this conversation. We wish you all the
best for the future!
47
: SICK Tour
>> This collaboration is expressed
in the KUKA-Stankin-SICK Educational
Technological Centre, where students
of engineering science and industrial
Safety technology for Stankins training centre
To Russia with best wishes
Stankin, Moscows University of Technology and Mechanical Engineering,
has gained two important partners for their training centre: KUKA as a
robot supplier and SICK as a partner for machine safety.
professionals can explore state-of-the-
art robotics and safety-oriented auto-
mation, and improve their programming
knowledge.
Robot technology from KUKA and safety solutions from SICK
Safety technology for
two robot cells
SICKs contribution to the training centre
consists of providing electro-sensitive pro-
tective equipment and intelligent safety
controllers that ideally support the various
functions of the two KUKA robot cells set
up side-by-side so the robots can work
individually or co-operatively. The safety
control configuration differs depending
on the mode employed. If the two robots
operate separately, the larger cell is pro-
tected with a vertical S3000 laser scan-
ner towards the smaller cell. The door
in the partially existent protective fence
is protected by an i200 safety interlock.
Parallel to this, a C4000 safety light cur-
tain monitors access to the smaller robot
cell, while the above-mentioned S3000
provides protection towards the larger
cell. The signals from the sensors in the
two cells are consolidated, evaluated and
co-ordinated by a UE440 compact safety
controller, which also handles the task of
upgrading from separate to co-operative
cell operation. Now only the C4000 and
i200 are active, while the safety function
of the S3000, through whose protective
field the work-pieces are passed, is con-
sequently switched off.
This safety configuration gives the
KUKA-Stankin-SICK Educational Tech-
nological Centre one of the worlds most
innovative solutions in the area of safe
sensor and control technology. It is also
safe to assume that it is no disadvantage
that the sensors and controllers are both
available from a single source.
INFO 241
>> Whether constructors, Project Manag-
ers, Managing Directors or users practi-
cal knowledge is important for them all,
though with differing emphases. Given
the continuously increasing interest and
the specific needs for information, SICK is
again offering user training and specialist
seminars for a variety of target groups in
2007.
The trainers both our own special-
ists and experts from Trade Associations,
federations or EU organisations pro-
vide participants with access to all the
important topics dealing with automa-
tion, safety, identification and process
measurement technology appropriate
for their questions and needs.
Major interest, prompt registration
Our Training & Education 2007 bro-
chure provides a detailed overview of
the topics and dates of the target-group-
oriented events. It can be downloaded
as a PDF file from the link below, or re-
quested from us directly. The number of
participants is limited in order to ensure
an optimum transfer of knowledge. We
also provide up-to-date information on
current topics and dates at: www.sick.
com/seminare.
Training 2007: target-group-oriented practical knowledge
48 2/2006
49
: SICK Tour
>> Dr. Erwin Sick founded an engineer-
ing office in Vaterstetten near Munich
on 26 September 1946. Very practically,
the up-and-coming company moved to
its current headquarters in Waldkirch on
its tenth anniversary, in 1956. SICK em-
ployed 25 employees then. Today 50
From a Munich-based engineering office
to a Group active worldwide
SICK celebrates its 60th birthday
SICK celebrated the companys 60-year existence at the end of Septem-
ber. Since its founding, the company has developed into an independent
Group active worldwide. Continuous innovations, and a technological and
price lead, have ensured that SICK now has a leading position in numer-
ous markets all over the world.
>> Whether students, industry profes-
sionals or researchers they all profit
from the support provided by SICK for the
Automation Systems Centre (ASCent) at
Manchester Metropolitan University.
As ASCent is also the UKs PROFIBUS
International Competence Centre, they
were naturally delighted (according to
Dr. Andrew Verwer, ASCents Centre
Manager) to receive the PROFIBUS-
enabled safety laser scanner, laser
distance measuring system and multi-
turn absolute encoder. The SICK sensors
will be used on a training rig. Their task
will be and how could it be otherwise
SICK supports Manchester Metropolitan University
Profiting from PROFIBUS sensors
in Manchester the automated handling
of a football.
So if England happens to become
World Champion in four years time
one will at least know where they learnt
their tricks ...
>> SICK Poland was awarded this years
Gold Medal at the AUTOMATICON trade
fair in Warsaw thanks to the IVC-3D in-
telligent camera sensor.
The trade fair took place for the
twelfth time, and the number of ex-
hibitors had never been so great and
likewise the competition vying for the
AUTOMATICON 2006 Gold Medal.
Despite the harsh competition, in
the end even the most famous of rivals
could be beaten to the highly sought-
after prize. The reason? The jury consid-
ered the IVC-3D including its technical
documentation and application descrip-
tion unparalleled in its class.
SICK Poland is very happy about re-
ceiving the Gold Medal and passed on
the jurys praise to SICK IVP, the produc-
er of the intelligent camera sensor.
Award at the
AUTOMATICON trade fair
SICK Poland recei-
ves Gold Medal
Company founder Dr. Erwin Sick
years later the SICK Group, as one of
the technological and market leaders
in factory and process automation, em-
ploys more than 4,200 personnel world-
wide. Sales reached almost EUR 600 m.
in 2005.
60 years of SICK means 60 years of
innovation in sensor technology from
the invention of the auto-collimation
photoelectric switch and the safety light
grid, through gas analysers and bar-code
reading devices, to the laser scanners,
camera systems and communication in-
terfaces of today. Dr. Erwin Sick, who died
on 3 December 1988, developed techno-
logical milestones over decades. He was
largely responsible for the innovative cor-
porate culture that still makes SICK the
technological leader in sensors. SICK will
set further standards in robustness, flex-
ibility and innovation on its way to devel-
oping the intelligent sensors of tomorrow.
50 2/2006
I accept that it may not be the best sea-
son to be talking about T-shirts. Thick jackets and
overcoats would be more appropriate. But it was July when I read the book for this
Book Corner, about 35C it was. And just thinking about wearing anything more substantial than a T-shirt
made me glow (ladies glow, men perspire and horses sweat). I found the title interesting, started going through the
book and learnt, on the one hand, a whole lot about cotton and the production and path taken by a T-shirt and, on the other
hand, about interactions in the world economy.
Author Pietra Rivoli was confronted, among other things, by the question Who made your T-shirt? during an anti-globalisation demonstration
at Georgetown University, This spurred the Professor of Economics to take a journey to check out the arguments of globalisation opponents.
A journey that followed the global route of a T-shirt, from the growing of the cotton to the ultimate disposal of the clothing. It first took her to
Texas because, along with China, the USA is one of the worlds largest cotton producers. There she met cotton farmer Nelson Reinsch and
his family. He took her on a journey through the history of growing and producing cotton in the US. She learnt a lot about the geographical
development of cotton growing; the working conditions; slavery; the natural enemies of cotton and the resultant crop failures; and the
symbiosis between researchers, government programmes and farmers own inventiveness.
Having gained a deep knowledge of cotton and its history she travelled to China, where her T-shirt had been produced. There
she got to know about the sweatshops (embroidery and sewing factories) that are a thorn in the side of the opponents
of globalisation because young women work there under almost inhuman conditions. How- ever
Rivoli was surprised to find that the girls themselves did not feel that the work was so
bad there, because it allowed them to escape even harder work on the land or, in some
cases, forced marriages and thus gain a minuscule amount of freedom. Although the
work is very hard, given these situations the country girls consider it a good job. Accord-
ing to Rivoli this is the main factor of Chinas success: young women who are compliant
and willing to work.
Back in the USA she made her way to Maryland, where prosperity is not unusual and
each year the average citizen throws away 68 pounds of material and textiles, or takes
them to a collection point. She explains what happens to the collected clothes and then
travels to Tanzania to see what would happen to her T-shirt.
Rivoli graphically describes the problem with downward cost competi-
tion and what this means for the world economy; and that other influ-
ences (such as automation and technical progress) pose far greater risks
for jobs in the expensive world.
This is a very easy book to read as the author understands the art
of writing without being overbearing, and her aim is to learn together
with the reader in order to be able to reach a joint judgement at the
end. The goal is to focus awareness on interactions. She masters the
trick that must form the basis of such material histories: the con-
stant transition between factual information and the abstract. She re-
flects on each event in a generalised way. I have learnt a lot about the
history of the worldwide cotton and textile industry over
these 300 pages, but have also gained a better insight
into global interactions.
The authors summation is that there is no global
free trade, that political influences such as subsidies,
lobbyists or customs barriers keep cotton production
alive in the USA, that the dominance of politics masters
the market in the global trade in textiles, that global
capitalism and the workers rights movement are not
adversaries, and that her lasting impression of the
journey is how well the people involved in the T-shirt
business communicate with one another they all
understand each other because the trade connects
them all, worldwide.
Summary: a book to be recommended. Clearly
written and enlightening.
: Book Corner
The Travels of a T-Shirt
in the Global Economy
This Book Corner is written by
Ingrid Rathfelder, Editor of the
SICK insight e-mail newsletter
The Travels of a T-Shirt in the
Global Economy
John Wiley & Sons Inc.
ISBN: 0-471-64849-3
I accept that it may not be the best sea-
son to be talking about T-shirts. Thick jackets and
overcoats would be more appropriate. But it was July when I read the book for this
Book Corner, about 35C it was. And just thinking about wearing anything more substantial than a T-shirt
made me glow (ladies glow, men perspire and horses sweat). I found the title interesting, started going through the
book and learnt, on the one hand, a whole lot about cotton and the production and path taken by a T-shirt and, on the other
hand, about interactions in the world economy.
Author Pietra Rivoli was confronted, among other things, by the question Who made your T-shirt? during an anti-globalisation demonstration
at Georgetown University, This spurred the Professor of Economics to take a journey to check out the arguments of globalisation opponents.
A journey that followed the global route of a T-shirt, from the growing of the cotton to the ultimate disposal of the clothing. It first took her to
Texas because, along with China, the USA is one of the worlds largest cotton producers. There she met cotton farmer Nelson Reinsch and
his family. He took her on a journey through the history of growing and producing cotton in the US. She learnt a lot about the geographical
development of cotton growing; the working conditions; slavery; the natural enemies of cotton and the resultant crop failures; and the
symbiosis between researchers, government programmes and farmers own inventiveness.
Having gained a deep knowledge of cotton and its history she travelled to China, where her T-shirt had been produced. There
she got to know about the sweatshops (embroidery and sewing factories) that are a thorn in the side of the opponents
of globalisation because young women work there under almost inhuman conditions. How- ever
Rivoli was surprised to find that the girls themselves did not feel that the work was so
bad there, because it allowed them to escape even harder work on the land or, in some
cases, forced marriages and thus gain a minuscule amount of freedom. Although the
work is very hard, given these situations the country girls consider it a good job. Accord-
ing to Rivoli this is the main factor of Chinas success: young women who are compliant
and willing to work.
Back in the USA she made her way to Maryland, where prosperity is not unusual and
each year the average citizen throws away 68 pounds of material and textiles, or takes
them to a collection point. She explains what happens to the collected clothes and then
travels to Tanzania to see what would happen to her T-shirt.
Rivoli graphically describes the problem with downward cost competi-
tion and what this means for the world economy; and that other influ-
ences (such as automation and technical progress) pose far greater risks
for jobs in the expensive world.
This is a very easy book to read as the author understands the art
of writing without being overbearing, and her aim is to learn together
with the reader in order to be able to reach a joint judgement at the
end. The goal is to focus awareness on interactions. She masters the
trick that must form the basis of such material histories: the con-
stant transition between factual information and the abstract. She re-
flects on each event in a generalised way. I have learnt a lot about the
history of the worldwide cotton and textile industry over
these 300 pages, but have also gained a better insight
into global interactions.
The authors summation is that there is no global
free trade, that political influences such as subsidies,
lobbyists or customs barriers keep cotton production
alive in the USA, that the dominance of politics masters
the market in the global trade in textiles, that global
capitalism and the workers rights movement are not
adversaries, and that her lasting impression of the
journey is how well the people involved in the T-shirt
business communicate with one another they all
understand each other because the trade connects
them all, worldwide.
Summary: a book to be recommended. Clearly
written and enlightening.
: Info
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