SICK Magazine

> 3, 2, 1
lift off
SICK Solutions Tour 2010
Sensonauts identify
new challenges
S I C K S C U S T O M E R M A G A Z I N E
www.sick.com
1 _ 2 0 1 0
Fast implementation
Porsche relies on
RFID technology from SICK

Page 15
Offering solutions
Interview concerning the
SICK Solutions Tour 2010

Page 22
Brakes ought to brake
Encoders and pressure sensors from
SICK ensure absolute reliability on
the test stand
Page 11
: Applications
2
01 2010
From the Innovation Marathon
to the Solutions Tour
Dear Readers,
Surely, you still recall the extraordinary title image of the last
SICKinsight: A victorious athlete, decorated with medals, an image
that arose graphically as a result of compiling SICKs innovation
products of the year 2009. In a difficult environment, it was especially
all of the numerous innovations made by SICK that contributed to
keeping business on track at least to a reasonable extent.
In the year 2010, too, we will once again invest all of our strength
into innovative products and services. However, that is not all
we are also showing you in what diverse ways our customers benefit
from SICKs sensor, control, and service solutions. To that end, at
www.sick-solutions-tour.com we are initially setting out into space so
that our sensonauts can beam in, i.e. identify, interesting challeng-
es in many industry sectors. The next click already takes you down to
earth and to customer solutions that might help you move forward as
well. Read up on what is behind it all specifically in the interview on
pages 22 and 23, and you can also learn in this issue about the layout
and content these web pages offer in addition to many other inter-
esting articles and information.
Consequently, there are many reasons for you as well to catch the
inspiration toward transferring expertise by reading the first issue of
SICKinsight in 2010.
Have an enjoyable read!
With best wishes
Hartmut Dages
Manager Central Department Marketing
: Editorial
Tour Stops Provys CZ & ET Systems .....................04
Tour Stops Vattenfall & Sidel ................................05
Tour Stops Linde Group & Cementos Bo Bo S.A....06
Tour Stops Itella & HISOFT ....................................07
: Applications
Sensor technology from SICK
supports intelligent value added ..........................08
Integrated safety for forklift trucks .......................09
Dynamic Focus permits unimagined efficiency ...10
Guaranteeing that brakes always brake .................11
More performance when positioning ....................12
First class for any bodywork ..................................13
Secondary fuels and corrosion risk under control ...14
RFID from SICK at Porsche ....................................15
Exactly right for packaging drives .........................16
Pin inspection with camera sensors .....................16
Checking injection-molded parts ..........................17
Always accurately positioned,
thanks to Smart Camera .......................................18
Object detection in small parts storage................19
Continuous identification of thin-film modules ....20
Photoelectric Sensor increases availability ..........21
: Interview
Background to SICK Solutions Tour 2010 ...........22
: Products
Dust Measuring Devices meet high expectations ...24
Detection via Photoelectric Line Sensor ..............25
Making gas visible ..................................................26
Device for the most diverse protective fields .......27
Bluetooth Hand-held Scanners
no wires, no worries ...............................................27
New 13.56 MHz system for intralogistics ............28
Well-rounded solutions for object detection ........29
Product-News .........................................................30
Electro-sensitive protection in IP 69K ..................32
Optical linear measurement for intralogistics ......33
Flexi Soft Application Manual ................................33
CE label according to the new
2006/42 EC Machinery Directive .........................34
Analog position detection for long piston travels ....34
Flexi Link: Networking a safe control system .......35
: Technology
Innovative sensor technology as
a basis for new series ............................................36
: SICK Tour
SICK at the Robotation Academy ..........................37
SICKs Safety Days .................................................38
Logistics Innovations Day 2009 ............................38
Customer day at Elsag Datamat in Genoa ...........39
SICK Airport Days 2009 .........................................39
: Internet
SICK Solutions Tour on the net .............................40
: Service .........................................................41
: News
03
>> Twenty years ago, the DME2000 was
the first optical distance sensor for po-
sitioning aisle stackers. Back then, the
use of time-of-flight technology gave the
device unequalled speed and precision
characteristics that have been improved
continuously until todays generation, the
DME5000. At the same time, the DME
series constitutes the cornerstone for
the distance measurement portfolio from
SICK. Scanning distance measurement
sensors such as the DS30 or the DT, as
well as the DME5000 and DME4000
series, which due to different measur-
ing range variants are optimized for use
both in miniload AS/RS and in high-rise
pallet warehouses, are today standard at
the major manufacturers of logistics fa-
cilities, to name but a few. Added to this
are numerous distance sensors based on
ultrasound as well as linear and rotative
distance measuring systems.
Thus, SICK is probably the supplier
with the worlds broadest program of
distance sensor technology and the lon-
gest application experience in industrial
automation.
Twenty years of optical
distance measurement via
time-of-flight method
Happy Birthday DME
With the DME2000, SICK presented
the first distance measurement sys-
tem with time-of-flight technology
in 1990. Today one cannot imagine
countless industrial applications with-
out the DME series and many of the
distance sensors derived from it.
19
th
VDI Material Flow Congress
1516 April 2010 Garching
VfS Congress Engaging in Construc-
tive Dialog with the Safety Industry
2021 April 2010 Leipzig
TV Rheinland Symposium
45 May 2010 Cologne
Find more event dates and locations
on our Solutions Tour Website.
>> The SICK Solutions Tour 2010
presents you with application exper-
tise live and firsthand. In the course
of the Solution Days, experience live
in lectures and demonstrations just
how SICKs sensor solutions for au-
tomation contribute to increasing
the efficiency of your equipment and
plants. Discuss your tasks with our
specialists. It is definitely worth par-
ticipating so register now.
>> From the solution with one sen-
sor to the complex system with
the most diverse sensor compo-
nents and control elements. When
it comes to your applications, why
not benefit from many years of ex-
pertise of one of the worlds leading
specialists?
In the course of the 2010 Solu-
tions Tour, SICK presents on a regu-
SICK SOLUTION DAYS
SolutionS tour 2010
www.sick-solutions-tour.com
lar basis sensor solutions from all
over the world directly from prac-
tical industrial operations in factory
automation, logistics automation,
and process automation. Every so-
lution is a stopover on our Tour of
Sensor Solutions around the globe,
introduced in detail as a Solutions
Tour Stop. Join us it is definitely
worth your while.
The Tour of Sensor Solutions: Wherever SICK is, sensors are there
as well and wherever sensors are, SICKs solution competence is
never far. Every task has special characteristics and so does every
solution. Sometimes simple, sometimes complex.
www.sickinsight.de
Now scrolling online!
Currently only available in German
01 2010 01 2010
04
SolutionS tour 2010
Safety
Process-efficient access protection
on a horizontal storage carousel
During order picking from a horizontal storage carousel of the Spanish
company ET Systems Global Storage Solutions, a miniTwin4 safety light
curtain protects the operating personnel while at the same time shorten-
ing access times.
>> The place of action is the Sant Joan
Despi Hospital near Barcelona. Here
articles are deposited in a horizontal
storage carousel from ET Systems into
storage containers that are in circula-
tion on a horizontal transport system.
The work stations at which employees
intervene in the storage system during
order picking have to be protected to
prevent injuries. Mechanical guards are
not compatible with operations in light
of 300 items ordered per hour, and they
would delay the removal and order-pick-
ing processes.
You can check out the way in which
miniTwin4 protects employ ees and simul-
taneously permits a smooth and signifi-
cantly faster removal and order picking
of the articles by looking at the Solutions
Tour at www.sick-solutions-tour.com
under the Tour Stops heading.
Tour Stop ET Systems //Warehouse & Distribution
>> The Czech special machine expert
Provys has developed for its customers
a testing device that allows inspection
of a large variety of plastic parts, e.g.
lock carrier covers for motor vehicles.
The complexity and variety of testing
tasks eight component variants with
more than 20 inspection features each
necessitated a flexible and adaptable
solution. The contrast conditions black
plastic parts against a black background
posed an additional challenge for the
testing procedure. After all, it was nec-
essary that the solution could write the
measured values and the images of the
parts inspections into LOG files, thus
allowing access to all of the production
and testing data at any time.
Why did Provys opt in favor of
sensor technology from SICK from
a single source and how does the
end user benefit from this? The
Solutions Tour reveals it to you at
www.sick- solutions-tour.com under the
Tour Stops heading.
In an automatic testing device, the
3D IVC-3D smart camera together
with a programmable DFS60 encod-
er allow flexible quality assessment
of a great number of different plastic
components.
Tour Stop Provys //Automotive & Part Supplier
Flexible Production
3D inspection of plastic parts in all areas of automotive parts production
05
SolutionS tour 2010
Flexible Production
Better performance for roll-fed
labeling systems
>> The integration of the systems into
different filling lines, increasingly higher
labeling speeds, the reduction of change-
over times, and varying label designs
make very high demands on the label po-
sitioning systems from Sidel in Mantova
(Italy). Instead of complex plant-specific
adaptations, sensor solutions from SICK
allow more flexibility, less waste, and
higher productivity.
Just how that happens is shown
by SICKs 2010 Solutions Tour at
www.sick-solutions-tour.com under the
Tour Stops heading.
When converting roll-fed labeling
systems, programmable encoders
and user-friendly print mark sen-
sors from SICK provide the highest
possible flexibility and time savings.
Increasing productivity as well as
reducing waste can be achieved by
using a laser sensor for end-of-label
detection.
Tour Stop Sidel //Packaging
Process Monitoring & Control
Filter monitoring in coal-fired power stations at minimum expense
Tour Stop Vattenfall //Power
poses a particular challenge. Because
of temperature changes the duct may
warp, causing a deviation of the optical
axis of the measuring device. The mea-
suring device is supposed to compen-
sate for this distortion.
How the combination of self-alignment
and pollution compensation of DUST-
HUNTER C200 works; how it ensures
in this way reliable measuring values;
and how these features contribute in
addition to long maintenance intervals
and low operating costs is revealed
by the success story at Vattenfall at
Tour Stops heading.
>> Depending on the coal-fired power
station, up to 250 kg of coal dust a
second are burnt to generate steam for
driving the turbines. Burning coal dust
may cause extremely high dust concen-
trations. The process gas is cleaned
from dust particles in the electrostatic
precipitator. For efficiently controlling
and optimizing the performance of the
electrostatic precipitator, it is necessary
to monitor permanently the minimal
to high dust concentrations. The dust
measurement devices must recognize
fluctuations of the concentration imme-
diately, for this is the only way to initi-
ate fast and meaningful countermea-
sures toward the dust removal process.
The rectangular design of the gas duct
Measuring high or low dust concentrations accurately with one device even
under harsh ambient conditions that is precisely what DUSTHUNTER C200
does with its two integrated measuring principles.
01 2010 01 2010
06
SolutionS tour 2010
Tour Stop Cementos Bo Bo S.A. //Cement
Quality Control/Process Monitoring & Control
Explosion-protected reliability in small measuring areas
>> A number of methods are in use for
manufacturing hydrogen. Frequently,
natural gas and higher hydrocarbons
are converted by adding steam in so-
called reformers into syngas, a mix-
ture of hydrogen and carbon monox-
ide. A large part of the carbon mon-
oxide (CO) is subsequently oxidized to
form carbon dioxide (CO
2
). Following
this, the hydrogen is subjected to a
pressure swing adsorption process to
reach a purity of up to 99.999 vol%.
The purity of the H
2
undergoes con-
stant monitoring at the adsorber col-
umn outlets. The sampling points are
located in an explosive area requir-
ing a high degree of safety. As a result,
all of the demands on the application
solution and the measuring device are
Due to its special design, the S721 Ex NDIR gas analyzer allows a total measure-
ment of CO and CO
2
with only one IR module certified for Explosion Zone 1.
Tour Stop Linde Group //Chemical
accordingly high. In addition to that,
you have the expectations of user-
friendly and economical use of the
measuring devices. Fast on-site ser-
vice is therefore a requirement.
Which features and benefits were in
favor of using the S721 Ex NDIR gas
analyzer at Linde AG Germany for total
measurement of CO and CO
2
and what
additional services SICK was able to
offer is something you may read up on
at www.sick-solutions-tour.com un-
der the Tour Stops heading.
Gas analysis, dust and flow measurement in the middle of the Chilean des-
ert, SICK implements for Cementos Bo Bo a multiple-component emission
measurement from a single source. The solution stands out due to high avail-
ability and reliable data transmission to the regulatory authority.
Process Monitoring & Control/Legislative Compliances
Complete solution for cement
factory in the desert
>> At Cementos Bo Bo, the task was
measuring emissions typical of cement
factories: sulfur dioxide (SO
2
), nitrogen
oxide (NOx), carbon dioxide (CO
2
), oxygen
(O
2
), dust concentration, and gas flow in
the smokestack. The goal is to pass on
the measured results, indicated as stan-
dard values in mg/m
3
and corrected rela-
tive to the oxygen reference value, to the
local authorities. Availability of the mea-
surements is crucial and must amount to
95 % at least. Due to the remote loca-
tion, it was important for Cementos Bo
Bo that all measurement devices for the
diverse measuring tasks as well as main-
tenance, calibration, and data transmis-
sion, came from a single source.
The equipment used is a CEM sys-
tem with low maintenance requirements
and data transmission via Internet a
complete package oriented specifically
toward these exceptional conditions.
Please read up on how comprehensive
emission monitoring works and what
benefits it offers to the operator under
www.sick-solutions-tour.com.
: Applications
07
SolutionS tour 2010
Tour Stop Itella //CEP & Postal
At a lumber mill of EHP European-Hardwood Production, the real-time LMS
laser measurement system from SICK analyzes the contours and surfaces
of logs, optimizes the yield of sawn timber, and ensures sustainable use of
resources.
Tour Stop HISOFT //Wood
>> IEHPs hardwood lumber mill in
Frauental, Austria, processes about
50,000 m
3
(approx. 65,390 cu. yards
or 21,190 MBFT) of timber. The lumber
(primarily for the furniture and flooring
industries) is manufactured from oak,
beech, and maple trees. In order to en-
sure sustainable and efficient manage-
ment while using resources optimally
and increasing throughput at the same
time, HISOFT Automatisierungs- and
Informationstechnik GmbH was com-
missioned with developing a solution
for contour measurement and surface
inspection of logs. The requirements in-
cluded flexible adjustability, a high level
of ruggedness and hardiness vis--vis
the operating environment, fast integra-
tion, easy operation, and low investment
and operating costs.
How this solution, which was realized
using an LMS400 laser measurement
system from SICK, works in practical
operations is portrayed in the report at
www.sick-solutions-tour.com.
Quality Control
Laser measurement system
optimizes yield of sawn timber
>> In four big cities, Itella operates par-
cel distribution centers in which unique
to date a combined sorting of letters,
packages, parcels, and bundle mail takes
place. The throughput performance for
letters and flat packages is up to 5,000
items per hour and system; for packages,
parcels, and bundle mail that figure is
10,000 items per hour and system. En-
suring such facility performances tech-
nically and at the same time integrating
aspects of economic efficiency and in-
voicing of services rendered is possible
only with sophisticated 1D and 2D code
readers featuring integrated imaging for
further OCR processing and video coding,
as well as calibratable volume measure-
ment systems for the larger containers.
How it was possible to integrate all
of SICKs components ICR890 code
readers, VMS520 volume measurement
system, MSC800 controller, and RDT400
remote diagnostic tool as a system into
the sorting facility and which benefits re-
sult for Itella from the permanent moni-
toring of device and system functions as
well as options for remote diagnosis and
maintenance? Read up on this topic at
Tour Stops heading.
Parcel distribution centers of the Finnish postal and communications com-
pany Itella benefit from SICKs integrated complete solutions for identifica-
tion and volume measurement of letters, packages, parcels and bundle mail.
Track & Trace/Process Monitoring & Control
Complete solution for identification and
volume measurement in parcel centers
01 2010
08
: Applications Access protection Parts inspection
Further product information:
www.mysick.com/applications
More about the customer:
www.cmb-automation.de
>> The facility was planned and deliv-
ered by AMKs subsidiary CMB Auto-
mation in Kirchheim/Teck. With our
lean-production plant components, e.g.
the fully automatic Cp9 palletizers with
integrated installation module and the
high-precision joining systems, we are
betting entirely on intelligent value add-
ed, explains Jens Labs, General Man-
ager of CMB Automation. Material han-
dling as a process not increasing value
per se is integrated directly into the indi-
vidual manufacturing stages in a space-
saving and cost-minimizing way. This
makes plants such as the one at AMK,
where 44 machines are linked overall,
compact and economical. Additional
aspects of intelligent production are,
among others, the autonomous opera-
tion of the production line and its equip-
ment over several hours and shifts, as
CMB Automation: Sensor technology
from SICK supports intelligent value added
Feeding reliably
+ inspecting dependably
= producing efficiently
Since January 2010, AMK, a supplier of drive and control tech-
nology based in Aichwald, produces electric motors on its new,
cutting-edge production line. Integrated into the plant, C2000
safety light curtains, Flexi Classic controllers, and vision sensors
of the Inspector series are delivering excellent performance.
well as the 100-percent inspection of
the manufactured and processed com-
ponents after each process step.
Person/material differentiation
in automatic stack feeding
More than a dozen Cp9 palletizer sys-
tems are in use at the AMK plant. All
of them feature two parallel transport
sections one for feeding stacked car-
riers with the appropriate work pieces
and one that transports the empty
work carriers or pallets as a stack out
of the machine. These feed zones on
the palletizer are protected by C2000
light curtains, explains Jens Labs di-
rectly at the machine. Together with
the WL14 Muting photoelectric reflex
sensors, the Flexi Classic controller in
the control cabinet ensures safe differ-
entiation between stack and person.
The stack is allowed to enter, nothing
and no one else.
Triple controls with vision sensors
Intelligent value added means not only
producing efficiently but also inspect-
ing the individual processing and as-
sembly stages promptly and close to
the process. In our facilities, only OK
components are forwarded to the next
respective processing step, says Jens
Labs. Wherever required we have there-
fore integrated into the machines vision
sensors of the Inspector I10 series with
ring light. First, all of the components
are presented to the vision sensor, which
detects the presence of a component,
e.g. a laminated core of a shaft, inspects
it with an accuracy of 1/10 regarding
various features and, if required, causes
the part to rotate in a different position.
Following this, the high-precision Z axles
carry out the joining and assembly pro-
cesses.
Drives with motor feedback
systems from SICK-STEGMANN
CMB has integrated more than 300 AMK
drives of the IDT4, DT3, DT4, DT5, DT7
series into the entire production line.
Whether as a motor for a transfer seg-
ment or as an axle drive in the palletiz-
ers or joining systems all of them uti-
lize the precision of the SRS50/SRM50
motor feedback systems in single- and,
respectively, multiturn design, in order
to be able to travel precisely themselves.
Inspector I10 vision sensor
is used for parts inspection
: Applications
www.elettric80.com
Safety Laser Scanner + Safety Controller + EFI
Elettric 80 relies on integrated
safety for forklift trucks
In its automated guided ve-
hicles, the Italian Elettric 80
Company, relies on a new, ex-
tremely efficient safety philo-
sophy from SICK.
>> Three S300/S3000 safety laser
scanners and the Flexi Soft safety con-
troller from SICK that communicates
with the sensors via EFI (Enhanced
Functional Interface) form an integra-
tion-friendly, highly available, and eco-
nomical complete solution for protect-
ing automated stacker vehicles. On
the one hand, the solution draws its
efficiency from the flexible, application-
specific selection of the sensor and
control components. On the other hand,
consistent use of safe bus technologies
for communication between internal
and external assemblies leads to an
enormous reduction of the wiring effort
in the vehicles. Another feature offered
by this safety design, implemented for
the first time in this form, is its open-
ness: It is suited not only for controlling
and monitoring the safety laser scan-
ners, the emergency stop pushbutton,
and additional safety-capable devices
from SICK but also for other safety sen-
sors, e.g. bumper strips of the LGVs (La-
ser Guided Vehicles) from Elettric 80.
Elettric 80 synonymous
for efficient final packaging
Operating worldwide, Elettric 80 is a
supplier of intralogistical solutions for
final packaging technology, including
transportation vehicles navigating per
laser. In terms of LGVs (Laser Guided
Vehicles), Elettric 80 is among the lead-
ing producers in Europe. What distin-
guishes the vehicles, apart from their
laser navigation, is vehicle protection
with laser scanners from SICK whose
monitoring fields can be switched auto-
matically in accordance with the oper-
ating route and the handling task.
The S3000 safety laser scanner from SICK (photo on the left), an essential
element of the overall safety solution, serves to protect automated stacker vehicles
Comprehensive safety solution
with the lowest possible integration
and operating costs
The objective was designing a complete
solution for 360 protection of a three-
wheeled, fully automatic fork-lift truck,
with special attention paid not only to
sensor technology compatible with the
function but also to high economic effi-
ciency in procurement, integration, and
operation. The requirements included,
among other things, an option for central
parameterization and diagnosis, quick
exchange of components in case of
malfunction without new programming
sequences, savings in wiring expenses,
and minimum space needed in the con-
trol cabinet. At the same time, the goal
was developing a standardized safety
design intended to be suitable for all LGV
variants and modular to such an extent
that the arrangement of components
can occur as easily as possible, empha-
sizes Giancarlo Gattamelati, Electrical
Engineering Manager at Elettric 80.
Under the label Extended EFI con-
nection, Elettric 80 and SICK then de-
veloped a solution that meets all of the
requirements mentioned. It consists of
two S300 Expert safety laser scanners
that monitor the areas on the rear and
the side of the vehicle, of an S3000
safety laser scanner for protecting the
travel paths as well as the area immedi-
ately below the respective load-handling
device, and of the Flexi Soft safety con-
troller.
Unique and from a single source
Integrating diverse safety laser scan-
ners, selected appropriate to function,
and a custom-designed safety controller
via the EFI bus interface, as well as fur-
ther integration of additional safety sen-
sors constitutes a solution that in this
form is unique to date. SICK was the
only supplier capable of solving the task
on its own drawing on the entire product
portfolio, says Franco Manzini, Automa-
tion System Manager at Elettric 80. In
this way, we managed to obtain both the
sensor and control components from a
single source and to reduce the risk re-
lated to interfaces.
Integrated safety solution
09
10
01 2010
: Applications
www.klauke.com
Intelligent bar code identification
>> Gustav Klauke GmbH in Remscheid
is an internationally operating supplier of
solderless cable connections, press and
cutting tools, handtools, piercing and
processing tools, cable pulling technol-
ogy as well as testing, measuring, and
inspection equipment for electrical, sani-
tary and heating engineering. Overall,
the company continuously stocks more
than 12,000 individual components
in the warehouse. Quantitatively, this
amounts to approx. 2,500 items a day
that have to be order-picked and shipped
in roughly 800 packages and up to 1,500
small load carriers, says Thomas Kiep-
ert, Head of Klaukes logistics center.
In order to cope with that, the bar code
readers must be capable of more than
reading bar codes they must inform us
at any time about the status of the facil-
ity so that we are able to take well-direct-
ed and timely measures ensuring utmost
availability of the intralogistics.
Perfect flexibility by
means of Dynamic Focus
At Klauke, it was possible to equip all of
the ID points uniformly with the CLV640
while still setting them in a way specific
to the operating location. This is made
One Bar Code Scanner for all stations and demands
Dynamic Focus permits
unimagined efficiency
Reading bar codes is a widespread capability. However, only one
device offers, e.g. at the logistics center of Gustav Klauke GmbH,
availability, networking capability, flexibility, proactive maintenance,
or economical stockpiling of spare parts: the CLV640 from SICK.
possible by the dynamic focus of the
scanners: By means of software, the
parameters relevant at the respective
ID point, e.g. reading distance, reading
field, or reading speed, are parameter-
ized, administrated via Ethernet utilizing
the central SOPAS configuration software,
and saved. This flexibility brings us many
benefits, says Dipl.-Ing. (FH) Sven Gent-
zen, Project Coordinator Automation Tech-
nology at Klauke. Installation and set-up
of the devices were uniform and simple.
Identical set-ups can be copied in a time-
saving way via drag&drop. We only have
to stockpile one device as a replacement
part that we can configure via parameter
download for any ID point, instead of four
to five versions that are prone to being
mixed up on top of that. Electrical installa-
tion, too, was simple, since we were able
to use the rotatable 90-degree connector
of the scanner to select the cable outlet in
the best possible way.
Maximum availability, minimized
operating and maintenance costs
The CLV640s open up a variety of opti-
mizing potentials. This starts already on
site, says Sven Gentzen. Directly on the
ID point, the bar code readers indicate
the actual reading quality. If it falls below
the preset limit, we can recognize directly
whether this is related to the code quality
or whether, for instance, the front screen
requires cleaning. Furthermore, the web-
based RDT400 diagnostic tool allows ad-
ditional control of the performance data
of all of the networked scanners. This
demonstrates the contribution that the
scanners make towards plant availability,
says Thomas Kiepert. By means of pre-
set threshold values for the analytic data
of the scanners, our maintenance team is
informed early via e-mail about a possible
maintenance requirement. In this way, we
can react proactively instead of only when
the error message comes in. Thus, we are
saving substantial repair effort and ex-
penses and avoid plant downtimes.
Christian Beede and Manfred Pierl from
SICK as well as Sven Gentzen and Thomas
Kiepert from Klauke (from left to right)
The bottom line: Scanner designs such
as that of the CLV640 are intelligent
if they adapt not only flexibly and uni-
versally to the respective installation
and reading conditions but are capable
also of minimizing operating and mainte-
nance costs, thus providing for optimum
utilization of conveyor, sorting, and ware-
housing facilities.
: Applications
11
Detection of speed and pressure values
11
www.axiscontrols.co.uk
www.3ctest.co.uk
>> The British Company , 3C Test Ltd. is
an independent testing firm that carries
out comprehensive tests regarding elec-
tromagnetic compatibility (EMC) of prod-
ucts and systems for customers from a
variety of industries. For this purpose, 3C
Test operates a well-equipped testing lab
in the immediate vicinity of the English
Formula 1 racetrack at Silverstone not
surprisingly, since the automotive indus-
try is among its most important custom-
ers. For instance, for all of the new brak-
ing systems coming on the market one
must verify that with respect to EMC they
meet the 2009/19/EC EMC Directive.
In order to carry out these tests, 3C Test
commissioned Axis Controls (NW) Ltd.
to develop a test stand enabling exami-
nation of the effect of electromagnetic
fields on the operating mode of braking
systems. In doing so, each wheel is pow-
ered and decelerated separately pro-
cesses that require an extremely robust
and reliable sensor technology.
Programmable DFS60 encoders and easy-to-configure PBS pres-
sure sensors from SICK do their part in test stands at 3C Test Ltd.
so that new vehicle braking systems brake reliably even in the
face of electromagnetic interference.
Programmable encoders
for speed measurement
The speed of rotation of each wheel is
monitored by one of four programmable
DFS60 encoders. Direct connection to the
rollers driving each wheel ensures accu-
rate detection of the rpm, eliminating the
effects of play in the drive system. Axis
was able to freely define the number of
pulses produced so that the measured
values reach a highly-precise linear reso-
lution of 0.5 mm. In addition to that, we
decided in favor of the DFS60 because
it features both a metal code disc and
a metal housing, thus guaranteeing the
required ruggedness and reliability in the
test stand, says Colin Hardy, General
Manager of Axis Controls (NW) Ltd.
Pressure sensors
detect braking action
Large speed variations while the brake
pedal is depressed causes the ABS to
start working. During the EMC tests,
the brake calipers for each wheel are
de-coupled and the hydraulic pressure
from each wheels brake line connected
directly to a PBS pressure sensor. Based
on the speed and pressure values mea-
sured, 3C Test can recognize how reli-
ably the ABS works under various elec-
tromagnetic conditions. Colin Hardy is
full of praise, above all for how easy to
integrate the pressure sensors are: Not
only was it possible to install them into
our test system without any mechani-
cal problems; configuring them via the
3-button control and the 330 rotatable
LED display was also simple, rendering
the process quick and reliable.
Using the measuring results on the
test stand from Axis at 3C Test helps
ensure that each tested braking system
not only conforms to the EMC Directive,
but much more importantly that sub-
sequently the vehicle will develop its full
braking action. The encoders and pres-
sure sensors from SICK make an impor-
tant contribution to this not least, be-
cause they meet the highest EMC stan-
dards themselves.
Encoders and Pressure Sensors:
extreme use in EMC chambers
Guaranteeing that
brakes always brake
: Applications
12
01 2010
www.psi-technics.com
www.skf.com
Long-range distance measurement
For distance measurement, PSI-Technics, a leader in the segment
of high-performance positioning systems, relies on laser-assisted
systems from SICK, e.g. the long-range distance sensor DME5000.
This means that the system adjusts
completely to the machine, not only
to the motor. The entire mechanics of
the facility is covered, not merely the
drive as is the case with conventional
systems. Thus, during the whole pro-
cess, the machine model is simulated.
Therefore, it is possible at any time, in-
dependent of load and speed, to travel
to the destination in the optimum time
and without any creep passages. In
the process, the complete travel pro-
file undergoes constant checking dur-
ing travel. This necessitated a system
for position feedback, says Karl-Heinz
Frderer. We are solving this task
with the long-range distance sensor
DME5000 from SICK.
Positioning highly dynamically via
laser
The DME5000 permits highly dynamic
positioning with the PSS. Depending
on the model, one current measuring
value is issued per millisecond, achiev-
ing in the process an accuracy of +/ 2
mm with a reproducibility of 0.5 mm. In
this way, one can generate very quickly
and precisely data for position feed-
back of the PSS and by using them,
the PSS from PSI-Technics can bring to
bear its highly dynamic capabilities.
Ideal solution for intralogistical
retrofit projects
Especially when retrofitting plants,
quick replacement or, respectively, the
initial integration of system compo-
nents constitutes a challenge. In this
context, the attachment technology of
the DME5000 allows both fast installa-
tion and simple and reliable alignment.
Finally, the DME5000 is also the ideal
sensor for our positioning system be-
cause of its different integration inter-
faces such as SSI at SKF, says Karl-
Heinz Frderer.
Due to independence from sys-
tems, the PSS can be integrated ideally
anywhere. Implementation is possible
in all new facilities of all manufactur-
ers and with respect to any imaginable
drives and controllers. The same ap-
plies to old plants with DC converters
so that it is possible in the course of
modernizing facilities to continue us-
ing the previous components such as
SPS, converters, and motors. Thanks
to the DME5000, the PSS is not only
a replacement of previous positioning
systems but actually a novel position-
ing technology that allows users to
achieve performance increases of 15
percent or more, even if the previous
drive and control components continue
to be used.
Thus, as a long-range distance sensor,
the DME5000 constitutes an ideal com-
ponent for PSS technology.
Laser distance measurement for intralogistics
More performance
when positioning
>> A current application example is the
European Logistics Center of the ball-
bearing manufacturer SKF in Tongeren,
Belgium. When the objective was re-
placing an old positioning system that
could no longer be maintained, PSI-
Technics was right there with its PSS
Positioning Solution System. To be
precise, this is a positioning control
circuit with optimized travel profiles as
well as flexible speed and acceleration
selection, explains Karl-Heinz Frder-
er, General Manager of PSI-Technics.
The first core feature of the PSS is
determining the ideal machine model.
Use at the logistics center: The DME5000 distance sensor from SICK is the ideal
component of the PSS positioning system
: Applications
13 13
www.daimler.com
>> At first glance, the task at the bodywork
plant of Mercedes-Benz in Sindelfingen
sounds easy enough: hazardous areas re-
quire protection against entry by persons;
goods, on the other hand in this case,
body frames on skids must be able to
travel in and out without hindrance. The
demands are becoming more complex,
however, due to the large number of dif-
ferent body frames and skids, but also
because of interfering objects, e.g. cables
hanging down. Both make high demands
on an entry/exit system especially when
it ought to meet future requirements as
well, for instance in case of new model
series or automation wishes. With the
C4000 Fusion from SICK, we have found
just the suitable solution for our body
frame infeed stations, says Gerald Hitzler
from the Department of Safety Technology
at Mercedes-Benz in Sindelfingen.
Model performance:
variety of variants unlimited
The C4000 Fusion safety light curtain
is a piece of electro-sensitive protec-
tive equipment that meets Performance
Level e according to EN ISO 13849
as well as SIL3 in compliance with IEC
61508 and is used for horizontal and
Flexibility and guaranteed future are the major benefits that the
C4000 Fusion safety light curtain offers as entry/exit protection
at the Sindelfingen plant of Mercedes-Benz.
vertical hazardous point protection. The
system design permits reliable differen-
tiation between material and persons,
detecting and evaluating static patterns,
e.g. the spars of the skids, and dynamic
patterns, e.g. a walking person. This oc-
curs absolutely electronically, i.e. without
additional secondary sensor technology
or additional control or display elements.
The benefits include not only simple,
space-saving and easy to install mount-
ing but also free programmability of an
infinite number of patterns thus, of
skids for new vehicle models as well,
says Gerald Hitzler. Moreover, another
factor decisive for the high availability of
the C4000 Fusion is its detection toler-
ance: smaller interfering objects such as
cables or film remnants that project into
the monitoring field are recognized as
such and suppressed.
Future security integrated
For Mercedes-Benz, the C4000 Fusion
is the solution with an assured future.
The system parameters for the new
models can be supplemented quickly via
SICKs CDS configuration and diagnostic
software. The variety of patterns is un-
limited thus the system offers an im-
portant prerequisite for standardization
throughout the entire corporate group.
With this standardization, Mercedes-
Benz reduces the costs for procurement,
stockpiling, and maintenance of entry/
exit systems. In addition to safe switch-
ing outputs with the EFI (Enhanced Func-
tion Interface), which is also constructed
in safety capable design, and in conjunc-
tion with the PROFIsafe for PROFINET IO
Gateways from SICK, the C4000 Fusion
features all of the options in terms of
plant automation that are relevant for
future integration solutions.
The protective design featuring the
C4000 Fusion for body frame infeed and
outlet stations is an example of how ef-
ficient industry-specific solutions can
materialize. SICK is among the techno-
logical leaders in safety technology, and
they know precisely what counts in auto-
motive manufacturing, confirms Gerald
Hitzler. Accordingly, application-oriented
solutions with great economic efficiency
are guaranteed.
Access protection
Good thing when safety light curtains are intelligent as well
First class for any bodywork
: Applications
14
01 2010
Gas analysis
>> In the past homogenous fuels, such
as gas, heavy fuel oil or coal have been
predominantly in use worldwide. Today,
conventional fuels are increasingly be-
ing replaced by secondary fuels pro-
duced from waste.
This trend, however, has had an im-
pact on gas analysis at cement plants.
At the kiln inlet, oxygen (O
2
) and car-
Kiln inlet measurement:
Secondary fuels and cor-
rosion risk under control
The use of secondary fuels in the cement industry is increasing
all over the world. The great variation of fuel composition and ag-
gressive gases adds major challenges to process management.
SICK offers the solution for the reliable control and regulation of
the combustion process and the monitoring of the product related
gas components. It consists of a modern hot-extractive multi-com-
ponent analyzing system, the MCS300P HW and the SCP3000, a
suitable gas sampling probe.
bon monoxide (CO) are measured plus,
in modern plants, nitrogen monoxide
(NO). But with the substitution of al-
ternative fuels there are partly higher
concentrations of chloride and/or sul-
fur within the gas circuit. The higher
concentrations at the kiln inlet have
caused a rise in the acid dew point in
the analyzed gas. Therefore, the re-
native. By applying SICKs hot extrac-
tive analyzer in combination with an
SCP3000 cement probe, reliable mea-
suring values are achieved.
SCP3000 gas sampling probe
This probe made by SICK has been tai-
lored specifically to the needs of the ce-
ment industry. The probe tube is made
of high temperature-resistant steel. A
special designed sampling probe open-
ing at the tip of the probe prevents the
direct entry of the gas-dust mixture
only dust-free gas enters the probe.
The measuring gas is further purified
in a heated dust filter. The dust filter
and the gas sampling probe can be
cleaned by the Shock Blower using
compressed air. A rotary device allows
periodically probe rotation by 45,
thus shaking off any accumulated
dust. In the case of any fault the probe
is pulled back automatically in order to
protect it from any damages. An inte-
grated control unit handles all control
and monitoring functions.
MCS300P hot multi-
component gas analyzer
The MCS300P is a non-dispersive pro-
cess photometer and can monitor up to
six IR active gas components simulta-
neously. Optionally it can be fitted with
an additional oxygen sensor. Thanks to
its great long-term stability, the ana-
lyzer from SICK can be applied reliably.
Even at high acid dew points the prov-
en measuring cuvettes withstand very
high concentrations. The measuring
range stretches from the ppm range up
to high volume percentages.
Reliable analysis results
SICKs reliable, robust MCS300P hot
extractive analyzer combined with the
SCP3000 cement probe is the opera-
tionally stable alternative for kiln inlet
measurements. Having a significantly
lower maintenance requirement com-
pared to cold-dry systems, it features a
higher rate of availability and helps to
cut expenses. quirements for gas conditioning and
analysis do increase.
The hot measuring principle has
delivered an optimal solution for pro-
cess monitoring of aggressive gases
at the kiln inlet, as the temperature of
all system parts which are in contact
with measuring gas are above the acid
dew point. This is where the single-
beam process photometer MCS300P
from SICK becomes an attractive alter-
The MCS300P has proven successful
for gas analysis on the kiln inlet
: Applications
15 15
: Applications
www.porsche.com
>> The 13.56 MHz system from SICK
is specifically designed for object
marking and identification in material
flows and intralogistics. Even though
the superb reading reliability and high
availability offer a maximum amount
of operating benefit, the decisive fac-
tor for choosing the RFID system from
SICK was something else. It had been
possible to test the suitability of the
system for this working environment
and to check various constructional
measures toward optimizing the read-
ing behavior in the heavily metallic en-
vironment as to their function. Follow-
ing the testing stage, it was possible to
assure Porsche that with the selected
standard components SICK meets the
Order picking of engine components at Porsche
RFID from SICK: from evaluation to
successful use in series production
The great variety of types makes engine building at Porsche in
Stuttgart-Zuffenhausen a complex process. The RFI341 RFID in-
terrogator, tested thoroughly prior to installation at SICKs Logis-
tics Technology Center with respect to the subsequent operating
conditions, ensures in the order picking process correct provision
of components in the sequence of jobs, ruling out mix-ups during
assembly when infeeding parts.
application demands reliably and de-
pendably. The system integration could
take place smoothly.
Whether Boxster, Cayman, 911,
Cayenne, or the new Panamera the
Porsche engines for all of the model
series are manufactured at the plant in
Stuttgart-Zuffenhausen. This requires
mastering a great variety of types: flat
engines, V8 engines, units with and
without turbocharging each require
individual material provision as well
as type-specific assembly and testing
processes.
The logistics area is where the type-
specific order-picking cycles for the flat
and V engines commence. The compi-
lation of components takes place on
The RFI341 RFID interrogator from SICK
features high scanning reliability
material carts whose RFID transpon-
ders are labeled with the order number
at the beginning of the order-picking
job. Each cycle has its own depots
with RFID stations arranged. At these
points, the order-picking carts are
parked in a defined order of jobs and
will be transported by an AGV into the
engine assembly shop. One antenna
each per parking space identifies the
cart. Using this information, one can
display the sequence and order-picking
status on a large flat screen and re-
quest an AGV at the appropriate time.
Plausibility check guarantees
process reliability
The vehicles transport the carts into
the engine assembly shop. Here an
RFI341 reading device identifies the
cart and transmits the transponder
number to the controller, which now
checks whether the cart made avail-
able indeed belongs to the assembly
job pending. Each of the empty carts
is once again collected via an AGV and
made available for new order-picking
processes.
Implementation of the RFID solu-
tion at Porsche, which is integrated
via PROFIBUS into a PLC, was almost
as fast as the sports cars it benefits:
The time that passed from first contact
to the tests at the Logistics Technology
Center and to start-up at Porsche was
slightly less than four months.
Radio-frequency identification
: Applications
16
01 2010
Precise position determination
>> Especially packaging machines, in
which speed, positioning precision, and
repeat accuracy matter increasingly,
benefit from the magnetic principle of op-
eration, the variable measuring lengths,
and the extremely high resolution. This
When it comes to positioning linear drives, Nitek, the Italian producer of drive
systems, relies on the TTK70 high-precision positioning system from SICK.
For good reason, as it currently constitutes the most compact solution of this
type on the market.
also applies to the ironless linear drives
from Nitek: They deliver convincing per-
formance due to their high level of rigid-
ity, ruggedness, and quiet running and,
thanks to the TTK70, utmost precision
as well.
TTK70 is part of the trend among
modified drive designs
The TTK70 linear encoder consists of an
absolute sensor head and a magnetic
tape as a fixed gauge. By comparison to
optical linear systems, the magnetic prin-
ciple of operation offers significant bene-
fits regarding price, susceptibility to con-
tamination, and availability. The TTK70,
including the plug connector, is barely
larger than a matchbox. This makes it
the smallest system of its type currently
on the market. The measured values are
transmitted to the master evaluation
electronics of the linear drive by means
of the HIPERFACE
interface a commu-
nication method that has established it-
self as the standard in the rotative mar-
ket. By means of integration into a linear
measurement system, SICK takes up a
trend prevailing in packaging technol-
ogy: due to their technical advantages,
linear motors are increasingly appearing
on the scene, for instance in automated
insertion and pick & place devices or in
packaging machines. On the other hand,
due to the previously common use of
mechanically coupled systems such as
spindles and toothed belts, the control
circuits of these machines feature a HI-
High-precision positioning of linear motors
Exactly right for packaging drives
Inspectors in stationary and mobile use
Pin inspection with Vision Sensors
Anyone checking faster has more time available for producing. For this rea-
son, Valeo uses vision sensors of the Inspector l10 series to inspect pins on
electronic control modules at its Czech plant in Rakovnik.
>> The Valeo group of companies spe-
cializes worldwide in the area of devel-
opment, manufacturing, and sales of
components and integrated systems
for passenger cars and commercial ve-
hicles. The plant in Rakovnik produces
air conditioning units as well as steering
and driver assistance systems for mo-
tor vehicles including their electronic
control modules. In order to determine
quickly, safely, and in a comprehensible
way whether their pins are present and
formed properly, the system integrator
LMT has developed a so-called camera
box that makes use of four Inspector l10
vision sensors overall. Two of the devices
are mounted in a stationary position; the
others travel on pneumatic cylinders,
checking pins in different positions.
Economical solution with turbo ROI
Now the entire inspection only takes
about three seconds from the position-
ing of the test specimens until data
output to an IO control module. Conse-
quently, the solution with the Inspec-
tor vision sensors is many times faster
than the inspection procedure applied
before. This time saving and the corre-
sponding increased production rate are
just as much responsible for the turbo-
speed ROI of the camera box solution
as the comparatively low investment
in the vision sensors. The devices are
compact and easy-to-use. The lighting
is integrated into the housing. All of that
made fast and cost-effective integration
into the camera box possible, says Mr.
Miler from LMT.
: Applications
17 17
: Applications
>> When choosing the sensors for the
injection molding machines, three as-
pects figured particularly prominently
for Tobias Schweiger from Hainz & Hrls
technology department: high flexibil-
ity for inspecting objects regarding fea-
tures, network capability for integrating
the sensors into the machine and control
environment, as well as high economic
efficiency and future investment security
of the technical solution. We found all of
that in the Inspector vision sensors from
SICK, he confirms.
No inspection wish left unfulfilled
Apart from the great variety of parts,
the secondary conditions make the ap-
plication at Hainz & Hrl so demand-
ing. The parts are changed every 23
days; several parts per carrier may be
within the measuring field at any time;
the size of the respective feature may
be in the range of 0.1 mm, the ob-
ject distance and thus the depth of
field are variable; and during inspec-
tion the plastic parts they may be
white, black, transparent, milky, yel-
low, or green are in front of critical
backgrounds, including aluminum or
carbon. To begin with, SICK tested
several parts internally and then dem-
onstrated the Inspector at our factory
under practical conditions, reports
Tobias Schweiger. It became apparent
rather quickly that with the suitable pa-
rameterization the vision sensors meet
all of the inspection requirements. Af-
ter a brief product training and start-
up support, staff at Hainz & Hrl were
able to set and commission these vi-
sion sensors on their own.
Use within a network
However, the Inspector I10 surpassed
other vision solutions in terms of not
only sensor performance but regarding
its integration options as well. At Hainz &
Hrl, the devices are connected, on the
one hand, directly to the machine con-
Network-enabled Vision Sensors for feature detection
Top performance in
checking injection-molded parts
trollers via the outputs. In addition, they
are linked via TCP/IP and connected to
our control center, says Tobias Schwei-
ger. In this way, we can access Inspec-
tors remotely, e.g. for teaching in parts or
for diagnosis via Internet. This makes it
far easier to monitor and guarantee the
quality of all of the products manufac-
tured on the machines.
Cost effectiveness convinces
The Inspector vision sensors are not the
first image-processing solutions at Hainz
& Hrl but by far the most economical.
The sensors save installation space,
are easy to mount, require no extra light-
ing, and can be connected in a variety
of ways, Tobias Schweiger puts it con-
cisely. The Inspectors are significantly
more reasonably priced than complex
image-processing systems anyway, but
even in terms of cost-benefit comparison
with similar device models, the solutions
from SICK and the professional support
convinced us.
Inspector I10 the top solution, not just
for injection molded parts!
www.hainz-hoerl.de
The way vision sensors can enhance the performance and quality of existing
machines is shown by the fitting of injection molding machines at Hainz &
Hrl Kunststofftechnik with devices of the Inspector I10 series from SICK.
Perspective of the I10 vision sensor
on the monitor
PERFACE
infrastructure for data trans-

mission. Thus, the TTK70 combines the
benefits of linear position detection with
the HIPERFACE
interface common in
the market.
Nitek confirms: TTK70 is
top-notch in terms of precision
According to its own tests, the TTK70 is
the most precise positioning solution of
its kind on the market. The analog trans-
mission of the sine-shaped incremental
signals with a pole and period length,
respectively, of 1 mm as well as 10-bit
interpolation, results in a very high reso-
lution of 1 m. The system accuracy, too,
shows a top value at < 10 m.
Whether linear or rotative: motor feed-
back systems from a single source
The TTK70 measuring system is the logi-
cal consequence drawn from the market
trend toward direct drives. As one of the
few suppliers worldwide, SICK can offer
the manufacturers of drives both rota-
tive and linear motor feedback systems
with integrated HIPERFACE
interface.
www.nitek.it
Inspectors in stationary and mobile use
Pin inspection with Vision Sensors
Valeo has already announced it intends
to implement seven additional camera
boxes with Inspector inside at the Ra-
kovnik plant alone. In addition, the plan
is to define the complete solution world-
wide as a plant standard for such inspec-
tion tasks. www.valeo.com
Two permanently mounted I10 vision
sensors in the camera box
Parts inspection
: Applications
18
01 2010
www.thyssenkrupp-krause.de
Industrial vision
>> Worldwide, ThyssenKrupp Krause
develops, constructs, manufactures,
and supplies for the automotive and
automotive supply industries turn-
key assembly systems for sets of
machines, including the associated
inspection and testing facilities. One
of the companys major technologi-
cal emphases is assembly facilities
for engines, transmissions, and axles,
as well as their subcomponents e.g.
cylinder heads, steering systems, and
wheel sets. There are many processes
that can no longer do without the use
of robots for parts feeding, says Nils
Ruchel, Project Engineer at Thyssen-
Krupp Krause. Since engine blocks,
ThyssenKrupp Krause: Visual guidance of robot in 3D
Always accurately positioned,
thanks to Smart Camera
When a robot needs to grip reliably, but the necessary position
tolerance is impossible to maintain, its a mission for the IVC-3D
smart camera. It can detect the position of parts quickly and
precisely in three dimensions an advantage used at Thyssen-
Krupp Krause for visual guidance of robots.
cylinder heads, transmission housings,
or mechatronics modules can rarely be
positioned so accurately in their com-
ponent containers that the robots can
grip the parts more or less blindly, we
are giving them the necessary vision
with the IVC-3D.
Always a grip on things
with a 3D image
The IVC-3D is a compact and thanks
to its application library an easy to
parameterize smart camera. It proj-
ects a laser line on an object, detect-
ing height fluctuations via integrated
CMOS technology. Supplemented by
the relative movement of the object
within the measuring field, a highly ac-
curate 3D position model of the object
is created, which allows determining
the approach coordinates of the robot.
Especially when handling automotive
components, this principle is very ad-
vantageous, since in contrast to cam-
era solutions with separate lighting
neither the usual lighting conditions
nor the almost always shiny and reflec-
tive surfaces affect the availability and
testing quality of the smart camera,
explains Nils Ruchel.
Mistaken gripping ruled out!
Whether engine blocks on euro pallets
or transmission components in blister
packs for every component, the IVC-
3D knows the space coordinates for ro-
bot control in a very short time. To this
end, the camera mounted on the robot
is guided over the respective compo-
nent in a linear movement. By using
the 3D image thus created, the cam-
era determines the target coordinates
(the approach direction is calculated
in the robot) for the robot a process
that takes all but two seconds from
the first scanning until data transfer to
the robot controller. There have been
no mistaken grips so far, Nils Ruchel
takes stock of the operating experienc-
es to date. The robot grips one part af-
ter the other with eyes wide open. For
end customers this offers the benefit
of having to invest no effort or expense
in positioning the components precise-
ly. The client can simply push the com-
ponent container or the pallet into the
station the rest is done by the robot.
And by the IVC-3D, of course
The IVC-3D smart camera from SICK is installed directly on the robot
and determines the target coordinates
: Applications
19 19
: Applications
www.am-automation.de
>> The latest development within the
W100 miniature series, the WL100
Bright Light, delivers convincing perfor-
mance due to its superb optical charac-
teristics. The particularly bright, heavily
contoured, and homogenous light spot
as well as the increased ranges by com-
parison to the standard models of the
W100 series set yet another record for
this size of sensor. In addition, the de-
vice sets a new top standard in terms of
reliability for detecting reflective or light
diffusing surfaces at close range. This
detection reliability in conjunction with
the space-saving construction and the
suitable mounting systems has led us to
integrate the WL100 Bright Light into the
storage and retrieval risers of our mini-
load AS/RS and to use their signals for
our RFID-supported tray management,
says Johannes Traub, Project Manager
at AM-Automation GmbH in Offenau. The
company specializes in project planning,
electronics, software and machine con-
Object detection in small parts storage
Miniature Photoelectric
Sensor detects tray occupancy
For electronic tray management in an automated small parts
storage of AM-Automation GmbH, the new WL100 Bright Light
photoelectric sensor from SICK proves the optimum solution for
a variety of reasons.
struction, the manufacturing of and ser-
vice for automated high-rise and small
parts storages.
WL100 Bright Light: Brilliant
results without incorrect signals
Just like the entire W100 series, the
WL100 Bright Light in the rugged plas-
tic housing is also suited specifically
for use in intralogistical facilities. The
extremely bright and homogenous light
spot facilitates alignment of the photo-
electric sensor and prevents interfer-
ing spill-over light effects. The wiring
technique is mechanically and electri-
cally compatible within the series and
conforms to the standard customary in
the market, so that we did not have to
carry out any design-related changes
for the WL100 Bright Light, Johannes
Traub explains, adding, It is also crucial
that this photoelectric sensor reliably
detects depolarizing surfaces at close
range as well.
Position information
clarifies tray occupancy
The RFID-controlled tray management
permits effective use of space both in
the actual storage and on the tray itself.
Each tray as well as each container on it
are tagged with a transponder. To detect
how many containers are positioned on
the tray at which location the controller
also requires the information from the
WL100 Bright Light. The moment a tray
pulls into the storage section, the pho-
toelectric sensors successively detect
the containers placed on it. Simultane-
ously, the transponders both of the tray
and the containers on it are identified
by an RFID reader. The reliability of the
signals from the photoelectric sensors
ensures in effect that in each case the
correct small parts are picked from the
crates on the respective tray, explains
Johannes Traub.
WL100 Bright Light the optimum
solution for detecting objects in extreme-
ly confined space!
Object detection
20
01 2010
: Applications Camera-based 2D code identification
The camera-based ICR845-2 code
reader from SICK masters even difficult
optical conditions
>> Grenzebach Maschinenbau GmbH
is one of the worlds leading suppliers of
material flow and process solutions. World-
wide, approx. 1,500 employees work at
seven locations about a third of them at
the principal factory in Hamlar. In the area
of conveying and handling technology for
Increase in efficiency, quality assurance, and traceability
Continuous identification
of codes on thin-film modules
With the top-performing ICR845-2 series, Grenzebach Ma-
schinenbau GmbH, a leading supplier of conveyor systems for
thin-film solar panels, uses 2D code readers that are capable of
reliably identifying ID codes lasered on glass substrates.
fers are lower substrate and raw mate-
rial costs as well as savings in energy.
From the perspective of quality, ensuring
consistent homogeneity of the solar pan-
els across the entire surface area is the
central issue, as this is decisive for the
subsequent photoelectric properties and
thus the output of the thin-film panels.
For this purpose, it is necessary to check
the panels after each relevant process-
ing step. To do so, every thin-film panel
must be identified at the respective test
station based on its lasered data ma-
trix code. For reading the codes with
a code size of 14 x 14 mm, a cell size
of only 0.7 mm, and a speed of 0.5 m/s
Grenzebach Maschinenbau opted in
favor of the ICR845-2 from SICK after
comparing numerous other makes.
Best buy due to top performance data
The ICR845-2 is an easy to integrate
and operate 2D code reader. The light-
ing is already integrated into the housing
featuring an IP 65 enclosure rating. The
WVGA-CMOS camera chip ensures fast
decoding with concurrently high resolu-
tion. Commissioning the code readers is
facilitated significantly by the Auto Setup
configuration, live images, and evaluation
of the reading results by means of a con-
venient diagnostic function.
A decisive factor for choosing the
ICR845-2 was, apart from the device
features, the fact that other makes did
not deliver the required performance
during the comparative tests at Gren-
zebach. Whether the issue was difficult
optical conditions due to substantial
reflections, usability for various reading
situations, suitability of the housing for
industrial applications, or the preserva-
tion of data and parameter sets in case
of a power outage all things consid-
ered, the ICR845-2 was the top perform-
er by a long shot. The operating practice
at Grenzebach confirms the test results:
All of the 2D code read gates in the facil-
ity generate stable reading results with a
read rate of 100 percent.
plants to manufacture thin-film solar pan-
els, the enterprise is number one today
among other things because the company
implements just as it does in identifying
the thin-film panels customers demands
for more efficiency and cost-effectiveness
into innovative solutions.
Continuous identification: in favor
of the process, against regress
In the production of thin-film panels,
photoactive semiconductors are applied
as thin layers to large-scale carrier mate-
rials, e.g. metal or plastic films or glass.
The benefits of this method as compared
to the production of classic silicon wa-
www.grenzebach.com
21
: Applications
21
www.witron.de
Detection independent of position
>> The customer, with more than 2,500
outlets among the leading grocery stores
in the USA, has been carrying out the
sixth logistics project with WITRON al-
ready. WITRON plans, designs, and im-
plements entire logistics and material
flow systems, including data processing
and control technology. WITRON also
develops and produces the mechanical
and conveyor system components on its
own. At the new distribution center, the
OPM system (order picking machinery)
from WITRON takes care of the complete
inhouse supply chain from the receiving
to the shipping area, largely without the
use of personnel. The core is the inno-
vative and patented case order machine
(COM). Through its refined technology,
the COM allows fully automated and
branch-specific preparation of 205,000
commercial units on order pallets per
day. The challenge for WITRON is the fact
that within the warehouse, pallets of a
different height are used for transport-
ing goods. This has consequences for
the detection of pallets. It is not always
possible to detect the pallets of varying
heights with one single photoelectric re-
Photoelectric Sensor with light array
Reduces installation costs
and increases availability
The Reflex Array Sensor, the new WL27-3 photoelectric sensor
from SICK with a light array 50 mm high, replaces several single
photoelectric sensors. This enabled WITRON Logistik + Informa-
tik GmbH based in Parkstein to save valuable installation costs
and to increase availability of the pallet conveying system in a
distribution center operated by a US food group.
flex sensor, since either their optimum
alignment is very time-consuming or a
second photoelectric sensor is indeed
required. Hence, WITRON approached
SICK AG to prepare the best possible so-
lution together.
Reflex Array Sensor, the
cost-effective solution for
pallets with different heights
The detection of pallets featuring dif-
ferent heights with two classical pho-
toelectric reflex sensors would have
increased installation costs, since it ne-
cessitates installing, aligning, and elec-
trically connecting two sensor housings.
Plant availability was enhanced, on the
one hand, due to the 50-mm light array
covering a homogenous detection zone
as compared to the incomplete detec-
tion zone when using two single light
beams and, on the other hand, by the
fact that pallets are detected despite a
certain degree of damage. This light ar-
ray is generated by combining a bright
red light PinPoint LED with the special
optics, creating a constant light array
50 mm high between the photoelectric
sensor and the reflector. This permits a
larger detection zone with only one sen-
sor housing, and it allows reliably detect-
ing, within the light array, objects greater
than 12 mm that vary in orientation or
height, independent of the position.
Thanks to the PinPoint technology, the
range of the WL27-3 Reflex Array Sen-
sor is up to 4.5 m. Therefore, the Reflex
Array Sensor suggests itself as the opti-
mum solution whenever minimal height
differences of objects are too much to
handle for classical photoelectric sen-
sors, for instance, when the front edge
is detected too late or multiple switching
occurs, triggered by heterogeneous ob-
jects within the light beam.
Prolonged availability due to active
contamination compensation
Usually, availability of optical detection
systems is diminished by dust in relation
to the operating period. The novel active
contamination compensation increases
availability of the Reflex Array Sensors
above average. This means that the
cleaning intervals for the external lens
surfaces can be extended significantly,
thus reducing overall effort and expense.
The decisive factor for this is switching
threshold compensation, which main-
tains at a nearly constant level the sig-
nal distance to the switching threshold,
which otherwise decreases gradually be-
cause of the dust accumulation.
Reflex Array Sensor: detection of
objects >12 mm independent of
position within the 50-mm light array
Reflex Array Sensor with
the light array 50 mm high
22
01 2010
: Interview Text Text Text Text Text Text
SICKinsight: Mr. Ferrandino, at the cen-
ter of the microsite www.sick-solutions-
tour.com there are solutions that SICK
has realized for customers with its port-
folio and services. What do you under-
stand by a solution, what does a solution
constitute?
Giorgio Ferrandino: In my view, a soluti-
on is anything that meets a customers
wishes concerning an application and
the business relations to us. It does not
matter how simple or complex the soluti-
on is. However, in order to speak of a so-
lution we must know what requirements
the customer has. Some demands need
to be scrutinized first; others are taken
for granted; others yet emerge only in
the course of a project. Therefore, it is
crucial to understand the customers
business and to have sectoral know-
ledge. This makes it easier to identify
customers needs and to implement ge-
nuine solutions.
SICKinsight: You are speaking about
sectoral knowledge. In which areas does
SICK speak the language of the custo-
mers and how do you ensure global ex-
change of expertise?
Gerhard Mutter: In terms of organiza-
tion, we have concentrated our core
competencies in three strategic orienta-
tions that we call Solution Centers: Fac-
tory Automation, Logistics Automation,
and Process Automation. Grouped toge-
Background to the SICK Solutions Tour 2010
Offering solutions means representing customer benefits in the best way possible
For suppliers of sensor and automation technology, every industry
poses specific challenges. Only those who know them and have
the suitable product and service portfolio can offer their clients
genuine solutions with diverse added benefits. Just how success-
ful SICK acts in this field is shown by the Solutions Tour 2010
at www.sick-solutions-tour.com. In conversation with SICKinsight,
Giorgio Ferrandino and Gerhard Mutter, the Heads of the Solution
Centers Factory Automation and Logistics Automation at SICK, re-
spectively, explain the background and objectives.
ther in each of these segments are vario-
us industrial sectors, e.g. the automotive
industry, packaging or electronics and
solar in Factory Automation; airports,
postal and parcel service providers or
warehousing and conveying technology
in Logistics Automation; as well as basic
industry, power industry or the area of
waste in Process Automation. Generally,
the respective industries have much in
common regarding the challenges they
make on suppliers of sensor technology
and services such as SICK and that ap-
plies worldwide. In the Solution Centers,
we are developing from these challenges
our industry sector expertise, combining
it with our products and services and
ensuring by means of global interaction
within the context of our network at SICK
that we can always offer our customers
the latest solutions worldwide.
SICKinsight: Yet customer requirements
and thus solutions as well are not static
quantities but instead always in a state
of flux. To what extent are both aspects
especially during or shortly after the
global economic and financial crisis af-
fected by important megatrends?
Giorgio Ferrandino: A series of interna-
tional megatrends influence and drive
our business. One of them is the topic
of quality. Customers wish to utilize re-
sources efficiently while at the same
time avoiding waste and unnecessary
environmental pollution. Thus, quality is
closely connected to the topic of Green
Policies. Flexibility is another megatrend
that was very much at the center of at-
tention especially in the 2009 crisis ye-
ar. An increasing number of companies
now have to produce within a manuf-
Giorgio Ferrandino, Head of the Solution Center Factory Automation, and Gerhard
Mutter, Head of the Solution Center Logistics Automation, in conversation
23
: Interview
Background to the SICK Solutions Tour 2010
Offering solutions means representing customer benefits in the best way possible
acturing environment originally desi-
gned for a low-variant mass production
customer-specific products in small
lots associated with frequent changes of
the product, type, or batch and doing
so in such an economical way that they
can still make money. This works best
using modular and scalable standard so-
lutions which in turn touches directly
upon the intelligence and versatility of
solutions in sensor and control techno-
logy. The focus of many clients is on the
topic of traceability. In some areas, this
aspect is regulated by law, in others it
is essential for entrepreneurial survival,
lets think for example about the area
of product safety or product and brand
name piracy.
Gerhard Mutter: Another megatrend
has emerged around occupational sa-
fety. This is certainly related to liability
claims also enforceable international-
ly against manufacturers of defective
machines but also to the fact that mo-
ed. Astronauts are identifying from the
Space Shuttle global tasks that require
solutions in the most diverse industry
sectors. Whats the idea behind the
space strategy?
Giorgio Ferrandino: On the one hand,
the topic of outer space continues to
be an effective eye catcher and that
holds true not only for the Internet
presence but also for the numerous
channels we use to communicate with
the market, e.g. with the print media
or at trade fairs. On the other hand
and that is somewhat related to the
eye-catcher function astronauts are
conveying messages such as innovati-
on, high tech, future orientation, global
presence, and openness to explore new
possibilities continuously. In the Solu-
tions Tour, however, we quickly descend
from this marketing altitude down to
earth by presenting our customers with
genuine customer solutions, showing
them ways to benefit as well.
SICKinsight: What does this look like in
specific terms?
Gerhard Mutter: The visitor to the mi-
crosite has two options to reach the goal
either by clicking on his or her indus-
try, e.g. packaging, or by selecting the
button indicating a specific challenge,
e.g. flexible production. In both cases,
the respective solutions we call them
Tour Stops are then introduced briefly
in the next step. If an interesting topic
emerges, another click suffices and the
application is portrayed extensively, with
the solutions described in a benefit-ori-
ented way. The page concludes with rele-
vant links concerning information about
the industry, products, and services,
thus making it easier for the client to
find possible starting points toward sol-
ving the task in question. The fact that
in the Tour Stops, we are authorized to
depict our customers logos speaks for
SICK, for only satisfied customers like
being named as a reference.
SICKinsight: At this point, whats left
is recommending to readers of this in-
terview that they immerse themselves
in the orbit of the SICK Solutions Tour.
Many thanks for the interview.
SICK focuses on making their industry sector expertise globally available
dern safety technology such as SICKs
contributes to improving the producti-
vity of machines and plants. As a last
point, let me mention the provision of
local service and support options for
our increasingly globally operating cli-
entele. Anyone observing the Solutions
Tour carefully will notice that solutions
from SICK repeatedly take up several
or nearly all of the current megatrends,
thus providing customers with genuine
added benefits and a safe investment
for the future.
SICKinsight: Future is the next key word.
The Internet presence of the Solutions
Tour is designed very futuristically inde-
:Interview Sensor Sollutions
24
01 2010
: Products Dust measuring devices
www.mysick.com/products
>> SICKs new in-situ dust measuring
system addresses these requirements
with the modular DUSTHUNTER range of
devices. They can take precise measure-
ments almost anywhere, including places
where other measuring devices struggle.
And for every type of application there is
a DUSTHUNTER model to suit.
Differing levels of dust concentration
and gas temperature, different duct di-
ameters and various wall thicknesses
even turbulence: its all no problem! The
new dust measuring devices from SICK
adapt flexibly to all locations or different
conditions of use, fulfill difficult analysis
requirements, are easy to operate and
have unusually long maintenance inter-
Install it. Then forget about it.
DUSTHUNTER Measuring Devices
meet high expectations
When it comes to the emission of hazardous substances, opera-
tors of industrial incinerators have to meet strict statutory con-
ditions. Indeed for optimizing control of the process, exact dust
measurements are absolutely essential. The expectations are
very high for durable and reliable analysis equipment that is
also easy to use, and does not cost a fortune.
vals. It is not without reason that we say:
DUSTHUNTER. Install it. Then forget
about it.
The DUSTHUNTER works with great
reliability and accuracy. Gas purification
processes can therefore be controlled in
an effective and cost-saving manner.
Always well thought-out
The DUSTHUNTER range works using
high-precision optical technologies that
have been employed by SICK for many
years and have become successfully es-
tablished in the gas analysis market.
One special new feature of the DUST-
HUNTER range is a combined transmis-
sion/diffused light meter. This can be
used for measuring both very small and
also very large concentrations of dust.
Especially in countries where environ-
mental standards are in a state of flux,
this can thus enable customers to plan
for the long term and have confidence
that their dust measuring devices are
future-proof. Dust concentrations that
change over time are also by no means
rare and can be measured surely and
reliably using this DUSTHUNTER model.
A particular innovation of the new
DUSTHUNTER is automatic self-adjust-
ment. Variations in temperature can lead
to ducts becoming warped. This also has
a detrimental effect on the optical axis
of the measuring system, which needs to
be manually readjusted. With the auto-
matic self-adjustment system newly de-
veloped by SICK, this warping is reliably
detected as part of a regular check cycle
and is automatically compensated via
2D-adjustable alignment of the measur-
ing axis. This makes it possible to extend
maintenance intervals to six months.
The DUSTHUNTER has been devel-
oped, tested and certified in accordance
with the latest directives and specifica-
tions. The range is also TV-tested and
certified in accordance with the require-
ments of GOST, MCERTS and EPA.
Tradition and innovation
SICK has a long tradition of dust mea-
surement. The companys first patent
in relation to smoke monitoring was ob-
tained over fifty years ago. SICKs first
mass-produced devices using the trans-
mission measurement method were
shipped in the seventies. Some of them
are still in use today. SICK has utilized
its many years of application experience
and combined this with modern tech-
nical capabilities, thus creating a new
generation of dust measuring devices:
DUSTHUNTER modular, adaptable, ro-
bust and reliable.
25
: Products Photoelectric sensors
>> When using normal photoelectric
sensors, the small light spots cannot
cover the gaps in the crosspiece pattern
completely. As a result, the same mesh
box is recognized multiple times, with
the sensor switching several times. The
WTB12-3 Line, on the other hand, is a
photoelectric proximity sensor with back-
ground suppression that was designed
specifically for detecting mesh boxes as
well as honeycombed or convex objects.
The proven chip technology from SICK
endows the sensor with superb optical
features and thus a maximum amount
of process reliability. Both in case of light
and dark object surfaces, dependable
detection occurs within a distance range
from 50 mm to 500 mm.
Switching reliability through
modified light spot
The optical system of the WTB12 Line
is modified in such a way that a line-
shaped, easily visible light spot appears
on the object. At a scanning distance
of 150 mm, it is possible to suppress
gaps of approx. 25 mm in width. Due to
this line geometry, one can ensure that
the sensor reliably detects the corners,
crosspieces, and gaps of the mesh box
as a uniform, homogenous surface. Con-
sequently, the WTB12-3 Line detects
every box only once, thus outputting a
switching signal only once downtimes
are reduced, availability of the automatic
conveyor system improves.
Robust, easy to integrate,
suitable for IO-Link
Whether baked goods, meat and sau-
sage products, fish, fruit, or vegetables
particularly users in the food industry
require high process reliability and de-
pendability, even under harsh operating
conditions. The WTB12-3 is prepared
for this: Its rugged metal housing is
resistant against high-pressure cleaning,
cleansing and disinfecting agents, or
temperature fluctuations from 40 C
to +60 C. Commissioning i.e. align-
ment by means of the bright light spot,
adjustment of the scanning distance,
and definition of the switching threshold
takes place quickly and easily, requir-
ing no elaborate training or technical
staff. In terms of installation, the versa-
tile mounting options prove helpful. The
chip technology of the WTB12-3 Line
allows equipping the sensor optionally
with IO-Link. In this way, it is possible
during use e.g. in harsh operating con-
ditions in the food and beverage sector
to implement preventive maintenance
measures.
Line optics, robust housing design,
mounting flexibility, and IO-Link with
the WTB12-3 Line photoelectric sensor
for mesh boxes, a sensor has become
available that combines reliable, univer-
sal object detection with the option of
extensive yet simple sensor monitoring.
Detecting mesh boxes on an automated conveyor system is not
always easy due to their structures and possible background
effects . The new WTB12-3 Line photoelectric sensor resolves that
problem all the way down the line.
Avoids unnecessary stoppages
Detection of mesh boxes via
Photoelectric Line Sensor
26
01 2010
: Products
Gas analyzers
>> SICKs GM700 tunable diode laser
spectrometers are used in various areas
of industry to analyze gas for emission
measurement or process control. They
facilitate the selective measurement of
gas components within a gas mix and
thus quickly determine the concentra-
tions of combustion and other process
gases. Measurements are taken, for
instance, of HF in the raw gas of an
aluminum plant for regulating the injec-
tion of aluminum oxide. Monitoring am-
monia slip in denitrification systems of
power stations, cement works or waste
incinerators is also no problem with the
GM700.
Successful mix
In many installations, GM700 probe or
cross-duct versions provide years of re-
liable precision, short response times
and high equipment availability in many
applications . Nevertheless, there are
some extraordinary analysis conditions
in which the use of in-situ instrumenta-
tion is sometimes not practical or even
totally impossible. This includes con-
ditions of high pressure or high tem-
perature and in very narrow gas ducts.
Specifically for such special analysis
situations SICK has therefore developed
the appropriate solution: the GME700
extractive analyzer.
While in in-situ measurement the
GM700s sender and receiver unit is
mounted directly onto the pipeline or flue
duct, when applications are done extrac-
tively, the GM700 analyzer is integrated
into a 19 housing unit. It is not the gas
duct directly that serves as the stretch
to be analyzed, but a long-path cell that
is adjustable in terms of analysis path
length. This long-path cell is heated to as
much as 210 C to avoid any condensa-
tion or absorption effects. With a dust fil-
ter system the analyzer can be easily em-
Tunable diode laser spectroscopy (TDLS) has proven itself over
recent years as a reliable analysis method in both process mea-
surement and emission monitoring. To cover a wide field of appli-
cations SICKs laser gas analyzer is now also available for the first
time as an extractive measurement system: the GME700. Thus,
in addition to in-situ instrumentation, the extractive method of
analysis is now an alternative option. SICK is thus opening up new
possibilities for analyzing difficult to measure gas components
such as hydrogen fluoride, hydrogen chloride and ammonia with
better than ever flexibility.
ployed without any further gas prepara-
tion. The GM700s outstanding features,
such as highly selective measurement
and a comprehensive self-test function,
are retained in extractive analysis, as is
the principle of drift and calibration-free
measurement. Unlike with other extrac-
tive systems there is there-fore no need
for the usual repetition of the calibration
procedure nor, of course, for procuring
or stocking any test gases.
Demanding gas analysis brought into line
The use of tunable direct laser spectros-
copy (TDLS) with a precisely coordinated
spectral line permits high-resolution
measurements without any influence
from cross-sensitivity. The laser diodes
wavelength is matched to a spectral line
of the sample gas component. The laser
beam goes straight through the gas to be
analyzed. The gas concentration is then
determined in the analysis of the signal
based on the wave-length-specific ab-
sorption.
And to cover a wide range of appli-
cations SICKs product portfolio includes
this technology in system components
with a measuring probe, in the cross-
duct configuration or as an extractive
analyzer. Which version is preferable to
use depends on the applications condi-
tions in each case.
Making gas visible
Laser spectroscopy now also
via extractive analysis
27
: Products
Safety camera systems Hand-held scanners
Device for the most diverse protective fields
Even more possibilities for the
Safety Camera System
With its extended ranges and the flex-
ible design of protective fields, the
V300 Work Station Extended safety
camera system opens new fields of
application for protection of hazard-
ous points and areas.
>> With the versatile universal sen-
sor V300 WS Extended, the necessity
safe switching outputs, of external de-
vice monitoring, and of the reset button.
In case of diagnostic action, the assign-
ment of the LEDs listed above allows
well-directed measures.
The V300 WS Extended safety cam-
era sensor meets the SIL2 Safety Integ-
rity Level in accordance with IEC 61508
and Performance Level PL d in accor-
dance with EN ISO 13849. Featuring a
range of 2.12 m diagonally, it is suited
for protective fields up to 1.5 m x 1.5 m,
with possible resolutions of 20 mm,
24 mm, and 30 mm. When it comes to
large monitoring areas side by side or
diagonally across, it is possible to con-
nect two devices to one, thus doubling
the size of the protective field.
>> Bluetooth wireless, the 2 in 1 scan
engine for standard, high-resolution, and
stacked codes, as well as the integrated
memory for up to 5,000 codes scanned
offline make the IDM 140-2 Bluetooth a
self-sufficient unit for mobile identifica-
tion directly on the object. Up to seven de-
vices can operate simultaneously on one
base station.
Great user-friendliness
The IDM 140-2 Bluetooth offers scanning
ranges of up to 600 mm and is capable of
identifying even codes whose cell size is
only a minute 0.076 mm. One thing users
appreciate particularly is the ergonomics
of the Bluetooth hand-held scanner. The
Without a wire, instead with plenty of possibilities
Bluetooth Hand-held Scanners no wires, no worries
Minimal alignment effort, excellent
accuracy, and freedom to move
within a radius of up to 30 m some
of the features the IDM140-2 Blue-
tooth hand-held scanner from SICK
offers.
feature responsible for this is, first of all,
the wireless device design. What makes it
user-friendly as well, however, is its mini-
mal weight and its linear imaging mod-
ule, which generates a bright scan line
distinctly visible on the barcode. Another
convincing facet: even poorly printed or
damaged codes are identified quickly and
reliably without multiple scans, without
no reads, without any loss of time and
nuisance.
Fast and versatile
Commissioning of the IDM140-2 Blue-
tooth is a matter of a few moments or,
respectively, of a few scans, since one
can choose starting the scanner either
via configuration codes or via the intuitive
IDM Setup Tool configuration software.
Depending on the field of application,
users have available various interfaces
such as PS/2, USB, and RS-232, all of
which are common in production, ware-
housing, and logistics.
of protective fields on machines being
rectangular is a thing of the past. Cable
channels, any kind of gap, design-orient-
ed machine openings, elongated, small,
diagonally across in L or V shape, visible
on the bar frame or invisible inside a
machine, vertical, horizontal or oblique
from whatever position the V300 WS
Extended imposes no limits to the indi-
vidual design of protective fields.
Start-up: Thats how simple it is!
Scarcely any other safety sensor is so
easy to install and start up as the V300
WS Extended. Two screws suffice to
mount the device reliably. In terms of
electric connection, one needs to lay one
cable only. The protective field is taught
in by means of one-button operation in
the teach-in mode. The display with four
LEDs supports this procedure, with one
LED each indicating the status of the
IDM140-2 Bluetooth
versatile even without a wire
28
01 2010
: Products Radio-frequency identification
Ranges of up to 150 mm, signal and data processing at speeds of
up to 3 m/s, space-saving design and openness to various Field-
bus environments as well as IT structures make the new RFH620
transponder read/write device the ideal identification solution for
intralogistics, e.g. in container handling technology.
Up-to-date, consistent, and reliable information: By linking the material flow with the information flow, the information
systems constantly map the current commodity flows. Thus, the pieces of information within the system are not only more
accurate but also more up-to-date.
Prevention of false bookings: Typical errors in receiving and shipping such as amounts recorded incorrectly, products
booked falsely, or forgotten bookings are avoided.
Reduction of search times: By using RFID, bookings, e.g. for transfers, are automated. Due to the elimination of this per-
sonnel-intensive process, it is possible to prevent manual errors and reduce costs.
No more losses of production: Precise mapping of material movements within the information system results in higher
inventory accuracy and enhanced delivery reliability.
Optimization of production planning: Since every material flow is also mapped immediately in the information system, pro-
duction planning can make arrangements more precisely based on up-to-date information.
Reduced capital commitment: Increased transparency and improved planning allow a reduction of surplus capacities of
containers and mobilization of tied-up capital.
Decentralized process control: Data management directly on the object allows controlling processes even without direct
access to databases (e.g. ERP systems). This leads to an increase in plant availability and a reduction in cost for plant
extensions.
Take advantage of the benefits that RFID from SICK offers to your intralogistics, too:
New 13.56 MHz system for intralogistics
Compact read/write device for ISO
and IEC-compatible transponders
>> The new RFH620 from SICK operates
in the HF range (high frequency) of 13.56
MHz, i.e. using a frequency that offers
high transmission rates and is ideal for
object tracking and container manage-
ment in internal and, respectively, closed
circulation systems. The system offers a
maximum amount of process and invest-
ment security on the one hand, because
it can read and program any transponder
that complies with the ISO/IEC-15693
standard; on the other hand, because the
universal connection technology supports
all Fieldbus systems customary in the in-
dustry. Added to this is the fact that the
data output formats can be parameter-
ized flexibly, with the option of using the
29
: Products
Photoelectric sensors
>> Select quickly, install quickly, and
use quickly these characteristics
apply to all V180-2 devices, as they
guarantee utmost availability, first-rate
functional reserve, and thus solutions
that are universal and economical to
the user.
Very efficient
As a result, the V180-2 is a well-round-
ed piece of equipment, particularly for
warehousing and conveyor technol-
ogy, handling systems, or packaging
machines, especially as the series
offers the user an exceptional price-
performance ratio. This is because the
variety of types concentrates on the
essentials and permits quick selec-
tion of the suitable sensor. At 100 mm,
400 mm, and 800 mm, the energetic
sensor versions cover all of the com-
mon scanning distances. The photo-
electric reflex sensor with polarization
filter yields excellent results at ranges
of 4 m in any ambient condition, and
the through-beam photoelectric sensor
with its range of 20 m delivers convinc-
ing performance with respect to long
object ranges. Processes with high ob-
ject speeds in particular benefit from
the fast response times of all V180-2
devices.
Ready for operation quickly
Whether featuring a connection cable
or an M12 plug thanks to the com-
mon M18 design and the short hous-
ing, all of the sensors are quick and
simple to install. They are easy to align
by means of the bright red emitter LED
sensitivity adjustment takes place
via potentiometer. Finally, two LEDs
and a 360 display ensure optimum
visualization of operating conditions.
V180-2 versatile object detection with
an attractive price-performance ratio.
Efficient, easy to install, and versatile the new V180-2 family
of M18 photoelectric sensors is a well-rounded piece of work.
Convincing winner in price-performance ratio
Well-rounded solutions
for object detection
output signals for independent, decen-
tralized controlling of process stages, e.g.
for actuating a conveyor switch or ejector
unit. Also beneficial for versatile and open
system use is the fact that the RFH620
complies with the European radio require-
ments according to CE and has the FCCs
radio approval that is important for the US
market.
Individual integration
suitable for the industry
With the RFH620, an RFID solution is
available that is oriented especially to-
ward the demands of industrial use.
Thus, the antenna was integrated into
the housing of the read/write device,
which achieved a compact, space-sav-
ing, and easy to install physical size that
also facilitates subsequent integration
into existing facilities. Featuring an IP 67
enclosure rating and operating tempera-
tures ranging from 25 C to +60 C,
the RFH620 is also suited for harsher
ambient conditions. An added strength
is the speed of the integrated signal and
data processing system. It allows reli-
The ideal identification solution for intra-
logistics: the new RFH620 from SICK
ably reading out and updating transpon-
ders even at conveying speeds of up to
3 m/s. Other features emphasizing the
RFH620s suitability for integration in-
clude its openness to various Fieldbus
and IT environments, flexibility in terms
of client and application-compatible defi-
nition of data output formats, as well as
the intuitive SOPAS operator interface
that offers the same look & feel for all
bar code and RFID systems from SICK.
30
01 2010
: Products Level sensors Motor feedback systems
>> Clear trend: The future belongs to
compact and robust direct drives with-
out bearings. With the SEK90/SEK160
hollow-shaft motor feedback systems,
SICK-STEGMANN has thought the idea of
the direct drive consistently through. The
new SEK90/SEK160 hollow-shaft motor
feedback systems with holistic system
scanning are fitted directly on the drive
shaft.
No wear, no generation of heat
The simplified, compact construction
stands for absence of wear and there-
fore reduced maintenance costs. Since
bearings are not used either, heat gen-
eration is reduced drastically.
Fast and precise
Thanks to the SEK90/SEK160 motor
feedback systems, the direct drives of
the new generation stand out due to
their high positioning accuracy and pow-
erful dynamics the preset position is
targeted quickly and precisely.
Turn & play for easy installation
without any tools
Time-related advantages concerning in-
stallation are inclusive: For starting up
the SEK90/SEK160, you need neither a
template nor any special tools simply
fit it on, turn, and get going: turn & play!
Many sizes, many fields of use
Whether for extruders on plastic injec-
tion molding machines, in the packag-
ing industry, in the automotive sector,
or in the food & beverage industry
for engine builders working with the
HIPERFACE

interface, the SEK90/
SEK160 hollow-shaft motor feedback
systems provide new possibilities: inside
diameters of 50 mm and 110 mm are
already available, additional diameters
are in the pipeline.
More direct is impossible: The new hollow-shaft Motor Feedback Systems
SinCos
SEK90/SEK160 without
bearings, compact, and robust
The robust turn & play solution for di-
rect drives with HIPERFACE
interface.
>> Using a uniform operating design, the
UP56 supplements the successful UP30
series from SICK. This opens up new
possibilities in applications with contain-
er pressures of up to six bar and filling
levels up to 5,000 mm.
Flexibility through non-contact
measurement
The temperature compensated ultrason-
ic measurement permits a very precise
and reproducible determination of levels
for solid and liquid media even in case
of a high proportion of contamination or
high viscosity. Teflon and PVDF, the ma-
terials of the UP56, which can be used
in a temperature range of 25 C to
+70 C, are accordingly resistant.
Ready for operation quickly
The 3 in 1 device design of the new lev-
el sensor analog level signal, switch-
UP56 is the name of the latest level sensor in SICKs portfolio. Ultrasound,
material selection, and the sensor design make the device a universal solution.
ing output, and operating display are
integrated into the device ensures fast
and easy installation and start-up. In the
process, the automatic signal detection
detects immediately whether the analog
measuring value requires output as a
current or voltage signal which facili-
tates integration further.
Ultrasonic level measurement for liquids and bulk materials
Small construction, great pressure resistance
31
: Products Safety light curtains Positioning encoders
>> In addition, as one of the first devices
of its kind it offers in this category a reso-
lution of 14 mm for finger protection. In
this way, protection can take place even
closer to the hazardous point which fur-
ther minimizes space requirements and
enhances the operating ergonomics of
the machine.
Universal possible applications
miniTwin2 was designed for tasks in
which the hazard analysis of a machine
stipulates Performance Level PL d ac-
cording to EN ISO 13849-1, or, respec-
tively, SIL2 in compliance with IEC 61508.
Reso lutions of 14, 24, and 34 mm,
ranges of up to 8 m, the operating tem-
perature range between 10 C and
+55 C, IP 65 enclosure rating, as well
Minivation continues: miniTwin,
probably the worlds smallest and
most flexible safety light curtain at
the moment, is now also available
as a Type 2 version.
as the 1-box design featuring the sender,
receiver, and evaluation unit in the same
combined stick throughout open up nu-
merous possible uses for the miniTwin2
when it comes to protection of machines.
This applies particularly to packaging ma-
chines, handling systems, or plant mod-
ules in electronics production.
Tried and tested features retained
miniTwin2 offers all of the benefits with
which miniTwin4, the Type 4 version,
already set new safety and integration
standards. Identical combined sticks
for stand-alone and cascaded solutions
reduce procurement and warehousing
logistics. The connection technology, flex-
ible and adapted to the needs of industry,
provides full functionality of electronic
device monitoring (EDM) and Reset. The
adaptive mounting solutions identical
for miniTwin2 and miniTwin4 permit
simple integration into diverse machine
designs. Blind zone-free monitoring, even
diagonally across, saves any correspond-
ing structural adjust-
ments to the ma-
chine. Commissioning
of the miniTwin light
curtains is fast thanks
to intuitive handling. In
operation, they impart to
the machine operator a
sense of security through-
out, since easily visible rows
of LEDs in the housings en-
sure that the active protective
field is displayed permanently.
Finally, the miniTwin2 currently
provides the highest diagnostic
convenience of Type 2 solutions,
thus optimizing availability of the
machines.
miniTwin2 the new standard in
Type 2 light curtains.
Now also for Type 2
miniTwin2 small, integrated, and universal
>> The encoders of the new DDS36 and
DDS50 series are used in factory auto-
mation wherever the crucial objective
is exact measurement of positions and
velocities especially in areas where in-
stallation space is a scarce commodity.
Among the common product features are
an IP 65 enclosure rating and an operat-
Small and cost-effective
Compact encoder for positioning
and velocity measurement
Space-saving due to small construction, rugged because of an aluminum
housing, precise through their optical technology, and cost-effective due to a
superb price-performance ratio the new incremental encoders of the DDS
series are a well-rounded matter.
ing temperature range between 10 C
and +70C both features guarantee
high stability when operating in demand-
ing environments. These characteristics
are unique in the encoder price range.
By using robust aluminum housings, both
encoders offer very good EMC addition-
al internal shielding is not necessary.
Versions with blind hollow shaft and
solid shaft are available
The DDS36 is available as a version with
blind hollow shaft for simple and direct
installation on the motor shaft and solid
shaft for confined installation settings.
In terms of construction, the DDS50
solid shaft encoder was adapted to the
requirements in the Asian market: its
clamp attachment and the arrangement
of the mounting holes correspond to the
Far Eastern application standard.
Worldwide and industry-wide:
the curtain rises
Whether in Asia, Europe, or elsewhere
in the world countless uses in factory
and logistics automation are among the
numerous possible applications of the
particularly economical DDS series.
32
01 2010
: Products Safety light curtains
>> In addition to machine safety, electro-
sensitive protective equipment such as
the C2000, C4000 Micro, or M2000
offers the benefit that the respective
machine is easily and ergonomically ac-
cessible for operating, cleaning, or reset-
ting purposes. Thanks to the new IP 69K
Housing, it is now possible to realize the
extra productivity that results from doing
without mechanical protective barriers,
e.g. doors and hatches, even in the harsh
operating environment of food production,
meat and dairy processing, as well as bev-
erage bottling.
Easy to integrate and durable in the harsh food environment
Without BBD: Electro-sensitive
protection in IP 69K enclosure rating
Resistant material, a construction compatible with food and
cleaning, respectively, and an IP 69K enclosure rating dis-
tinguish the new protective housings for various safety light
curtains from SICK. Tried and tested safety technology thus
becomes usable even in the harshest conditions without a
best-before date.
Certified durability
The IP 69K solution stands out due to
a compact, space-saving design. The
food-compatible construction in accor-
dance with EN 1672 prevents deposits
from building up and facilitates clean-
ing. Cleaning certificates from ECO-
LAB and JohnsonDiversey confirm the
high resistance level of the materials
used. Another point worth emphasizing
is the fact that as a complete system
this IP 69K Housing solution features
an IP 69K enclosure rating i.e. of the
housing including the special connec-
tion cable used. As a result, it can with-
stand even high-pressure washers up
to 100 bar and water temperatures up
to 80 C, thus guaranteeing maximum
availability of the protective equipment
on the machine.
Safety without best-before date
The IP 69K Housing makes it possible
to install and integrate various standard
safety light curtains from SICK into ma-
chine or plant control systems in the
familiar simple ways. Operators benefit
not only from machine safety without a
best-before date but also from countless
operating advantages on the machine;
these optimize its flexibility and produc-
tivity, thus ensuring more economic ef-
ficiency.
33
: Products
Linear measurement sensors Safety controllers
>> The OLM100 is a camera-based sys-
tem with integrated LED lighting for dis-
tance measurement on straights and in
corners. It is used, among other things,
Superb ruggedness and precision and great variety of interfaces as well
distinguish the OLM100. Featuring the new CANopen version, the optical linear
measurement system now offers integrators in intralogistics even more pos-
sibilities for automation.
for positioning and collision prevention on
overhead electric conveyors, aisle stack-
ers, or transport shuttles. In addition to
its precision, repeat accuracy, and the
>> Today, safety solutions for machines
and plants must do more than merely
provide safety from accident hazards
what matters more to both integrators
and users all the time is the added ben-
efit in terms of information and automa-
tion technology. SICKs portfolio of safe
sensor and control solutions puts these
requirements into action and just how
this happens is explained by numerous
application examples depicted in the
Flexi Soft Application Manual.
Multimedia presentation throughout
Whether the example relates to the emer-
gency-stop centralization on a fishery ves-
sel, complete protection of a newspaper
The new Flexi Soft Application Manual shows how machine safety can be im-
plemented reliably and efficiently by using safe control and sensor technology
from SICK. From eccentric press to newspaper palletizer or automated guided
vehicle all the way to the meatloaf baking station the spectrum of possibili-
ties is vast.
palletizer, or realization of the complex
logic for a meatloaf baking station all
of the tasks are described exactly to
begin with, before explaining the method
used to implement the safety solution. In
this context, the items explained include
the hardware-related configuration of
the sensor technology and the Flexi Soft
controller as well as the linking of the
safety logic by means of the user-friendly
and free Flexi Soft Designer software.
Extensive attention is also devoted to
depicting safety-relevant processes and
to additional benefits in terms of infor-
mation and automation technology when
integrating and operating the respective
machine or plant.
Depiction of the Flexi Soft applications
is not limited to the manual the en-
closed CD containing easy to grasp
animations of various projects further
supports the printed version. On top of
that, one can retrieve countless appli-
cation solutions from SICKs microsite
at www.sens- control.com.
high functional reserve, plant operators
praise above all the special ruggedness
and stability that contributes to optimizing
the availability and economic efficiency of
their facilities.
Easy to integrate for intralogistics
sector
Integrators highlight the metal housing
that can be mounted in a space-saving
way, as well as the fast and cost-effective
installation the latter is made possible,
among other things, by the integrated opti-
cal alignment aid but also by various inter-
face options the OLM100 offers. In addi-
tion to RS-422, RS-485, and SSI, a system
version with CANopen interface is now
available, too. Consequently, it is possible
to link up the linear measurement system
with other manufacturers automation
components and to integrate it into intra-
logistical plant and control designs in the
optimum way.
Now with CANopen
Optical linear measurement
for intralogistics
What safe control technology from SICK can do
Flexi Soft Application Manual
versatile in detail
34
01 2010
: Products Safexpert safety software Magnetic cylinder sensors
>> The approach used by the user-friend-
ly software to pave the way to the CE label
and the corresponding documentation
conforms to the new 2006/42 EC MD. In
Safexpert 7.0, it is attached and linked as
a text in full.
CE label according to the new
2006/42 EC Machinery Directive
Already on the safe side
for 2010?
Whether machine manufacturers or plant operators the
Safexpert CE Safety Software Version 7.0 enables anyone to plan,
market, and use machines or plants in conformity with the EUs
new Machinery Directive.
tive. The CE safety software accompanies
them in eight easy to handle steps along
the entire conformity process from the
classification of the product in keeping
with the MD, clarification of the appli-
cable standards and risk assessment all
the way to issuing the declaration of con-
formity. In the process, all of the relevant
legal guidelines are taken into consider-
ation and observed.
In case of changes, too: standards
situation always up-to-date
The online NormManager integrated into
Safexpert 7.0 provides continuous infor-
mation about the current standards situ-
ation changes are displayed via mouse
click, and so are the projects affected. In
this way, the user receives optimum sup-
port toward a process conforming to the
new Machinery Directive at all times.
Support for the machine
operator as well
Once the CE label is attached and follow-
ing the operator taking possession of the
equipment, the latter assumes responsi-
bility for the safe use of the machine. In
this context, he or she is well advised to
use Safexpert 7.0 as well, e.g. the inte-
Safexpert 7.0: Hands-on
CE implementation in eight steps
With the assistance of Safexpert 7.0,
both machine manufacturers and plant
operators are on the safe side concern-
ing the 2006/42/EC Machinery Direc-
SICK expands the MPS series even further: The magnetic position sensors for
analog polling of pistons on pneumatic cylinders are now suited for cylinder
stroke of up to 256 mm.
>> All of the sensors deliver convincing
performance due to flexibility, ease of
use, precision, and speed.
Flexibility guaranteed
Featuring possible detection ranges
from 32 mm to 256 mm, the MPS of-
fer a maximum amount of flexibility. As
a result, the T-slots on the cylinder do
not have to be occupied by a large num-
ber of sensors for individual switching
points, thus eliminating the need to ad-
just them mechanically. In addition, MPS
allows free selection of the installation
direction which ensures an optimum
cable outlet.
User-friendly commissioning
The MPS from SICK convince due to
installation and adjustment within a
matter of minutes. The sensors can be
placed from above into all of the com-
mon T-slots via drop-in, with two bolts
attaching them firmly. The zero and end
points can be adjusted with the push of
a button. Commissioning is supported
by the in-range LED display that shows
the respective current position of the
Distance measurement for pneumatic cylinders up to 256 mm
Analog position detection for
long piston travels
35
: Products
Network solutions
grated check and acceptance assistant.
It supports the operator not only during
initial commissioning of a facility but also
subsequently during operation and in
case of extensions or conversions as
a result of which the operator, too, be-
comes a manufacturer as defined by the
Machinery Directive.
Safexpert 7.0 and SICK
the MD Insurance
Certainty instead of uncertainty, time sav-
ing instead of huge effort, flexibility and
future capability Safexpert 7.0 offers
all of this to its users. And anyone wish-
ing additional support beyond this MD
Insurance on all issues concerning safe
design of machines and plants can rely
on comprehensive services by SICK. This
applies particularly to quality and safety
management. In this respect, SICK of-
fers accredited safety inspections by
Deutsche Akkreditierungsstelle fr Tech-
nik e .V. (DATech; German Accreditation
Authority for Technology) on machines
and their safety devices in accordance
with DIN 45004, Type C.
piston. In case of a product change, the
new switching points are defined via the
controller mechanical resetting of any
position switches on the cylinder is no
longer required at all.
Precise position detection
Electrical adjustment of the measuring
range achieves optimum resolution and
linearity with respect to any construction
length. Since the housing design also
minimizes blind zones, losses in stroke
are avoided in this way, short-stroke
cylinders in particular can be used for
their entire piston travel.
Unrivalled speed
All of the MPS offer a scan rate of 0.5 ms
and thus an added gain in efficiency
as this amounts to many times the rate
common on the market to date. There-
fore, machines with fast cycle times can
now also benefit from analog distance
measurement.
>> Flexi Link maps the modular con-
struction of machines consistently. Fre-
quently, various machine modules are
only assembled at the users location, or
they are supplemented there later after
operating for a while. In this context, the
safety design plays a decisive role, as
protection of both the individual module
and of the entire equipment constella-
tion must be taken into consideration.
This is where Flexi Link comes in. De-
tection and parameterization of plant
components not yet in place but already
prefabricated permit implementing this
strategy. By way of detecting and param-
eterizing on site, it is possible to assem-
ble or supplement subsequent machine
or plant components without starting up
the machine anew.
Intuitive extension
of safe control structures
Flexi Link from SICK is a new functionality
of Flexi Soft that allows linking up to four
Flexi Soft safety controllers with one anoth-
er in a flexible and functional way. Integra-
tion takes place via a safe device interface
from SICK called EFI (Enhanced Function
Interface). It serves the connected or, re-
spectively, networked devices to exchange
their safety-relevant signals directly i.e.
without additional module. Within the inte-
grated Flexi Link system, the stations can
transmit up to 52 bit each.
For flexible machine designs and interlinked plants
Flexi Link: Networking a
safe control system reliably
One thing emerges particularly in practical operation of modular plant designs:
Flexi Soft safety controllers rarely come singly. And since this is the case, SICK
developed a solution toward networking controllers: Flexi Link.
Setting up a safe Flexi Soft network with
Flexi Link is easy. Adding new stations in-
cluding definition of default process im-
agers for optional stations as well as ad-
ministration and diagnosis of the entire
integrated system takes place by means
of the familiar Flexi Soft Designer param-
eterization tool. Thus, the user is familiar
with the operator interface and its look
& feel. If required, the whole Flexi Link
network can be integrated into all of the
common Fieldbus systems using the ap-
propriate Flexi Soft Gateways.
For modular, expandable,
and interlinked plants
Flexi Link permits integration of Flexi Soft
safety controllers into a network wherev-
er plants are designed in a way capable
of migration and machine modules inter-
act or are interlinked with one another.
Intralogistical facilities and packaging
lines are only two examples of applica-
tion fields in which machine builders and
end users can benefit from the advan-
tages of safety- and operation-related
networking with Flexi Link.
36
01 2010
: Technology Encoders
Innovative sensor technology as
a basis for new series
SICKinsight: No battery, no transmis-
sion, and yet detecting revolutions and
direction of rotation absolutely whats
the principle behind or, as it were, in
your new encoder series?
Magnetic encoders distinguish themselves
by a high degree of ruggedness in the first
place. Now SICK goes one step further and
presents based on a technology integrat-
ed for the first time a new series that man-
ages without external energy and is thus
robust, self-sufficient, and energy-efficient.
Heiko Krebs, Head of the Business Unit En-
coders, explains just how this works.
The A3M60 absolute multiturn encoder is the first device of a new family of de-
vices from SICK. Thanks to Wiegand wire technology, the encoder featuring an
integrated PROFIBUS interface works without any battery and transmission and
thus entirely without energy and wear. The magnetic functional principle and an
IP 67 enclosure rating make it extremely robust and durable. The absolute position
detection offers a resolution of 31 bit. With its installation depth of only 60
mm, the A3M60 is particularly suited for confined spaces. There is
a choice of version with different blind hollow shaft and hollow
shaft diameters. As a result, the encoder is suited for a vari-
ety of possible uses, e.g. in palletizing systems, part feed-
ing devices, on crane vehicles, in wood-processing
machines, or in packaging technology.
Counting multiturn without buffer battery and transmission
Heiko Krebs: The starting point of our
new development was the wish of many
customers to enhance even further
the ruggedness of magnetic multiturn
encoders, which was already good to
begin with. This concerned, on the one
hand, the topic of temperatures, lower
than 20 C, and on the other hand,
shock and vibration resistance i.e. the
aspect of the integrated components,
especially the mechanical transmis-
sion. Therefore, we considered how we
might count multiturn even without any
battery and transmission. We were pro-
vided with the answer by the Wiegand
wire technology. It works completely
without energy and is capable of de-
tecting both the number of revolutions
and the direction of rotation without any
transmission mechanics.
SICKinsight: A wire replaces the battery
or the transmission?
Heiko Krebs: In principle, yes, but this
is not any old wire. A Wiegand wire is
mm thick and consists of a special alloy.
The shell is made up of a magnetically
hard metal, the core on the other hand
of a magnetically soft metal. As a result,
the shell and the core have a different
magnetizability. When a magnetic field
acting from the outside generated in
our encoders by a rotating magnet
exceeds a certain strength, a rapid re-
magnetization of the core occurs. The
voltage impulse created in this process
is detected by a spool within the encod-
er surrounding the Wiegand wire and
counted as actual revolutions. More-
over, this method also allows detecting
the direction of rotation.
SICKinsight: What are the benefits that
this technology and your new encoder
series offer to users?
Heiko Krebs: To begin with, it fulfills the
customers most important concern:
more ruggedness and absolutely wear-
free operation. The non-contact mea-
suring principle as well as doing with-
out a battery and the moving parts of
a transmission improves the operating
life, especially during use in harsh envi-
ronments. Thus, costs for maintenance
and repairs decrease. Additionally, the
encoders working independently of any
power supply contribute their share to
more energy efficiency. Our Wiegand
wire encoders also deliver convincing
performance due to enhanced manu-
facturing efficiency: a magnet counts
singleturn and multiturn and the entire
sensor unit including the evaluation
are located on a single, automatically
assembled circuit board. The reduc-
tion of the components in the encoder
Heiko Krebs, Head of
Business Unit Encoders
37
: SICK Tour
thus shortens production time. All of
this together results in more economic
efficiency and faster availability fea-
tures to which customers attach great
importance in addition to all of the rug-
gedness.
SICKinsight: What remains is the ques-
tion of versatility. What about the con-
struction sizes, installation depths, and
interfaces?
Heiko Krebs: In this respect, too, we are
very close to customers wishes. In a first
step, we will present the encoders in
the tried and tested industry standard
in the 60 series version, while keeping
open all of the options for smaller ver-
sions because of the compact design.
With respect to installation depth, with
the 60 mm of our new Bus encoder we
are occupying a top value that contrib-
utes to being able to construct machines
and plants in the most compact way
possible. In terms of interfaces, for the
new A3M series we have simply packed
the PROFIBUS interface right into the
housing thus no longer requiring any
external Bus covering. The same applies
to the other Ethernet-based interfaces
currently under development.
SICKinsight: What does the new mag-
netic technology mean for the encoder
portfolio? Are the optical times over?
Heiko Krebs: No, the optical times are
not over, for this technology, too, has
its justification, e.g. when you consider
the benefits regarding precision and
speed. However, with the new magnetic
encoders, we have created the basis for
a new structure in the portfolio best
of both worlds, as it were. In this way,
our customers can cover their require-
ments even more flexibly. Depending on
the application, they choose between
optical and magnetic technology, de-
termine the desired construction and
decide independently which of the dif-
ferent fieldbuses PROFIBUS, Ethernet
IP, PROFINET, or Ethercat they wish
to connect to the Bus interface of the
encoders.
SICKinsight: Mr. Krebs, thank you very
much for the interview.
In February 2010, SICK Vertriebs-GmbH organized its first event entitled Inno-
vative Safety Technology as a partner of the Robotation Academy in Hanover.
It was sold out early on showing just how hot the topic continues to be.
>> Robots and automation are used
in an increasing number of industries.
These technologies are no longer limited
to large corporate groups by any means
small and medium-sized companies al-
so utilize them as tools toward increased
competitiveness. Deutsche Messe AG
has recognized this trend, cooperating
with Volkswagen Coaching GmbH to
found the first cross-producer robot and
automation academy at the exhibition
site in Hanover the Robotation Acad-
emy. On more than 2,500 m of office
space, interested companies can book
training seminars all year round or like
SICK as a partner of the Academy orga-
nize events themselves.
Safety goes down well
With its first event, SICK took up the
topic of innovative safety technology.
Was it the current changes to the EUs
Machinery Directive and standards, or
does it have to do with the possibilities
of realizing more efficiency and profit-
ability? In effect, it was probably these
and additional reasons that caused the
event to sell out quickly. And the topic is
hot for many people: for newcomers that
deal with the subject for the first time,
but also for experienced users intent on
using the event to bring their knowledge
up to date. In the end, the presenter
from SICK, Olaf Ophoff, and guest pre-
senter Freddy Heinzelmann from SEW
Eurodrive received good grades from
participants for their comprehensive
package of lectures concerning the sys-
tem of standards as well as safe sensor,
control, and drive technology, as well as
the aids toward practical implementa-
tion.
Safety remains a crowd puller
SICK is reacting to the great interest,
continues to bet on closeness to the cus-
tomer, and will offer, in the context of the
Robotation Academy, additional events
on the topic of safety in the months
ahead. Those interested can already put
their names down at www.sick-safe-
typlus.com. Just in case Hanover seems
too far, SICK offers you further informa-
tion events and practice-oriented after-
noons all over Germany. Surely there will
be a time and place scheduled near you
please read up on it on the Internet at
www.sick.de.
Opening event on safety technology booked out early
SICK at the Robotation Academy
01 2010
: SICK Tour
38
>> SICKs annual Safety Days are meant
as a forum giving as many experts on
machine safety as possible an oppor-
Diverse aspects from technology, industry, and law examined
SICKs Safety Days bring experts together
Safety has many aspects SICK took that fact into consideration at the Safety
Days in October 2009. Experts from manufacturers, universities and colleges,
associations, inspection agencies, and law firms met in Waldkirch for an ex-
change of opinion that was productive for all participants.
tunity to obtain technical information
and engage in discussion. Participants
came from the most diverse fields; as
a result, the subject areas addressed
also varied very much. They ranged
from questions of product liability for
machine builders to trends in safe sen-
sor technology, pneumatics and drive
technology, safety solutions for station
platforms or autonomous vehicles, and
all the way to possible safety designs
for accident-free cooperation between
persons and robots.
Mark October 2010 in your
calendar today
At the next meeting, too, scheduled for
21 and 22 October 2010, the agenda
will again feature the latest trends in
>> Whether with or without economic
crisis that hit parts of the logistics sec-
tor particularly hard enhancing effi-
ciency in the logistical process chain is
always a topic that attracts great inter-
est. General cost control, reduction of
inventories, or lowering specific process
Lower process costs and more process efficiency through using innovative so-
lutions following that maxim, SICK organized the Logistics Innovations Day
2009 on 13 November of last year. The event met with a positive response
from more than 50 industry experts attending.
and handling costs are options to ensure
more efficiency in logistics. However,
it is equally effective as well to provide
for more competitiveness of automated
warehouses and distribution centers by
utilizing innovative solution strategies
and that is precisely where SICK picked
up the thread with its Logistics Innova-
tions Day 2009.
Innovative solutions in demand
anytime, any place
The event held at the premises of GS1
in Cologne highlighted effective ap-
proaches toward cost control based
on innovative solutions created in good
partnership with the respective custom-
ers and by using SICKs sensor exper-
tise. Together with the more than 50
industry experts attending, numerous
adjusting levers toward more process ef-
ficiency were identified along the entire
logistical supply chain among others,
with respect to supplying flexible produc-
tion lines, automation solutions in the
warehouse, or the automation of filling
supermarket shelves. The approaches
to the solutions were discussed from a
scientific perspective, from the angle of
practical operations, and in light of the
knowledge regarding the possibilities of
intelligent sensor technology.
After that day, all of those attending
certainly agreed on one topic: innova-
tions will ensure that the logistics sec-
tor will be able to participate actively in
shaping and taking advantage of the
next upturn.
Participants in the SICK Safety Days
came from the most diverse industries
technology, interesting applications,
the current development of standards,
and problems requiring critical ex-
amination. Individuals interested in
participating in the forum may now
request a reservation by e-mailing to
Doris.Lilienthal@sick.de.
Logistics Innovations Day 2009
Innovations for optimized processes in auto-
mated warehouses and distribution centers
: SICK Tour
>> Airport experts from SICK and from
the airport industry provided participants
with interesting information, presenting
the latest developments. The topics ad-
dressed included, among others, secu-
rity, detection of passenger flows in air-
port buildings and terminals, approaches
to solutions for automated, collision-free
On 11 and 12 November 2009, the
Airport Days at SICK took place for
the first time. Participants agreed:
The event ought to take place
every year!
docking of airplanes to gates, benefit
potentials of loading luggage with robots
and the improvements that RFID technol-
ogy may open up for luggage handling.
The high information content of the
contributions, the intensive exchange of
ideas with the experts, as well as a visit
to SICKs Logistic Technology Center in
Reute were assessed as being very valu-
able. The flying altitude was perfect,
one participant concluded small won-
der that he and many others wish to
check in again at the next of SICKs
Airport Days.
Industry experts at the 2009
SICK Airport Days
SICK Airport Days 2009
Event at the optimum flying altitude
39
>> With a staff of 3,800 employees world-
wide and sales amounting to 700 mil-
lion Euro, Elsag Datamat is among the
heavyweights in the industry. Especially
for the customer day, organizers at the
Genoa site had provided space in one of
Customer day at Elsag Datamat in Genoa
Technology transfer on location
SICK Italia was able to welcome nearly 100 engineers and designers from Elsag
Datamat, an Italian producer of sorting plant systems, to the customer day at their
Genoa plant. Not only the large number of participants but also the professional echo
was overwhelming.
the workshops. SICKs event at our lo-
cation yielded great benefit for everyone
participating, was the positive conclu-
sion drawn by Dr. Di Stefano, Head of the
Airport and Carrier Automation Systems.
In his view, this result was due above all
to the fact that SICK presented, on loca-
tion and in an impressive way, extensive
industry-specific expertise as well as inno-
vative technologies and their benefits for
Elsags system solutions.
In focus: sensor applications
and specialist knowledge
After all, the presentation included not
only the latest standard sensors but also
solutions that might be worthy of consid-
eration specifically for the airfreight and
packet sorting facilities from Elsag Data-
mat. Participants showed great interest
in image-processing solutions, identifica-
tion applications, volume measurement
systems, in safety technology and infor-
mation on SIL standards. Of course, it
was perfect that SICK not only had the
hardware there but simply brought along
the respective product specialist as well.
Thus, no questions concerning the sys-
tem technology, means of integration,
and benefits of use remained open,
says Dr. Di Stefano.
The upshot: customer day at Elsag Data-
mat was a great day for everyone in-
volved.
Subsidiaries
celebrate!
25 years of SICK Denmark
founded 10 May 1985
15 years of SICK Brazil
founded 06 June 1995
15 years of SICK Hungary
founded 16 June 1995
: Internet
01 2010
>> In nearly a dozen languages, the
Solutions Tour Website presents solu-
tions that SICK has realized in various
sectors together with the respective
customers to fulfill their specific tasks.
Everything revolves around the major
trends and challenges, the so-called in-
dustry challenges that companies and
industry sectors have to cope with today
in the area of automation.
In terms of content, the customers
application is described to begin with,
before presenting the solution and the
benefit the customer obtains by using
products and services from SICK. The
spectrum ranges from the inspection of
automotive components to the protec-
tion of doors on suburban trains and
luggage handling via robot and all the
The Solutions Tour Website thus offers the reader maximum benefit by means of:
>> searching and finding applications via the industry search or by
selecting an industry challenge
>> extensive information concerning the respective application
>> supplementary links to products, services, and industrial sectors
>> an overview of events that might be of interest thematically
Microsite with maxi benefit
SICK Solutions Tour on the net
Is there any free space left on
the favorites bar of your mon-
itor? In that case, you should
hurry to enter SICKs new
website www.sick-solutions-
tour.com there and check out
the diverse customer solu-
tions.
way to holistic emission measurement
at a cement factory in the Chilean des-
ert. Nearly every week, new solutions are
added and the fact that SICK is autho-
rized in this context to depict the respec-
tive customers logo speaks for itself.
www.sick-solutions-tour.com surely,
your new favorite bookmark as well!
www.sick-solutions-tour.com
40
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Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com
Phone +49 7681 202-0 Fax +49 7681 202-38 63 info@sick.de
Coordination: Stephanie Rott Stephanie.Rott@sick.de
Specialist editor: TOP MEDIA Dirk S. Heyden 69469 Weinheim info@topmedia-weinheim.de
Layout: ad:johnson Kommunikation 76133 Karlsruhe info@adjohnson.de
Translator: Dr. Erwin D. Fink 79106 Freiburg info@transmedia-translations.com
Printing: Dinner Druck 77963 Schwanau info@dinner-druck.de
Pictures: SICK AG, www.ausloeser-fotodesign.de
Individual contributions may be reproduced after prior consent. Please contact us at:
Phone +49 7681 202-3878 Errors excepted Subject to technical change
>> Imprint
: Info Trade fairs Imprint Contacts
>> Visit SICK at the Trade Fair!
Trade fair dates Germany
Trade Fair Location Dates 2010
HMI Hanover 04/1904/23
Euro-ID Cologne 05/0405/06
Automatica Munich 06/0806/11
MOTEK Stuttgart 09/1309/16
Fachpack Nuremberg 09/2809/30
Security Essen 10/0510/08
parts2clean Stuttgart 10/1210/14
Trade fair dates Europe
Total Processing & Pack Birmingham, UK 05/2505/27
Vision & Robotics Veldhoven, NL 05/2605/27
TOC Valencia, ES 06/0806/10
Drive & Controls Birmingham, UK 06/0806/10
Packology Rimini, IT 06/0806/11
Photovoltaic Solar Valencia, ES 09/0609/09
HET Amsterdam, NL 09/2810/01
Industry & Automation Utrecht, NL 10/0510/08
PostExpo Copenhagen, DK 10/0610/08
Trade fair dates worldwide
Oil & Gas Teheran, IR 04/2204/25
NA2010 Cleveland, US 04/2604/29
The Vision Show Boston, US 05/2505/27
Korea Pack Seoul, KR 06/0106/04
RAX Tel Aviv, IL 06/0806/10
Neftegas Moscow, RU 06/2106/25
KOFAS Seoul, KR 09/0709/10
CeMAT Asia Shanghai, CN 10/2510/28
Further trade fair dates with SICK worldwide at www.sick.com/fairs
SICK AG Erwin-Sick-Str. 1
79183 Waldkirch Germany
Phone +49 7681 202-0
Fax +49 7681 202-38 63
info@sick.de www.sick.com
Australia Phone +61 3 9497 4100
+1800 3 3480 2 tollfree
sales@sick.com.au
Austria Phone +43 22 36 62 28 8-0
office@sick.at
Belgium/Luxembourg
Phone +32 2 466 55 66
info@sick.be
Brazil Phone +55 11 3215 4900
sac@sick.com.br
China Phone +852 2763 6966
ghk@sick.com.hk
Czech Republic Phone +420 2 57 91 18 50
sick@sick.cz
Denmark Phone +45 45 82 64 00
sick@sick.dk
Finland Phone +358 9-25 15 800
sick@sick.fi
France Phone +33 1 64 62 35 00
info@sick.fr
Germany Phone +49 211 5301-301
kundenservice@sick.de
Great Britain Phone +44 17 27-83 11 21
info@sick.co.uk
Hungary Phone +361 371 26 80
office@sick.hu
India Phone +91 22 4033 8333
info@sick-india.com
Israel Phone +972 4 999 0590
info@sick-sensors.com
Italy Phone +39 02 27 43 41
info@sick.it
Japan Phone +81 3 3358 1341
support@sick.jp
Netherlands Phone +31 30 229 25 44
info@sick.nl
Norway Phone +47 67 81 50 00
austefjord@sick.no
Poland Phone +48 22 837 40 50
info@sick.pl
Republic of Korea
Phone +82 2 786 6321/4
info@sickkorea.net
Romania Phone +40 356 171 120
office@sick.ro
Russia Phone +7 495 775 05 30
info@sick.ru
Singapore Phone +65 6744 3732
admin@sicksgp.com.sg
Slovenia Phone +386 (0)1-47 69 990
office@sick.si
Spain Phone +34 93 480 31 00
info@sick.es
Sweden Phone +46 8 680 64 50
info@sick.se
Switzerland Phone +41 41 619 29 39
contact@sick.ch
Taiwan Phone +886 2 2375 6288
sales@sick.com.tw
Turkey Phone +90 216 587 7400
info@sick.com.tr
United Arab Emirates
Phone +971 4 8865 878
info@sick.ae
USA Phone +1 (952) 941 6780
info@sickusa.com
More at www.sick.com

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