>Identifyingsolutions

Yourindustryinourfocus

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1 _ 2 0 1 1S I C K ’ S C u S t o m e r m a g a z I n e

Handling,storing,sortingNewsensorandsystemsolutionsintheindustryfocuslogistics Page4to13

PackagingasachallengeIndustryfocuspackaginghighlightsnewtrends Page14to23

TrendsinlogisticsInterviewwithProf.tenHompelofFraunhoferIML Page24

: anwendungen

2 01 2011

LearningfromeachotherDearReaders,

Inthecourseoftheswifteconomicrecovery,wewereableattheendofthe2010fiscalyeartoexceedevenourrecordsalesin2008.Wearedelightedaboutthissteepupturn,foramongourcustomers,too,thingsareimprovingnoticeably.Byadaptingcapacities,weman-agedtorespondtotheirlargenumberoforderswithpromptdeliveries.

Inordertobeabletocontinueprovidingourclientswithahighlevelofservice,wehavenotonlyhiredmanynewemployeesbutalsoalignedourorganization,ourproductrange,andourspectrumofservicesaccordingly,inanevenmorecustomer-orientedway.Thisapproachalsoentailscontinuouslyqualifyingourstafffurther,especiallyinSer-vicesandSales.Inthisway,theygettoknowevenbetterthetasksandsecondaryconditionsofmanydifferentindustrialsectors,devel-opingtogetherwithourcustomersandproductspecialistsproposalsforsolutionsthatarebothtechnicallyandeconomicallyefficient.

Moreover,itisnotonlywewholearnfromourcustomersbuttheyalsolearnfromus.Onpage53,youcanfindoutmoreaboutaccreditedsafetyservicesfromSICK,suchasplantwalk-through.Thisstrategyinvolvesoursafetyexpertscooperatingwithoperatorstodeterminethemajorsafetyaspectsonmachinesandplantsonlocationandtoformulaterecommendationsforeffectivesafetystrategies.

Basedonthe2010readersurvey,youhaveshownusthatyouappreciateSICKinsightverymuchandthatyouwouldenjoyreadingevenmoreaboutourproductsandsolutions.Therefore,wewouldliketothankyouforyouractiveparticipationandpresentyouinthisissuewithmajor-interesttopicssuchastheindustryfocusonlogisticsandonpackaging.BothattheCeMATinHanoverandattheinterpackinDüsseldorfyouwillhaveanopportunitytoexchangeideaswithourindustryspecialistsonthelatesttrendsinyourindustry.Weareconfi-dentthatwewillmanagetofindasolutionforyourtaskaswell,aso-lutionthatprovidesgreataddedvaluetoyourmachinesandfacilities.

Alreadywearelookingforwardverymuchtobeingabletowelcomeyouthereatourexhibitionstandsandwewouldliketowishyouaninspiringread!Yourssincerely,

MarkusVatterMemberoftheExecutiveBoardFinance/HumanResources

: editorial: IndustryFocusLogistics.........................04SwissPostalServicestrustsinautoIDsystem...06Compartmentclear–clearsailingforthepallet...07Safehandlingofcontainersandpallets...............08High-endcamerasystemsatTNTAirHub............09Oslo:Trafficinvoicingvialasermeasurement.....10Sensorformobilerobots.......................................11Automaticreturnsdetectionofprintedproducts....12Collisionpreventionatthequay...........................13

: IndustryFocusPackaging......................14Piracyprotectionforpharmaceuticalindustries....16Battleagainstproductpirates...............................17Sensordesignsforthepackagingindustry..........18SimplywellpackagedwithVISTAL®:W9-3...........19SensorsfromSICKwithIO-Linkinterface............203Dqualitycheckforlidsandcaps........................21PerfectdetectionofpreformsandPETs...............22Automationofwashingfacility..............................23

: Views & VoicesAutonomouscontrolandswarmintelligence.......24SICKaspartnerinteaching...................................26

: applicationsWorkflow-orientedCEmarking..............................27Bookreturnwithoutmomentofshock.................28Luminescencevisionsensorongluepatrol.........29EmptiesreturnstationatMigros..........................30Greenhousefertilizationwithgasanalyzers........31Safetytechnologyin-companytrainingatSEW....32Sensorsforwaferandbiscuitbakingplants........33ControlwithSICK3Dcolorcamera......................34

: technologyIntegratingintelligentlyusingIDpro......................35

: Know-howMutingandpatternrecognition............................36

: ProductsUniversalsolutionsforrotarypathmeasurement...38Codereaderforpharmaceutical,logisticsandautomotiveindustries......................39Laserscannerfeaturingmulti-echotechnology...40MotionControl:monitoringzero-speedsafely.....41UpgradeoftheMLGautomationlightgrid...........42Cylindricalconstructionwithafuture...................42Inoxportfoliocomplemented................................43NewversionsoftheInspectorvisionsensor.......44FlexiLink:networkingsafetycontrollers..............45Leveldetection,plug&play..................................46IMA–inductiveplusanalog..................................46Inductivesensorsforanymachinedesign...........47Motorfeedbackpurelydigital...............................48Safetylaserscannerinminiaturedesign.............49Newforksensor:litheandlissomeandmore.....50Photoelectricsensorfortransparentmaterials...51GasanalyzersystemGMS800–oneforall.........52

: Service & SupportWithaccreditationandatrainedeye....................53

: SICK tour.......................................................54

: SICKinsight[plus]

Automobiledevelopmentunderbamboosandpalms...................................56

: Service.............................................................57

: news

03

Federal President Christian Wulff visits SICK

“I’dhavelikedtobecomeanengineer”AspartofhisinauguralvisittotheGermanfederalstateofBaden-Württemberg,FederalPresidentChristanWulff,togetherwithhiswifeBettinaWulff,formerBaden-WürttembergMinisterPresidentStefanMappusandhiswifeSusanneVerweyen-Mappus,paidavisittoSICKAGinWaldkirchon16December2010.

Federal President Christian Wulff in conversation with Dr. Robert Bauer and Gisela Sick. In the background, on the left, Bettina Wulff and, on the right, Stefan Mappus, former Minister President of the German federal state of Baden-Württemberg

>>FederalPresidentChristianWulffwascapturedbythefascinationofsensorintel-ligence.Duringthetouroftheproductionandfinalassemblyfacilities,hewantedtoknowindetailwhichstepswerenecessarytomanufacturehigh-techandhigh-qualityphotoelectric sensors. He expressed hisinterest and enthusiasm for sensors bysaying:“Iwouldhavelikedtobecomeanengineer.” At his express wish, the tourendedwithavisittotheelectronicstrain-ingworkshopfacility,wherehediscussedwithtrainees.Inthecourseoftheconver-sationswiththepressthatoccurreddur-ingthetour,theFederalPresidentwasvis-iblyenthusiasticaboutthecompanySICK,itsinnovativestrengthandthesenseofto-gethernessamongthestaff,whichhelpedthe company to successfully survive theeconomiccrisis.HeconsidersSICKtobeamong the important factors driving theupturnintheGermaneconomy.

“The visit of the Federal Presidentwasnotonlyagreathonorandrecogni-tionforourcompany;italsoallowedanexchange of views and knowledge in avery pleasant atmosphere,“ Dr. RobertBauer,ChairmanoftheExecutiveBoardofSICKAG,summedupafterwards.

>>Thestudyof“BestPlacestoWork inGermany” for assessing the attractive-ness of employers is carried out by theGreat Place to Work Institute Germanyand Handelsblatt. The participants in-cluded 290 enterprises overall, dividedintofoursizecategories.

top placements confirm SICK as an attractive employerLast fall,onceagain, thegreatvarietyofopportunitiesSICKofferstoitsemployeesand their families found expression in aconvincing,positivevote.Amongallcom-paniesentered,SICKoncemorereacheda secure place in the top 100, securingfifth place among the 19 enterprises in

>> In the last issue of SICKinsight, wequestionedour readersabout thestruc-ture, content, design of our customermagazine.Theresultslookquiterespect-able:SICKinsightgoesdownsowellthatthemajorityofthosesurveyedwouldliketoreadmorethantwoissuesayear.

Inconnectionwith the2010readersurvey,weraffledoffastylishMP3play-er as well as additional Solutions Tourprizes.GüntherOdenthal (on the left inthe photo) from SIVAplan in Troisdorfwasthehappywinnerofthemainprize,whichChristophBrinkmann(ontheright)fromSICKVertriebs-GmbHpresentedtohiminperson.

SICKisatop-rankingemployer–onceagain,thisistheoutcomeofanannu-allyconducted,independent,andnation-wideevaluationofcompanies’jobat-tractiveness.ForthefactthatSICKhasnotonlyreachedthetop100in2011buthasdonesoeveryyearsince2003,thecompanywasawardedthespecialdistinctionof“TrustChampioninGold.”

eighty-seven percent of employees find their workplace great

DistinctioningoldforSICKasanemployer

SICKinsight reader Survey 2010

Andthewinneris…

its size category. A particularly positivenote: Nearly 87 % of employees foundtheirworkplaceatSICKtobeverygood.

SICK–agreatplacetowork!

www.sickinsight.com

01 201104

: IndustryFocusLogIStICS

>> Inmany companies, logistics is thearea with the greatest potential for in-creasing efficiency and reducing costs.As an intralogistics insider and techno-logicalleader,SICKisinnovativeaccord-ingly when it comes to pursuing newpathsintermsofwarehousing,materialshandling,ordistribution.

Solutions for conveyor systems, sorters, industrial trucks, and cranesIncartonconveyortechnology,sensorsfromSICKdetectandclassifyobjectsofthemostdiversesizesandshapesandrecognizeundesiredoutwardbulgesincartons.Thispermits trouble-freestor-age processes, continuous tracking ofcartons,aswellasmaximum through-putratesofsuchfacilities.Reliablepal-let and loaddetection, forwhichSICKsuppliesdifferent approaches to a so-lution, guarantees the highest level ofplantavailabilityandprocessreliability.By means of SICK’s sensor systemsfor volume measurement and objectidentification, sorter systems becomehighly accurate in their sorting, alsoproviding a database for exact invoic-ing. In overhead conveyor systems,sensorsfromSICKensurecollision-freeand space-optimized plant operationswith high sorting quality and continu-ous tracing of goods.With respect to,amongothers, AGVs,mobileassemblyor transport platforms, aswell as ser-vice robots, solutions from SICK pro-vide safety in curves and narrow and

top industry competence combined with broad all-in-one portfolio

SICK–theintralogisticsinsiderForall logisticalandintralogistical industriesandareas,SICKoffersexten-sivelogisticscompetenceandacompleteportfoliofromasinglesourcethatisprobablyunique.

winding courses, optimum speeds forthe highest possible transport perfor-mance,aswellaspositioningandnavi-gationsupport.

In the intralogistics trend: sensor highlights from SICK at the CematAttheCeMAT,SICKpresentsaseriesofin-novativesensorsolutions for intralogisti-calfieldsofapplication.Itishardtoimag-ineintralogisticswithouttoday’svarietyofautomatical identification technologies.WithIDpro,SICKisthefirstmanufacturerto introduceacross-technologyplatformand portfolio strategy for bar code, 2Dcode,andRFID.Onthisbasis,thepresen-tationalsofeaturesconsistentconnectionconcepts for PROFIBUS and EtherCAT.New possibilities for distance measure-ment and positioning, respectively, areofferedby the linearmeasuringsensorsoftheOLM200productfamilywithPRO-FIBUSandtheInspectorP30visionsen-sors.Byusingthesesensors,onemeetsthemostexactingrequirementsonpreci-sion and performance when positioningaisle stackers highly accurately to rackcompartments. The W27 photoelectricsensor permits reliable object detectionevenwithrespecttoirregularshapes.TheS300Minisafetylaserscannerprovidessafety and economic efficiency for pro-tection ofmobile compact vehicles. Thelegal-for-tradeVMS520Sorterforvolumedetection and further innovations com-pletethisyear’stradefairspectrumfromSICKattheCeMAT.

>LOGISTICS

: IndustryFocusLogIStICS

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>> As an international key trade fairfor logistics, the CeMAT is the suit-able platform for demonstrating howefficient, reliable, and sustainableautomation solutions from SICK arefor logistics. At the same time, SICKpresentsitselfasacompetentpartnercoveringtheentirelifecycleofafacility–fromfindingasolutionattheprojectstagetomaintenanceandrepairoffa-cilitiesduringongoingoperations.Andworldwideatthat!

Well prepared for logistical challenges Whether the objective is selecting indi-vidualsensorsorintegrationofcomplexsensor systems or technologies – thelogisticssolutionsfromSICKhavebeenknownintheindustryforyearsfortheirscalabilityandmigrationcapability.Thisgoesbothforsensorapplicationsontheobject, e.g. detecting, identifying, andmeasuring, and for plant-related tasks,e.g. detecting speeds, distances, orien-tations,andoperatingconditions,aswellassafety-capablemonitoring.Withcon-tinuousinnovations,SICKhasadecisiveinfluenceonnewlogisticalconcepts,e.g.

>> Trade fairs, symposiums, seminars,customerandthemedaysofferanoppor-tunity toget talking tousersand trend-setters. To this end,SICKused, amongothers,theairporttradefairinChina,toorganizeawell-attendedcustomerdayinChina on the topic ofwarehousing andmaterialshandlingtechnology.Thehigh-light in theFarEastwaseventually theconfermentoftheAGVSAward2010dur-ingtheCeMATAsiatradefair.Theprize,awarded by an independent selectioncommittee, honors SICK’s contributionto innovative products and solutions intheareaofautonomousguidedvehicles.

AdditionaleventsorganizedbySICKinthefieldoflogisticswere,amongoth-ers, the InnovationsDayLogisticsAuto-mationinGarching,heldatthebuildingsof theTechnicalUniversityofMunich,aseminar dealing with CEP and logisticsatTNT inLiège,andaseriesof furtherevents at customers’ and users’ prem-ises.

Internationality in intralogistics is abig topic forSICK in2011aswell.ThisisdocumentednotonlybyparticipationattheCeMATinHanover,butalsobythecompany’spresenceattradefairsinim-portantglobalregions–includingCeMATRussiaandCeMATBrazil.

Sensor and system solutions for logistics

Efficient,reliable,andsustainable

Logistics happens worldwide

Onlocationinterna-tionallywithexpertise

AttheCeMAT2011,SICKshowsinnovativewaysfortop-rateproductivity,safety,availability,andqualityoflogisticalfacilitiesandprocesses.Thefo-cus ison thekindofscalablesensorandsystemsolutions thatarepos-sibleonlywithwhatprobablyconstitutesthebroadestsensorportfolioforlogistics.

Around the globe, SICK is on theroadasacompetenceproviderandpartnerforsensorandsystemsolu-tionsinlogistics.

withrespecttoautonomousandflexibleshuttlesystems,cellularormodularma-terials handling and modern transportsystems, orminiature vehiclesand ser-vice robots.Moreover, innovations fromSICKarealsoindemandwhenitcomesto stationary or mobile assistance sys-temsforcollisionprevention.

oriented toward sustainability One important yardstick for an innova-tion is – in intralogistics as well – itssustainability. SICK takes this idea intoaccount–fromdevelopmenttoproduc-tion, todistributionandoperationof itsproducts right to the end of their ser-vice life. Manufactured with methodsthat conserve resources and minimizeemissions,smaller,lighter,moreenergy-efficientintheirsystembehavior,easiertorecycleanddispose–thesefeaturesensureefficiencyandanassuredfuturebeyond tomorrow. Solutions from SICKalso help our customers, for example,to control complex sorting facilities orvolume-optimized freighthandling, thuscontributing their share to environmen-tallyfriendlylogistics.

Visit us at the fair:

CeMATinHanover from2to6May2011 Hall27–StandC43

01 201106

: IndustryFocusLogIStICS

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.post.ch

Parcellogistics

>> The increase in reading rates – es-pecially in thecaseofdamaged,dirty,orincompletebarcodes–andoptimizationofsortingprocesseswerethemostimpor-tant goalsbehind themodernization. Forthis purpose, automatical identificationsystemsfromSICKarenowusedinvariousareasof the facility: ICR890camerasys-tems,CLV490barcodescanners,OPS590omniportal code reading system, andVMS410 volumemeasurement systems.TheyensurereliabledetectionofbarcodesandDataMatrixcodesandpermitimagingforautomatedvideocodingaswellasvol-umemeasurementofalltransportedandsortedparcels.

automatical identification in the network – from a single sourceSICK’s MSC800 modular system con-troller helped implement optimum andreliablenetworkingof all individual com-ponents to form complete automaticalidentification solutions. Moreover, for

transferringtheprocessdata,thespecial-ists from SICKworked together with thePostal Services team in developing anEthernet Powerlink interface, which metthe system requirements for real-timecommunication between sorter controlandtheautomaticalidentificationsystem.Inongoingoperations,SICKalsoprovidesfor remote monitoring and diagnosis ofthe camera systems using the RDT400software tool, whichmade it possible tofurtheroptimizesystemavailability.

SICK recognized as a CeP expertWhen it came to awarding the project,SICKconvincedthoseinchargeatSwissPostal Services with technical expertisein the field of identification and volumemeasurement for CEP (courier, expressand parcel services) sorting facilities aswell as with its extensive range of ser-vices furnished by contact persons di-rectly on location. Due to the completeproduct portfolio with laser scanners,

volumemeasurementsystems,andcam-eratechnology, itwaspossibletomatchthesystemsindividuallywiththerequire-mentsofSwissPostalServices.Thiswascrowned by success: “We managed toachievea reductionof ‘no reads’byap-prox.twopercent,whichinlightofmanualfollow-upcodingentailsa30-percentsav-ingsinrequiredworkingtime,”saysJosefMeierhans,ManagerTechnologyServicesat Swiss Postal Services and jointly re-sponsible for theHärkingen, Frauenfeld,and Daillens sites. “Evaluation quality,positioning,andmonitoringoftheparcelsonthetippingtrayswasoptimizedaswellbymeansofthecamerasystems.Withre-specttodataintegrationandtheproblemof interfaces, we also worked togetherverywellandinagoal-orientedwaywiththeteamfromSICK,”JosefMeierhansof-fersaverypositiveassessmentnotonlyofthesensorandsystemtechnologybutalsooftheservicesprovidedbySICK.

SwissPostal Serviceshasmodernized the conveyor and sort-ingfacilitiesatitsthreeparcelcentersinHärkingen,Frauenfeld,andDaillenswithefficientoptical readingsystemsfor1Dand2DcodesfromSICK.

Swiss Postal Services trusts in automatical identification system from SICK

ForparcellogisticswithSwissprecision

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TheS100ProfessionalcompactlaserscannerfromSICKisper-fect for checkingoccupancyof storagebays inmultiple-depthstoragemodelsanddifferentstorageaids.Viastore,anintralo-gisticssystemshouse,viewsthingspreciselythatwayaswell.

>> This assessment is based on thepositiveexperiencesgatheredusingthelaserscannerinvarioushigh-baystorage

projects. Featuring a scanning angle of270°,switchablemonitoringfields,andahigh levelof integrationease, thede-

vice minimizes equipment, installation,andcommissioningexpensesdecisively.

thinking “outside the box”InoneoftheViastoreprojects,thespe-cificissuewasstoringandretrievingdif-ferent storage aids at multiple depthsusingaislestackers. “Inorder to imple-ment this taskwith theknownpossiblesolutions,i.e.withphotoelectricsensors,wewouldhaverequiredatleast17sen-sors,” reports Ralf Link, Team Leaderviasprint/Conversion at Viastore Sys-temsGmbH.“Ontopofthat,installation,adjustment, and commissioning wouldhavetakenseveraldays.”

By using the S100 Professional la-ser scanners, Viastore opted for a sig-nificantlymoreefficientandeconomicalsolution.“Withitsupto16fieldsets,thesensor can detect the entire compart-ment depths to be occupied plus adja-cent storage bays,” explains Ralf Link.“Thus, through the simple field defini-tion,onecannotonlyascertainwhetherthe target storage location is occupiedbut also whether the adjacent storagelocation is properly filled or whether acollisionmightoccur.”

accurate with every scanThe Viastore project leader has identi-fiedanadditionalbenefitfortheongoingplantoperations:“Especiallyinthecaseofdouble-depthstorageanduseofsen-sortechnologywithsimplecheckpoints,a few isolated detection problemsemerge,sinceduetotheflexionandtor-sionoftheloadhandlingdevice,photo-electricsensorsmaymissthetarget,asitwere.”Thisproblemdoesnotemergewhen using the laser scanner and itstwo-dimensionalfieldmonitoring.“Here,everyscanhitsthemark,”saysRalfLink.

Compartment clear – clear sailing for the pallet

Multiple-depthcheckforcompartmentoccupancy

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.viastore.de

Using the S100 laser scanner from SICK, one can detect the entire compartment depth, even of adjacent storage bays

Checkingforoccupancyofstoragebays

01 201108

: IndustryFocusLogIStICS Safetravelpathmonitoring

At King Shaka International Airport in Durban, South Africa,S3000 safety laser scannersmonitor the travel paths of rail-mountedheavy-dutytransportvehiclesforairfreight.

>> Theprojectwas realizedby ICMAir-port Technics GmbH, Viernheim, whichbelongstotheUnitechnikGroup.Theen-terprise deals with the implementationof semi- and fully automated transportsolutionsintheairportsphere.

Collision protection for fast 7-tonnersThe rail-mounted vehicles are so-calledETVs (elevator transfer vehicles). Inte-gratedintoanoverallmaterialshandlingsolution,thesehoistingvehiclestakeonthetransportofairfreightcontainersandpallets.Speedsofupto2.5m/sandagrossvehicleweightofnearlyseventonsdemanded a protection solution that

wouldnotimpairtheavailabilityandper-formanceofthetransportvehiclesatthesametime.

S3000: protective requirement fulfilled, availability ensured In choosing the S3000 safety laserscanners,Unitechnikhasoptedfortheoptimumprotectivesolution–optimumbecause it is non-contact and flexiblyprogrammable. One scanner each isinstalledforeveryvehicleanddirectionoftravel.Useoftheparameterizedfourwarning and four protective fields andtheir switching depending on the cur-rentspeedguaranteesthehighestpos-

travel path monitoring for airfreight transport vehicles

Safehandlingofcontainersandpallets

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.icm-airtec.com

The S3000 safety laser scanner from SICK (top right) offers the highest possible safety when monitoring the travel paths (bottom right) of rail-mounted airfreight transport vehicles (image on the left)

sible level of protection in every travelsituation.Whendetecting an obstacle,the scanner signals slowdown the ve-hicle to creep speed, stopping it at adefineddistance ifnecessary.Assoonastheobstaclenolongeroccupiesthetravelpath,thetransportvehiclestartsmovingagain.

Inthisway,theS3000safetylaserscan-nersprovidenotonlypersonalandcol-lision protection in accordance withguidelines and standards but also thedesired availability and performance ofthetransportvehicles.

:IndustryFocusLogIStICSImage-basedbarcodeidentification

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TNTExpresshasmodernizedthehigh-performancedistributioncen-terattheinternationalairporthubofLiège,andindoingso,equippedtheconveyingandsortingfacilityoftheairhubwith25newbarcodereadingstationsthatareendowedwithimage-basedICR890fromSICK–withoutinterruptionofongoingoperations.

>> The air hub operated by TNT in theBelgian city of Liège is one of thema-jor hubs for airfreight on the Europeanmainland. Every night, about 450met-ric tonsof parcels, courier andexpressconsignments are delivered and trans-shipped,which equals close to 15,000parcelorgoodsconsignments.

Ident tunnel engineered by SICKThenewhigh-endcamerasystemswereintegrated into bar code tunnels indi-vidually constructed by SICK and theydetect1Dand2Dcodesonfivesidesofpackaged goods. The scanner tunnelsconsist of robust aluminum structuresequipped with three image-based ICR890high-end readingsystems.Eachofthemfeaturesreal-timefocuscontrol,ahigh-performancedecoder,aswellasadigitalzoomfunction.

reading performance improved significantlySince the old system caused readingfailuresofmorethansixpercent,itwas

particularlyimportanttoTNTtoincreasethereadingratewithdamaged,contami-nated, or incomplete bar codes. It waspossible to achieve this already whenimplementingthecomparativesystem.

Smooth conversion during ongoing operations Actually,theteamfromSICKhadamaxi-mumofthreedaysavailabletoinstallonecompletereadingunit.Throughstringentplanning and implementation on thepart of SICK, it was possible to reduceinstallationtimeofacompletesystemtotwodays–successfulimplementationofthe25entirelynewbarcodereadingsta-tions at the Liège air hubwas finishedwithinamerethreeweeks.

top grades from tntAlainLamarche,SystemManagerLogis-ticsatTNTLiège,believesthathisdeci-siononthenewtechnologypartnerSICKhasbeenconfirmed.“Thecompletesolu-tionfromasinglesourceincludessimpleintegrationandexpandabilitytoOCRand

High-end camera systems from SICK at tnt air Hub in Liège

Nonstopidentification–integrationduringnonstopoperation

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.tnt.com

The bar code reading stations from SICK are equipped with image-based ICR890 code readers

video-codingapplications,aswellastheoption of also measuring volumes, lowmaintenance requirements and mini-mumoperatingcosts.Wewereparticu-larly impressedby thehigh reliabilityofthedatadetectionof1Dand2Dcodesby the ICR890 camera scanner dur-ing running operation,” Alain Lamarchesumsup. “Inaddition,SICKoffersusareallyhighlevelofsecurityanddepend-abilitybymeansoftheir24/7hotline.”

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01� 201110

: IndustryFocusLOGISTICS

The�Norwegian�capital�of�Oslo�has�one�of�the�world’s�most� in-novative�toll�systems.�The�central�component�of�the�29�munici-pal�toll�stations�overall�are�LMS211�laser�measurement�sensors�from� SICK.� They� detect� the� vehicles� on� all� lanes,� at� different�speeds�–�and�no�matter�what�the�weather.�

>>� The� features� making� this� possible�are� the�LMS211’s�proven�detecting� la-ser� measurement� technology� with� its�scanning�angle�of�90°,�intelligent�eval-uation�processes� that�produce� reliable�measuring�values�even�in�snowfall,�rain,�and� fog,� as� well� as� the� weatherproof�and�heated�outdoor�housing�with�IP�67�enclosure�rating.�

“Non-contact toll detection” lets traffic and …The�Oslo�Toll�Ring�System�is�an�entirely�electronic� toll� detection� system� –� for�any� type� of� vehicle� and� for� single-lane�and� multiple-lane� operation.� Another�special�feature�is�that�in�many�respects�–�among�other�things,�on�bridges,�traffic�

light�systems,�extra�wide�lanes,�or�spe-cial�aspects�of�residential�development�–�it�can�be�adapted�to�city�planning�and�road� construction� characteristics� as�well�as�to�traffic-related�conditions.

In� Oslo,� entry� into� the� municipal�area� is� monitored� at� 29� toll� stations�overall.� The� system�configuration�used�in� each� of� these� stations� consists� of�one�front�and�one�rear�camera�system�each�with�infrared�light�for�photograph-ing�vehicles,�as�well�as�an�LMS�unit� in�between� connected� to� an� antenna� for�vehicle� identification.� The� LMS� unit�consists�of�two�parallel�systems�aligned�across� the� road,� which� detect� the� ge-ometry�and�speed�of�the�vehicles.�If�the�antenna�detects�a�toll�transponder�in�a�

Traffic invoicing via laser measurement

Oslo:�Municipal�toll�system,��“state�of�the�art”�

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

passenger�car�or�an�on-board�unit�(OBU)�in�the�case�of�trucks,�the�toll�is�charged�automatically� for� these� vehicles.� If� the�antenna�does�not� receive�a�signal�dur-ing� passage,� the� respective� vehicle� is�photographed�from�the�front�and�back,�the� vehicle� owner� determined� via� the�license�plate,�and�the�toll�invoice�deliv-ered�via�mail.�

… toll revenues flowSince�commissioning,�the�Oslo�Toll�Ring�System�has� distinguished� itself� due� to�high�availability�and�accuracy.�By�means�of� this�system,�an�average�of�350,000�vehicles�a�day�can�be�detected.�There-fore,�in�Oslo�two�things�are�flowing:�both�traffic�and�toll�revenues.�

The vehicles entering Oslo’s city zone are detected by LMS211s

Vehicle�detection�in�electronic�toll�systems + More�information��on�page�13

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Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.kokeisl.net

S300 CMS safety laser scanners from SICK with integratednavigationsupportprovidenotonlysafetyonthetravelpathsofKOKEISL’smobile picking robot but also assist with navigationandpositioning.

>> Personal protection and navigationsupport–theobjectiveofthesafetylaserscanners with CMS function from SICKis theconcurrenthandlingofprotectiveand navigation-supporting functions bya single sensor. In this connection, thedevices, such as the S300 CMS usedon aKOKEISL picking robot automatedguidedvehicle,utilizethemeasurementdataaccumulatingduringsafety-capabledetectionofspacecontours.

navigation without “artificial” landmarks Inordertocarryoutautonomoustrans-port tasks in complex environments,the picking robot must move quicklyandflexiblythroughthemodernproduc-tion facility, i.e. navigating freely andadaptingtorapidlychangingprocessesand conditions. Based on the contour

measuring S300 CMS safety laserscanners from SICK, BlueBotics devel-oped the ANT (autonomous navigationtechnology) navigation system used intheKOKEISLpickingrobot.Tonavigateautonomously,thevehiclerequiresnei-therpre-definedroutesnorspecialland-markssuchasinductiveor,respective-ly,magneticstrips,points,reflectors,orthelikeinthebuilding.

Safely on the move in any situation and position Assisted by the measured value tele-grams of the S300 CMS, the naviga-tionprocessoronthevehicleconstantlychecks the environment,measures thedistances to potential obstacles, andknowsatany timewhere thevehicle islocated. In doing so, it recognizes,withthehelpofcontourmeasurementbythe

Personal protection and navigation assistance for mobile robots

Onesensor–twofunctions

Illustration: The S300 CMS safety laser scanners detect natural and artificial landmarks in the environment

S300CMSandthecorrespondingevalu-ation in the navigation system, any ob-jectsorworkingpersons,eitherstoppingoravoidingthemreliably.

The bottom line: AGVs such as theKOKEISL picking robot do not requireanyadditionalsensortechnologytosup-porttheirnavigationsystemiftheyhavesafety laser scanners from SICK withCMS functionality on board. Use of the“2 in 1” designminimizes the cost forcomponentsandwiring,andinaddition,often valuable because scarce installa-tionspaceissaved.Asaresult,onecanreachamaximumamountofeconomicandcostefficiency.

Automaticguidedsystems

01 201112

: IndustryFocusLogIStICS

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.isi-automation.comwww.gwbi.de

Image-basedbarcodeidentification

>>Here,theimage-basedICR850codereaderliterallyplaysthe“deciding”role.Thelinecameraidentifiesrandomlyori-entedandpositioned1Dand2Dcodeson greeting cards, calendars, and giftbooks in different sizes. Sorting theprinted products requires high process-ing speeds that could be achieved bymeansofintegratingtheICR850directlyintothemachine’sLAN.

Sorting challenge: quantities, compo-sition, and product formats indefiniteOneofGermany’sleadingproducersofgreetingcards,GrafikWerkstattBiele-feld,manufactureshigh-quality graph-ics and printed text products. Theystand out due to their atmosphericimagery, philosophical and expressivetexts, much care for detail in design,and great appreciation of quality inmanufacturing.Productsnotsold,e.g.after Christmas or at the end of theseason,aretakenbackbyGrafikWerk-stattBielefeld. In the returnsprocess,

High-speed identification with direct ethernet integration

AutomaticreturnsdetectionofprintedproductsForGrafikWerkstattBielefeld, ISI Automationhasdevelopedahigh-performancereturnssortingsystemfeaturing ISIPlus® thatwasequipped completelywith code readers, distance sensors,andphotoelectricsensorsfromSICK.

thechallengeistotakeinquicklylargequantitiesofproductsvaryingwidelyinsize,color,andmaterial.

Versatile identification improves returns detection In order to increase returns perfor-mance,thepeopleatGrafikWerkstattopted foraspecialmachinewith inte-gratedconveyor,control,andoperatingtechnology from ISI Automation. Theimage-based ICR850 code reader isused in themachine to sort theprod-ucts by means of their 1D and 2Dcodes.ADT20distancesensor,andaphotoelectricsensor fromSICKtriggerthe code reader, which then reliablyidentifies thearticlespassing through–despitedifferentproductheightsandtherandompositionsofthecodes.Themachine’s ISIPlus® measuring systemsynchronizes the processing stepsand– due to direct integration of theICR850intotheEthernetLAN– isca-pable of checking the detected prod-

ucts forplausibility in real timewithinthe ISIPlus® measuring system, thuscomparingthereturns.Productswhosecodesarecoveredaredetectedmanu-ally afterwards using cordless hand-heldscannersfromSICK.

evidence of performance and overall package were decisive Prior to using the products from SICKin the special machine, ISI Automationconductedextensiveperformancetests.Thesewerepassedsuccessfully.Thisre-sult,theavailabilityfromasinglesource,as well as the commitment of SICK’sstaff in planning the project eventuallymadeuptheoverallpackagethatwasre-ceivedverypositivelyatISIAutomation.

Reinhard Becker, Grafik Werkstatt; Frank Marek, ISI Automation; Michael Gulsch, PxC Phoenix; Helmut Wieneke, SVD, and Wolfgang Störmer, Grafik Werkstatt (from left to right)

: IndustryFocusLOGISTICS

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Further product information:www.mysick.com/applicationsMore about the customer:www.libraterminais.com.br

Collision prevention

>> LMS laser measurement sensors from SICK do an excellent job, among other things, preventing collisions on hundreds of installations at all of the major container ports worldwide. In-creasingly, the focus of terminal opera-tors such as Libra Terminais, but also of terminal suppliers, shipping com-panies, and insurance companies, is on preventing accidental collisions of crane booms and the superstructures of ships via sensors. The reason: Insur-ance statistics confirm that damage costs as well as follow-up expenses in the so-called ship-to-shore (STS) area can be eliminated almost entirely by suitable electronic sensor solutions.

Libra Terminais relies on efficient and safe terminal facilities Together with two other terminals in Bra-zil, Libra Terminais belongs to Grupo Li-bra, one of largest port operators and lo-gistics enterprises active in the nation’s

Collision prevention at the quay

No chance for crane crashes

When cranes collide with ship superstructures, the consequence may be damages in the millions of dollars. In order to prevent these, the people at Libra Terminais in Brazil rely on laser mea-surement technology from SICK as anti-collision sensors.

foreign trade. Libra moves approx. 16 % of all containers in Brazilian ports, for in-stance, at the Libra Terminais Terminal in Santos. Few months ago, two new STS cranes from ZPMC, a Chinese manu-facturer, were put into operation here – equipped with LMS laser measure-ment sensors for collision prevention. “In 2011, we will – just in time for the 15th company anniversary – also retrofit the existing STS cranes from wire cable systems to LMS, because they provide the required safety and thus represent a lasting investment with a guaranteed future,” says Roberto Lopes, General Di-rector from Libra Terminais in Santos. In addition, Libra Terminais is planning to use intelligent laser measurement sen-sors to modernize the other lifting vehi-cles and cranes, such as reach stackers, and RTGs, safely and reliably for con-tainer handling in the container stack area whose functionality is assured in the future.

Laser measurement technology for ports and terminals: precise, reliable, and extremely weather-resistant.Currently, SICK offers various laser mea-surement sensors for STS collision pre-vention. The LMS211 has been tried and tested for many years in several thou-sands of installations around the globe. The application experience gathered us-ing this product family and further tech-nological refinement have resulted in the development of a new laser measurement sensor, the LMS511. For port and termi-nal applications, e.g. positioning, profiling, distance measurement, and collision pre-vention on cranes, crane booms, straddle and van carriers, gantries and AGVs, the enhanced range and optimized detection performance under extreme weather con-ditions are the most important improve-ments of the new LMS500 family.

LMS laser measurement sensors from SICK – the reliable anti-collision solution for ports and terminals.

+ More information on page 10

01 2011

>PACKAGING

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: IndustryFocusPaCKagIng

>> Increasingly, consumers wish toselect more target group orientedproductsfromasteadilyincreasingas-sortment. In this context, in additionto attractive price, individual designor environmentally suitable packagingdetermine their choices. Other buyingstrata concentrate their attention onpackage size, simple preparation orhandling,aswellastherecyclabilityofthepackaging.Retailers,on theotherhand,wishtobeabletotransporttheproductssafely,stowthemawayorre-arrange themquickly, aswell asposi-tiontheminappealingways.Therefore,producersveryrarelymanagewithonlyfewpackagingsizesorfinalpackagingformats. The most common scenariois plants that package even smallerbatch sizes in increasingly more pro-ductive and flexible ways without ex-tensivechange-overtimes–anddoingsoinlightofpackagesdesignedforthe

Sensor technology in packaging machines – flexible and fast

NewpackagingneededThedemographictransitioninindustrialsocieties,smallerhouseholds,andever-acceleratingproductlifecyclesarechangingthedemandforfood,con-sumergoods,beverages,andcosmetics.Thisconfrontsproducersandplantengineerswithnewchallenges.

mostdiverseproductshapes,suchasbags,cups,boxes, trays, tubes,glass-es, wraparound packs or blisters, allthe way to folding cartons or thermo-formedpacks.

meeting new requirementsThis so-called shelf ready packaging(SRP) is currently changing both pro-duction and plant design as well asautomationtechnology.Inthiscontext,flexibilityandproductivityarethemostimportant features that distinguishmodern packaging machines andplants. Playing an important role inthis,sensortechnologyischargedwithsupporting automation technology.SICKofferssensorsinmodulardesignthatcanbeadaptedquicklytoproduc-ers’ new requirements. They are easyto access during malfunctions, avail-able worldwide, and thus keep down-timesasshortaspossible.

: IndustryFocusPaCKagIng

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>> Following the motto of “Packagingdiscusses trends,” last October morethan 60 customers, researchers fromDeutschesVerpackungsinstitutdvi(Ger-man Packaging Institute), and productmanagers from SICK talked about newchallenges and technological trends inthefieldofpackaging.Forthefirsttime,machinebuildersfromthepackagingin-dustry and brand name producersmetatSICK’sCustomerCenter inWaldkirchtoexchangeideas.Theeventwillbecon-tinuedthisyear.

SICK at the interpackAdditional information on this topicwillbe available at the interpack trade fairinDüsseldorfinHall06,StandC01.Ina trade fairmodel of a standard pack-agingmachine by Somic, one can viewmachinemodules, controllersandvisu-alization from Schneider Electric/ELAUinstalled together with sensor technol-ogy from SICK. The modular mecha-tronic system, comprised of software,electronics, and mechanics, provides

recognizing trends in time

Packaging–hiddenchampioninmarketingFormanufacturersofmachines,topflexibilityinthepackagingfieldmeansstructuringtheirpackagingmachinesasmuchaspossibleincost-effectiveandmodularways,enabling theequipment tocopewithanychallengeonlocation.SICKsupportstheminthisendeavorwithnewsensors.

Newpackagesrequiregreateraccu-racyandfasterdetectionbysensorsin soft, smooth, reflective, or mattsurfaces just thesameas in trans-parentpackages.

nearlyunlimitedtechnicalpossibilitiestoreact quickly and reliably to customers’wishes.

What SICK sensors stand for In this connection, sensors from SICKstand for robust detection (WTB4), forpreventivemaintenance (WL4G), for re-duceddowntimes(WTB12),andforpro-cessreliability(LUT9).Themeasuredval-uesareindicatedonanIPCofSchneiderElectric/ELAU, the company that alsosupplied thedecentralizedplug-indriveandcontroltechnology.

>> Moreover, these packages must besorted carefully, filled accurately, andguidedwithoutscratching.Thisrequiresa measuring technology that in addi-tion tohighmeasuringaccuracy isalsocapableofquicklydetectingandfurtherprocessingthemeasuredvalues.Repeataccuracy in the measuring process iscrucial for theaccuratecuttingofpack-agingmaterial–themoreprecisely,thelesswasteaccumulates.Thissavesen-ergyandtime.

The great variety of packagingmen-tionedabovealsoresultsinsmallerbatchsizesandmorefrequentchangesofcon-tainers. This costs changeover timeandmeansadditionaltoolingprocedurespre-ponderatingintermsoftheavailabilityoffilling and packaging plants. Intelligentsensorscanbeadjustedtotherespectiveproduction conditions using preset andtaught-inparameters.AtSICK,a specialASIC building block networks the intelli-gentsensorswithallofthemajorfieldbussystemswithoutany interfaceproblems.Whenchangingformats,allittakestoad-justthesensorstonewcontainershapes,sizes, or colors from themaster controlsystemispushingabutton.

Challenges for sensor producers

Thecalculationisworkingout

Visit us at the fair:

interpackinDüsseldorf from12to18May2011 Hall06–StandC01

Packaging specialists convened in Waldkirch

01 201116

: IndustryFocusPaCKagIng Anti-counterfeiting

Furtherproductinformation:www.mysick.com/applicationsMoreinformationaboutEFPIA:www.efpia.org

>> Looking at recent developments inanti-counterfeiting such as pilot projectsinSwedenfromEFPIAandnewlegislationinTurkey,FranceandBrazil,itisexpectedthatEuropewillgofor2DDataMatrixcodetechnologyforserialization.AllspecialistsagreethatthequestionisnotIFEuropewillchoosethe2DDataMatrixcodetechnol-ogybutWHENEuropewillcomeupwithanewlegislation.Lookingatthepharmaceu-ticalpackageproposals for theEuropeanCommission,apackageofsafetyfeaturesis proposed. Overt and covert features,individual product codes (2D codes) andsealswhichrevealanyopeningofthepackshallprotectthelegalsupplychainagainstcounterfeitedmedicines.

If you have a need to detect safetyfeatures,sealsorserialized2DDataMa-trix codes it is important that you usehigh-performing and reliable systems.You can implement the most powerful“Track&Trace-software”,butwhenyourreader does not read the 2D codes oryoursensorsarenotdetectingtheseals,thiswillhaveanegativeinfluenceontheproductivityofyourpackagingline.

Counterfeitmedicines,afast-growingproblemworldwide

Sensors from SICK offer added value through reliable detection of 2D Data Matrix codes

Counterfeitingmedicinesisagloballywidespreadandfast-grow-ingproblem.DrivenbytheWorldHealthOrganisation(WHO),Eu-ropeancommission,FDA(FoodandDrugAdministration),EFPIA(European Federation of Pharmaceutical Industries and Asso-ciations)andothers,anti-counterfeitingmeasuresarebeingdis-cussed,testedandimplemented.Allofthemhaveonethingincommon:theserializationonthepackagelevel.

This iswhere the 2D code reader andsensors from SICK have their addedvalue.Yearsofexperience inR&Dandproduction as well as experience inmanyotherindustrieshavemadeSICKsolutionsreliable,fast,robustandeasytouse.Additionally,SICKcanofferyou

a service covering the lifetime of yourreaders and sensors, from consultingtoservice.Withaworldwidenetworkofmorethen50subsidiarieswecansup-portyouatallyourinternationalproduc-tionlocations.

With an extended expertise inbar code reading, RFID, vision systemsandautomationsensors,SICKisyourin-ternationalpartnerconcerningyouranti-counterfeitingchallenges.

barcodereading

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By now, pirated products often are so perfect that on the outside they can hardly be distinguished from the original. Counterfeit-proof marking of products, components, and spare parts protects machine and plant builders from harm. The rule is: The more complicated a marking, the safer is the system.

>> According to the VDMA (German En-gineering Federation), pirated products and product theft cause annual sales losses in German machine and plant construction amounting to 6.4 billion euros. Meanwhile, two thirds of compa-nies manufacturing investment goods are reportedly affected by the issue of illegal copies. The problem in this: In addition to the financial damage, the companies’ reputation is also at stake. Therefore, protection from forgers and product piracy ought to be part of qual-ity assurance.

By means of a multi-stage protec-tive barrier comprised of safety marks, companies can protect their products, components, and spare parts. The cru-cial goal: Keep expenses for verification as low as possible and the effort for the plagiarist as high as possible. At the same time, all measures against piracy ought to be integrated into the entire product life cycle, with the safety guide-lines also practiced and internalized in the company.

At the lowest safety level, one can use safety marks such as holograms and safety labels. The devices serv-ing for detection are sensors or cam-era systems that recognize colors, structures, and shapes. A combina-tion of safety marks applied openly and concealed offers a higher safety level. Here, the products can also be marked with UV color pigments that sensors specifically developed for this purpose identify reliably. With SICK’s luminescence scale, for instance, one can define and apply the desired pig-ment proportion even as a package is

designed. Subsequently, in the packag-ing line, luminescence sensors check for presence of the markers.

The top safety level combines tech-nical and organizational features. With a randomly generated data matrix code and an archived serial number, one can mark products, packages, and spare parts unmistakably. Every code is unambiguous worldwide. If required, customs or service staff can read out the secret manufacturer’s information

Battle against product pirates

Quality assurance does not stop at factory gate

Further product information:www.mysick.com/applicationsMore information about VDMA:www.vdma.org

using the mobile IT4820i or IT4600 2D hand-held scanners and compare it with the database. Certainly, in terms of packaging, this involves a change: Instead of pallets, individual products now require labeling and registering. At cycle times of 300 to 400 units a minute, this is a specialty of the image-based LECTOR®620 code reader. How-ever, if all safety marks are matched perfectly to the demands, product pirates have a difficult time imitating originals.

A luminescence sensor from SICK checks for presence of a marking in a packaging line

01 201118

: IndustryFocusPaCKagIng Hygienicdesign

Oneof the great challenges facedby the food industry is theconstantlyincreasingdemandonthepartofmajorretailchainstoachieve longerbest-beforedates forpackaged foods. Inor-dertoattainthisgoal,themicrobiologicalcontaminationofthepackagedfooditemmustbereduced,whichhasadirectimpactonthepackagingprocesses,cleaningprocesses,andmachinedesign. At the same time, the permanently mounting pricingpressureonfoodandbeverageproducersrequiresconsiderablyfaster set-up times when changing over varieties or packagesizesaswellashighercyclespeedsofthepackagingfacilities.

>>Anessentialkeytobeingabletomeetboth of these challenges at the sametime is fine-tuned,modernsensortech-nologythatsetsnewhygienestandardsand features robust electronics as wellas more efficient communication solu-tions. This becomes possible by fusingtheclassicrequirementspheresoffacto-ryautomationandprocessautomation.In this connection, process automationcontributestheclassicruggedmaterialssuch as stainless steel,with high stan-dards regarding toughness, the familiarhygienic certificates for theprocessas-

pectsuchasEHEDG,aswellastheneedforoutputsignalsthatgobeyondamerebinary signal. From factory automationcomethe typicaldemands forminiatur-ized construction sizes, simple deviceselection,extremelyeasycommissioningandoperation,veryfastresponsetimesof the sensor, remote parameterizationplus standards of leak tightness in ac-cordance with IP 69K and cleanabilityofthehousingaccordingtoECOLABandDiverseystandards.

Thus,with respect to thenew fam-ily of W4S-3 Inox photoelectric sen-

sors,SICKreliesnotonlyonastainlesssteelhousingmadeof316Lsteel thatfeatures a continuous and extremelysmooth surface due to production us-ing the MIM method (metal injectionmolding). The company also appliesseveral innovations to comply with anIP69Kenclosureratingandguaranteesoptimum cleanability throughout evenwithaggressivecleaningagents.Forex-ample,thecontrolpanelisnotmadeofplasticasiscommon;instead,thesen-sor has a laser-welded stainless-steelmembrane and is thus literally fusedwith the stainless-steel housing. Dueto the “snap-action” effect of the sen-sor,atactilefeedbackoftheoperatingprocedure is provided in an ideal way.Thefrontscreenofthesensorfeaturesspecial quartz coating and is fittedinto the housing with high precision.The coating and the special gluing ofthefrontscreenresult instabilityevenagainst 30-percent hydrogen peroxide.Bymeans of the efficient teach-in op-tionandautomaticswitchingthresholdadjustment, the sensor also sets newstandards in detecting transparent ob-jects, which increases the availabilityoffillingmachinesandpackagingfacili-ties.Thesensorhasthecommonclean-ing certificates such as EHEDG, ECO-LAB,andDiversey.

Thus, the reduction ofmicrobiologi-cal contamination can be achieved us-ing sensors constructed accordingly,suchastheW4S-3InoxortheLFPlevelsensor. However, one can improve theshorteningofcommissioningprocesses,cycleand set-up timeseven further: byrealizing the sensory functions in a co-ordinatedwayfromasinglesourcewithcontinuous operating, connecting, andcommunicationdesigns.

For this reason, SICK has been ex-tending its rangeofsensors formeasur-ingquantitiessuchaslevel,pressure,andtemperatureforyearsinordertobeabletooffermanufacturersoffillingmachinesand packaging facilities in particular acomprehensive range that allows usingsynergy potentials in construction, com-missioning,andeverydayoperations.

Food neatly packaged

Newsensordesignsforthepackaging industry

Sensor technology from SICK sets new hygiene standards

: IndustryFocusPACKAGINGSmall photoelectric sensors

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Food neatly packaged

New sensor designs for the packaging industry

Performance in the extremely robust VISTAL® housing as well as a unique mounting variability make the new family of W9-3 photoelectric sensors the perfect solution for the high demands on ruggedness, and application variety in the pack-aging machine.

>> Not made of metal and yet nearly as robust as steel – VISTAL®, the highly rugged housing of the W9-3 shows what is possible in plastic housings when it comes to stability and leak tightness. With this housing, the sensors achieve a ruggedness that assures users of first-rate availability even in a harsh operating environment.

Unlimited mounting options Just as unprecedented as the rugged-ness is the great variety of mounting options. The devices are available as de-sired with M3 or M4 hole pattern. In ad-dition, the complementary slotted hole design provides even more flexibility con-cerning sensor integration.

Performance and variabilityThe refined chip technology in connec-tion with the powerful PinPoint LED, the photoelectric proximity sensor with a second emitter LED for the best pos-sible background suppression, the auto-collimation-based photoelectric sensor, as well as the glass photoelectric sen-sor with automatic switching threshold adjustment are other features worth

Top grades for ruggedness, performance, and variability

Simply well packaged with VISTAL®: W9-3

Further product information:www.mysick.com/products

Further product information:www.mysick.com/applications

The hygienic LFP level sensor combines, in an exemplary way, the spheres of fac-tory and process automation. The sen-sor, measuring only 54 mm in diameter, works according to the principle of guid-ed radar (time domain reflectometry), which makes it nearly independent of the properties of the fluid to be mea-sured and thus obviates the need for re-parameterization when the composi-tion of the fluid to be measured changes. Moreover, it features at the same time an analog output signal and two switch-ing points, which permits the realization of efficient control concepts using a re-duced number of sensors and therefore less cleaning effort. In addition, the LFP as well as SICK’s photoelectric sensors have IO-Link, a simple communication protocol independent of the manufac-turer, which renders remote parameter-ization and error diagnosis far more ef-ficient, without displaying the complexity setbacks of existing bus systems. Similar to the W4S-3, the LFP is made of 316L stainless steel and features an IP 69K enclosure rating as well as the common hygiene certificates. The use of a mea-suring method following state-of-the-art technology allows standardization to one device family, reducing restrictions con-cerning installation requirements.

Thus, it is possible to meet the cur-rent challenges on packaging and filling processes using a new generation of sensor technology that pursues a holis-tic approach. In this connection – follow-ing the hybrid field of application in the packaging industry – the classic advan-tages of factory automation and process automation are merged. The essential point in this is reduced complexity and minimized maintenance effort, without having to compromise on ruggedness and hygienic suitability.

highlighting. The device is convincing in terms of performance and variability in order to actually solve any application in the packaging process.

The W9-3 from SICK features varied options for mounting

01 201120

: IndustryFocusPaCKagIng IO-Linktechnology

Furtherproductinformation:www.mysick.com/applications

>>With IO-Link, industryhascreatedastandardthatisvaliduniversallyforsen-sorsandactuators inthefield.Athree-core unshielded cable connects thesensors to the automation systems. Bymeansofadownwardcompatible inter-face,onecantransmitalloftheconfigu-rationdatatothesensor,makingitpos-sibletoretrofitevenoldermachineswiththe latestsensors.SICKhasdevelopedan ASIC module that evaluates differ-entstatesandmeasuringvaluesof thesensorandtransfersthemtothemastercontrol system. Function blocks for the

programmingtoolsfromSiemens,BoschRexroth, Schneider Electric, and Beck-hoffsupporttheprogrammerinadaptingtheintelligentsensors.

Usingtheeasyaccesstothemeasur-ing values and parameters thus allowsteaching in optical sensors specificallywithrespecttonewproducts.Inthisway,the sensor can distinguish packagesin different sizes, colors, and shapes.During commissioning, it is possible toteach-inandsavealloftherelevantdataforeachproduct individually. Inproduc-tion changeovers, all there is left to do

isloadingscanningdistances,switchingpoints, and hystereses into the sensor,which then guarantees safe switchingthatcoversalloftheobjectsprocessed.

This method is particularly suitablefor packagingmachines and packaginglinesthatrequirefrequentchangeoverorareexposedtoseverestrainsfromtheirenvironment.Bymeansofthetransmit-tedstatussignaloftheIO-Linksensors,itispossibletodetectcontaminationorslowchangesearlyonand toeliminatethemspecificallyduringthenextproductchangeover.

Sensors from SICK with Io-Link interface

Producingmoreflexiblybyusingintelligentsensors

Wheneveranewmachineneedstobeinstalledoranewpro-duction line converted to new packaging formats, onemustadapt thesensor technology tonewtasksaswell. Intelligentsensorsbasedon theopen IO-Link interfaceeliminate thesebottlenecks,openingupnewpossibilitiesforflexiblemachineandplantconcepts.

The possibility of conveying clusteredmeasuringvalues to thecontrolsystemallows detecting the quantity of lumi-nescent additives even during ongoingoperation. In thisway, onecanmonitoroil lubrications of machines, glue ap-plications,orcheckpackagesforpiracyprotection.

With the function locking the teachbutton during operation and the intel-ligent sensor identification, SICK offersimprovedprotection frommanipulation.Thus, the machine builder can deter-mine individuallywhich sensor variantsto admit for replacement. Viewed fromthis perspective, this amounts tomorefunctionsatthesamesensorprice.

Intelligent sensors from SICK are usable in versatile ways in the packaging and food industries

: IndustryFocusPaCKagIngCheckingforpresenceandposition

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The IVC-3D smart camera from SICK inspects caps of plastic barrels for being placed correctly; On the bottom right, there is a plastic barrel with a “cocked cap”

>>TetraPak inLund,Sweden,hascho-senIVC-3DsmartcameraswhenitcomestocheckinglidsandcapsofpackagesforitsTetraToppackage.TetraPakisaworld-wideleadingcompanyintheareaoffoodprocessingandpackagingsolutions.

Benefit of the 3D cameraWith the extremely precise 3D cameratechnology from SICK, Tetra Pak foundthe suitable solution for checking lidsand caps. The IVC-3D smart cameracombines image processing, lighting,andevaluationinasinglehousing.

AtTetraPak,thesefeatureswereper-fectlysuitedforcheckingcapsonTetraToppackage.The3Dcameralocatesthecapsof thecontainersathighspeed,verifyingproperfit.Ineachimage,theheightandin-clinationofthecaparemeasuredtocheckthe correct application. By using the 3D

3D quality check for lids and caps

3DcamerasusedinliquidpackagingSICK’ssensorsandvisionsystemscanbeusedtocheckinglidsandcapsofliquidpackaging.

method,solutionsarepossibleevenwhenthecontainersarelocatedinacartonandwhensolutionsusingthe2Dmethod/backlightingcannotbeapplied.Containerswithflawed lids are sorted out and themea-suredvaluesaretransmittedtothemastercontrolsystemforanalyticalandstatisticalpurposes.

High quality ensured The 3D camera technology from SICKensures high standard of quality prod-ucts and satisfied customers. MartinThuresson,developerof the3D inspec-tion system at Tetra Pak says, “A 3Dsolution was chosen to enable simplepackagevolumechangeoverwithoutme-chanics. Thisway, the solution requiresnooperatorintervention.The3Dsystemofferscorrectmeasurementsevenifthepackageposevaries,aswellasaninte-gratedunitwithsimpleinterfacing.”

AndMarcus Ek, responsible for the3Dinspection system adds, “The systemgives a good quality inspection of ourpackagesandallowsasimpleandstan-dardized installation, which was impor-tantinourapplication.”

Theeasy-to-operatecameraisfacto-ry-calibrated and thus simple to install.Moreover, the camera met additionalrequirements by Tetra Pak, featuringuncomplicated data exchange with themastercontrolsystemsbymeansofEth-ernet(EtherNet/IP,OPC,TCP/IP),DigitalI/O, or RS-485, as well as stand-aloneoperationwithoutPC.

The 3D method works even in thecaseofdivergingpositionsandinclinedcontainerswiththetypeofreliabilitynotpossiblewhenusing2Dsolutions.

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.tetrapak.com

01 201122

: IndustryFocusPaCKagIng Detectionoftransparentmaterials

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.kosme.com

TheAustrianKOSMECompany,specializinginmachinesfortheproduction of PET bottles, relies on the WL11-2 photoelectricsensorfromSICKwhenitcomestodetectingtransparentpreformsandthin-walledPETs.

>> “With the WL11-2 from SICK, weare using a photoelectric sensor in ourstretch and injection blowmoldingma-chines on which we can rely anytime,”saysWilhelmHofstätter,TechnicalHeadatKOSMEinSollenau,Austria.“Itisper-fectly suited to detect thin-walled andtranslucent objects such as preformsandPETbottles,sinceitreliablydetectstheminimalattenuationofthelightpathbythetransparentmaterials.Inthisway,itworksflawlessly incountingandsort-ingoutevenwhenthemachinesareop-eratingattopspeed.”

KoSme: up to 12,000 Pet bottles an hourThe Austrian KOSME Company basednear Vienna is active in the area ofplastic packaging, specializing, amongother things, in the production of PETbottles. The stretch blow molding ma-

chinesofthecompany,awhollyownedsubsidiary of KRONES AG, can covera broad spectrum of bottles. “Thisranges from mini PETs holding 0.05liters all the way to large 30-l con-tainers,” confirms Wilhelm Hofstät-ter. “Depending on the requirements,machine capacities of up to 12,000bottlesanhourarepossible.”Thehighspeedsmakespecialdemandsonpro-cess-reliable detection. The WL11-2meetsthemdependably.

WL11-2: the photoelectric sensor that “sees through” Following functional tests under realproduction conditions during ongoingoperations, KOSME switched from an-other brand to theWL11-2 fromSICK.With its high-performance PinPointsender technology, the sensor provedhighly suitable due to its adjustable,

Detecting, counting, and sorting out transparent materials

PerfectdetectionofpreformsandPETs

high response sensitivity for detectingmaterialsthattypicallyfeatureareduc-tion of the optical light path betweenthe sensor and reflector by less than10%.“Thesignalsusedforcountingorfor activating the pneumatic cylindersornozzlesareveryreliable,eventhoughthe speedsare veryhighand the vari-etyofobjecttobedetectedverygreat,”WilhelmHofstätterconfirmshispositiveoperatingexperiences.

Another advantage of theWL11-2is its ease of integration. The space-saving and extremely robust housingaswellas thepracticalmountingandconnection features provide universalintegrationoptions.Anaddeddetail issimple operation. “Fast alignment bymeansofthevisibleredlightspotandadjustmentofsensitivityusingteach-inaremasteredalikebymachineopera-torsandmaintenancepersonnelwith-out any additional training,” WilhelmHofstätterpointstoanaspectparticu-larlyimportantfortheenduser.

Hisconclusion:“TheWL11-2photoelec-tricsensorkeepswhatitpromises!”

The WL11-2 (image on the left) is extremely user-friendly even when in-stalled: easy-to-access teach button (image on the right)

: IndustryFocusPaCKagIngPositiondetectioninharshenvironment

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Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.daloon.com

The rugged V18V cylindrical photoelec-tric sensor from SICK does a good job in a harsh environment

The Danish Daloon Company, the world’s largest producer ofspringrolls,reliesonthehighlyruggedV18Vcylindricalphoto-electricsensorsfromSICKintheharshenvironmentofanauto-maticwashingfacility.

>>The taskof thesensors is todetectreliably the position of stainless steeltransport cars, used in production totransportvegetablesforthespringrolls,withinthewashingfacility.

required: maximum detection reliability and plant availabilityTheemptytransportcarsarrivingfromproductionarepre-washedintheauto-maticcleaningfacility,freedfromresi-duesusingacidicandalkalineagents,pressure-washed at 100 °C, disin-fected and force dried. For this fullyautomatic process, they must be po-sitionedpreciselywithin themachine.Thoughspecifiedaccordinglyonpaper,

sensors from other manufacturersusedpreviouslywerenevercapableofwithstanding the harsh conditions formore than threeweeks. Availability ofthecleaningfacilitywasthusimpairedcorrespondingly. Incontrast, theV18Vcylindrical photoelectric sensor fromSICKprovestobetheperfectsolutionineverydayuse.

V18V: perfect performance in practical applicationDuring an intensive advance trialphase at Daloon, the V18V provedthat it met the indicated specifica-tions, including IP69K, foruse inthisextreme environment, ensuring per-

manent availability in detecting theposition of the transport cars. “Theydetect the transport car only if it isin the correct position at the start ofthe cleaning program,” explains PeterMadsen,responsible forplantmainte-nance at Daloon. “This method guar-anteestrouble-freeoperationswithoutany possible damage to the cleaningfittingsorthetransportcars.”Asare-sult,availabilityandthroughputofthewashingfacilitynowmeetDaloon’sre-quirements and expectations. At thesametime,thesensor-relatedexpendi-turesformaintenanceandrepairwerereduced substantially, thus improvingthe economic efficiency of the clean-ing system considerably. “At last, wenowhavethephotoelectricsensorthatsolvesourautomationproblem.Italsoshowshow theboundariesof useareshifting or nullified when the devicelayout–andnotmerelythedatasheet– is designed consistently toward theapplication requirements,” confirmsPeterMadsen.

Simple on paper, tough to implement in practice

Automationofwashingfacilityusingstainlesssteelsensors

01 201124

: Views & Voices Trendsinlogistics

Intralogistics isabouttoembarkonanewera.That istheim-pressiononegetsfromthe“CellularTransportSystems”project,whichinvolvesaswarmof50autonomousvehiclesdemonstrat-inghowmaterialshandlingaswellasrackstorageandretrievalwillwork in the future. Theprojecthasbeen realizedandwillbeshownatthe2011CeMATtradefairbytheFraunhoferIns-tituteforMaterialFlowandLogistics(IML).Howandwhyants,autonomouscontrol,andintelligencewithinaswarmarerede-finingintralogisticsisexplainedbyProf.Dr.MichaeltenHompel,ProfessorattheTechnicalUniversityofDortmund.HeholdstheChair ofMaterialsHandlingandWarehousingSystemsand isManagingHeadoftheInstituteatIML.

SICKinsight:Currently,theIMLisattract-ingpublicinterestwithnewtopics.Somepublications have referred to you per-sonally as the “100-million-euro man,”because you have obviously managedto use these topics to tap somemajorfundingpots.Whatarethesetopicsthatmoveboththenationaleconomyandtherelevantindustry?

autonomous control and swarm intelligence

»Cellulartransportsystemswilldominatetomorrow’sintralogistics«

In conversation: Prof. Dr. Michael ten Hompel, Professor at the Technical University of Dortmund and Head of the Institute at IML

Prof. Dr. Michael ten Hompel: Let usrather speak of the “100-million-euroteam.”Ahugeresearchclustersuchasthisonealwaysconstitutesajointeffort.Inourcase,more than120companiesand11researchinstitutionsshareintheproject.Nevertheless,Iamcertainlyde-lighted verymuchpersonally about oursuccess! This success is based quite

essentially on the fact that we haveidentified,throughtheEfficiencyCluster,thegreatchallengesforlogistics.Attheheartof it, there isthequestionofhowwecanefficiently control the individualsupplywithgoods,production,andmo-bility. Inmyview,thisconstitutesatthesametimeoneofsociety’sgreatestchal-lenges. Acting prudently in terms of lo-gisticsandthusefficientlymustbecomeattractive.Atpresent,weareproceeding,particularlyine-commerce,basedonthemotto,“Idon’tcarehowthegoodsreachme, as long as they are on the tablewithin24hours.”Wewillhavetomodifyourviewonthatscore.Asecondcrucialdevelopmentisurbanization…

SICKinsight: What effects will thesemegatrendshaveonworkflowsandthedesignofmachinesandplants?

Prof. Dr. Michael ten Hompel:Beforeor-ganizingorcontrollinganything,wehaveto start by measuring and identifying.Thishasalottodowithproductmarking

: Views & Voices

25

MoreabouttheFraunhoferIML:www.iml.fraunhofer.de

andimprovedsensorswhosedatamustbeavailableinrealtime.Thisrepresentsthebasiswithoutwhichweareunabletocontrolanysupplychainproperly.More-over,weoughttogiveuptheideathatto-daylogisticscanbecontrolledwithafaxandacalculator.Usingsuchmeans,onecannot even begin to master the com-plexityofmodernlogistics.What’smore,thecomplexityandspeedarecontinuingtoincreaseexponentially.WemustlearntorelyinfutureonInternettechnologiesandautonomouscontrol. Thisdoesnotmean that humans are left excluded –

with the development of intelligent airfreight containers all the way to cloudcomputinginthelogisticsmall.However,aroundthetimeoftheCeMAT,Iparticu-larly like telling people about our cellu-lar transport systems. By the time theCeMAT comes around, our large-scaleexperimentinvolving50autonomousve-hicles, the so-calledMultishuttleMove,will be finished. In a 65-meter (approx.71 yards) hall, built specifically for thispurpose,wewillshowthatusingsuchaswarmallowsrealizingtheentireclassicmaterials handling technology as well

»Beforeorganizingorcontrollinganything,wehavetostartbymeasuringandidentifying.Thishasalottodowithproductmarkingandimprovedsensors…«

quite thecontrary!Oneof theessentialtasksofmodernassistancesystemswillentailhidingcomplexityandvirtualizingcomputingperformance.

SICKinsight:Whatarespecificfutureproj-ectsthattheIMLpursuesandwhataretheinterestgroupstowhichtheyappeal?

Prof. Dr. Michael ten Hompel: Well,where shall I start? In more than 700projectsayear,wearedealingwiththeentire spectrum of logistics, beginning

The Fraunhofer IML is regarded as the prime location concerning questions ofholisticlogistics,workinginallfieldsofin-houseandexternallogistics.Currently,attheFraunhoferIML,foundedin1981,staffincludes190scientistsaswellas250Ph.D.candidatesandstudentswithanintermediatediploma,allofthemsup-portedbycolleaguesinworkshops,laboratories,andservicesectors.

Teamsputtogetheraccordingtoprojectandcustomerrequirementscreatecross-industryandcustomer-specificsolutions,including,amongothers,inthefieldsofmaterial flow technology,warehousemanagement,businessprocessmodeling,simulation-supportedcorporateandsystemplanning,aswellasinthesectorsoftrafficsystems,resourcelogistics,ande-business.FraunhoferIMLmanagesthe“Internetofthings”acrosstheentirenetworkofFraunhoferinstitutes.Ifrequired,the IMLcan fallbackon17,000employees in80 institutesof theFraunhofer-Gesellschaft.

The largest logistics research project in Europe today is the EfficiencyClusterLogistikRuhr,involving120associatedcompaniesand11researchinstitutes.

InadditiontoDortmund,furtherlocationsareCottbus,Frankfurt/Main,PrienonLakeChiemsee,Lisbon,andBeijing.

Brief information on the Fraunhofer Institute for material Flow and Logistics (ImL)

as rack storage and retrieval. This con-stitutes the consistent implementationof autonomous control for the in-housesphere.Justthinkofthewholethingasananthill…

SICKinsight: What is the contributionthatmanufacturersofautomationcom-ponentscanormustmaketocopewiththese future scenarios? In this context,we from SICK are obviously interestedaboveallinsensortechnology.Couldyougiveussomeindicationinthisrespect?

Prof. Dr. Michael ten Hompel:Sincewedidcompletelywithoutconventionalma-terial handling systems, nothing standsinthewayanymore.Thecellulartrans-portsystemsbringthegoodsdirectlytotheir destination. Since nothing standsin the way anymore, we are no longerrequired topositionasaccuratelywhenmoving,butwemustquicklyandinthreedimensions detect the environment,other vehicles, persons, and obstacles,operatingaccordinglywithintheswarm.For thispurpose,weneed fast, reason-ably priced 3D sensors and methodsfor sensor fusion inorder tomerge theknowledgeoftheswarminto“swarmin-telligence.”

SICKinsight: Autonomous transportunits, busy as an ant, with intelligencethatisdistributedandyetcoordinatedbyanoverridingprinciple–consideringthepossibilitiesthatopenuphere,logisticsexpertswill not be the only ones goingintoraptures.Manythanksforthisinfor-mativeconversation.

01 201126

: Views & Voices Universityeducation

MoreabouttheAschaffenburgCollege:www.fh-aschaffenburg.de

SICK’sstrongcommitmenttosupportinguniversities,colleges,andinstitutespractically isnosecret. “However, the fact thatSICK isalsoviewedasasuitablepartnerforteachingisaspecialdistinc-tion–andatthesametimeanincentive,”HaraldSchmidt,lecturerinsafetytechnologyattheCollegeofAschaffenburg,makesclearinourinterview.

SICKinsight: Mr. Schmidt, how didSICK’s involvement at AschaffenburgCollegecomeabout?

Harald Schmidt: SICK has an extensivetrainingprogramtobeginwith.Coursesonsafetytechnologyinparticulararesowellattendedbyourcustomersthat it isdiffi-cultsometimestofindsuitablepremises.Collegesanduniversities,suchastheonein Aschaffenburg, offer such capacities.One of these customer-training seminarswas attended by Prof. Dr. Armin DennerfromtheFacultyofIndustrialEngineering;aftertheevent,heapproachedus,askingwhetherwewereinterestedinfamiliarizingnotonlyexistingcustomersbutalsopoten-tial future customers with the subject ofsafetytechnology.Theideawasborn…

SICKinsight:Safetytechnology isnothingnew indeed, but something must havearoused thecollege’s interest in integrat-ingsuchaseminarintothecurriculum…

university education: SICK as partner in teaching

TeachingassignmentinsafetytechnologyatAschaffenburgCollege

In conversation: Harald Schmidt, SICK Safety Solution Development and Lecturer at Aschaffenburg College, and Bernd Herkenrath, Senior Consultant at SICK

Harald Schmidt: Safety technology iscontinuously changing. Just think ofthenewMachineryDirectiveorthenewstandards pertaining to the functionalsafetyofmachines.Formany,thetopiccomes to life only when technical andnormative theory meets head on withoperationalpractice.Mystudents–nowI ambeginning to talk likeaprofessor– specialize in production and manu-facturing engineering and will becomeoperators of machines and plants. Inthiscontext, topics liketherightsafetydistancesor,else,theconsequencesofmanipulationsonprotectiveequipmentbecome relevant really quickly. Manyare also completely unaware of the li-ability aspects associated with lackingsafetytechnology.Suchinsightsalwayscauseagreatahaeffect…

SICKinsight:WhydidthecollegedecideinfavorofSICK?Simplybecauseyouwereintherightplaceattherighttime?

Harald Schmidt:No,probablythatwouldhavebeentoothin.Inthecustomerwork-shops,weprovedtobeconvincingasamanufacturer offering competent con-sulting.Ourdidacticmaterials,abovealltheGuidelinesSafeMachinery,areverytechnicalandinformative.Asaqualifiedindustrialengineer,Ihavebeenworkingin safety technology for more than 10years,andIamaTÜV-certifiedexpertonfunctionalsafety.SICKranksamongtheleaders in innovation regarding safetytechnology. All of this combined guar-anteesahighqualityof teachingat thelatest level of knowledge – and this isimportant to the college. The goal is tosharpenawarenessofthetopic,toshowwhatneedstobemastered,andtopro-vide an overview of individual aspects.Ifthishasbeenachieved,thebenefitintermsofsafetytechnologyisenormous.

SICKinsight: How is your course posi-tionedwithintheFaculty’scurriculum?

Harald Schmidt:Thelectureonmachinesafetyheldinthepastwintersemester,isarequiredcourseforprospectiveindus-trial engineers specializing inmanufac-turing and production engineering, andattheendofJanuary,Ischeduledawrit-tenexam.Ofcourse, itwasnice toseethatnoone failed.Although thegradesdiffered heavily, all in all, thematerialshadbeenwellabsorbedandapplied.Inthe upcomingwinter semester, the lec-turewillonceagaincoverthesametop-ics.Asakey topic,machinesafetycon-tinuestoberelevantforteaching.

SICKinsight: In thatcase,wealsowishyou every success in the future with“your” students – and for additionalteachingassignmentsaswell…

: applicationsSafexpertsafetysoftware

27

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.kohler-germany.com

Inordertoensurerisk-compatibleandcontinuousmachineandoperatorsafetyovertheentirelifecyclesoftheirmachines,thepeopleatKOHLERMaschinenbaurelyontheworkflow-orientedsafetyengineeringusingtheSafexpertsafetysoftware.

>>KOHLERMaschinenbauGmbHintheBaden town of Friesenheim is a manu-facturerofstripfeedinglinesforpressesandautomatic punchingmachines. “Weofferexpertiseforperipheralsconnectedto presses. Over 5,000 facilities fromKOHLER are operating worldwide,” saysJürgen Scheuerle, Management Repre-sentativeandAssociateofKOHLERMas-chinenbauGmbH.Customersincludetheautomotiveandautomotivesupplyindus-tries,fabricationshops,manufacturersofwhitegoods,thefittingsindustry,aswellasvariousnichemarkets.“SinceoftennoC-standards exist for our machines, wealways face the challenge of developingasafetyconceptofourownandoftrans-ferringthatintotheriskassessment,”ex-plains Edgar Bund, BSc. Eng., TechnicalEditoratKOHLERMaschinenbauGmbH.WithSafexpert,KOHLERhasbuiltupaninternal CE network via the Sales, Plan-ning,MechanicalandElectricalConstruc-tion,QualityAssurance,FinalInspection,and Documentation departments. All oftheareascanworkon integratedsafetysolutions simultaneously, coordinatedandparalleltotheproductionprogressoftherespectivemachine.

Workflow-oriented Ce marking

Safeconstructionoflevelingsystemsandpressperipherals

Edgar Bund (BSc. Eng.), Technical Editor at KOHLER, and Carsten Gregorius, Portfolio Manager at SICK

In focus at KoHLer: risk assessmentRiskassessmentasthecoreof theen-tireconformityassessmentprocedureisthefocusatKOHLERaswell.Theprepa-rationoftheengineandcomponentlisttakes place in the framework of a sys-tematicprocess.“Itincludesalloftheac-tuatorsandsensorsrequiredaswellastheirrespectivefeatures,”outlinesEdgarBund.“Inaso-calledsafetymatrix,theyare thenassigned to the respectiveac-cesspointstothefacility,followingwhichonedefinesthecut-offcircuitsforeachof the machine sectors.” With respectto examining the safety risks resultingfromapossibleforeseeablemisapplica-tion,Safexpertalsooffersvaluablesup-port,e.g.anoverviewlistingallpossiblehazardsandcoveringdifferentgroupsofpersons.

Safety as teamwork InSafexpert,everymeasurecanbeas-signeda“todo”withresponsibilitiesanddate.“Thus,measuresoncedefinedcanbetakenintoconsiderationevenduringthedesignphase,”explainsEdgarBund.“Andnomatter ifwe envisage a safetygateorelectro-sensitiveprotectiveequip-

ment, therisk isassessedbymeansofSafexpert before andafter every safetymeasuretaken.”After finishing thesys-tem, what follows is completion of aninternalproductioncheckaswellas in-stallationofthefacilityatthecustomer’ssite,includingitstechnicalsafetyinspec-tion.“Inthisconnection,theproperfunc-tion of each safety-relevant componentisestablishedinaccordancewithanin-spectionschedulederivedfromthesafe-tymatrix,”elucidatesEdgarBund. “Thetestresult,e.g.themechanicalfunction-ality of gatesor the safety-capable cut-off of drives, are documented meticu-lously. Ifeverythingworkssmoothly, theCElabelisattachedattheend.”Thetestandinspectionassistant integratedintoSafexpertprovidesvaluablesupport forthispurpose.

Thebottomline:Safexpertistheidealso-lutionforsafetyengineeringatKOHLERMaschinenbau.

01 201128

: applications Handandfingerprotection

TheSwissTrionAG,manufacturerofautomaticreturnsystemsforlibraries,usesminiTwin2safetylightcurtainsintheterminalstoprovideoperationwithoutamomentofshock.

>>Trionisactiveworldwideasasupplierof facilities for intralogistics in librar-ies. “The systems consist of individu-allyrealizableconveyorsections,sortingmodules, as well as issue and returnterminalsforindoorandoutdoorareas,”explainsRichardJaworsky.Whenbooks,CDs,orDVDsarereturned,these itemsareidentifiedintheterminal.Afterthat,theyaretransportedthroughthemodu-larconveyorsystemtoasortingstation,where they are classified automaticallyaccording to subject areas and sortedout to roller carts standing by. “Everyyear,werealizeinjointprojects,primarilywithRFIDsystem integrators, about30suchfacilitiesinthemostdiversestagesof development,” says Thomas Steiner,HeadofProductionatTrion. Inadditionto availability of the systems, everyoneinvolvedattachesparticular importancetosafeoperationoftheterminalsbycus-tomers.“Thereisnoriskofinjurystem-mingfromtheterminals’gentlyopeningandclosingslidingpanels,”saysRichardJaworsky. “However, we wish to avoid,e.g.childrenoroldercustomersgettingafrightifthepanelclosedtooearlywhen

inserting a book.” In order to rule outsuchmomentsofshock,TrionintegratescompactminiTwin2safety lightcurtainsintoitsterminals.

minitwin2: safe, compact, and easy to integrateIntheminiTwin2safetylightcurtain,thesenderandreceiverelementsaswellastheevaluationunitareaccommodatedinasingle,alwaysconsistentlybuiltandwell-designed housing stick. “What isparticularlyimportantforourlibraryter-minals,” says Thomas Steiner, “is thatthelightcurtainisbuiltverysmall,hasnoblindzones,andatthesametimeof-fersaresolutionof14mmcompatiblewith finger protection. Thismeans notonly that even small children’s handsare detected reliably but also that wecan mount the light curtain directlybehindtheslidingpanelsinawaythatsavesspaceand isergonomic tooper-ate.”Thetopicofintegrationisalsocru-cial to Trion from another perspective.The special housing construction witha flat and curved side as well as thedesign of the electrical connection by

Left: In the case of miniTwin2, the light curtain is formed by the installation of two miniTwin sticks tilted at 180° to each other, placing the sender and receiver modules opposite each other; Right: Inserting a booklet, for instance, into the user terminal, inter-rupts several beams of the light curtain, preventing premature closing

meansofastandardconnectioncablewithauniversally rotatable,5-pinM12connection plug rules out errors bothregarding the mechanical and electri-cal connection. In addition, the variedalignment, status, and diagnostic dis-plays ensure a high level of operatingconvenience for commissioning and incaseofservice.”

Safe sensor solution contra moments of shock Inoperationonlocation,theminiTwin2sdeliver convincing performance due totheir extraordinary insensitivity againstany kind of ambient light. “Other sys-temsdonotoffer that, therebycausinghighfalsealarmratesthatareunaccept-ableforeither librariesor theirclients,”confirmsThomasSteiner.Thatdoesnotapply to theminiTwin2. “Even in brightnatural light, the sensor technology isnot dazzled, preventing moments ofshockbyprematureclosingand impair-ing neither the return process nor themonitoringfunction,”commentsRichardJaworsky.

Intelligent sensor design supplemented by professional all-inclusive package TheadvantagesofminiTwin2aresignifi-cantbutnottheonlyaspectsthatwere

operator safety for automatic library terminals

Bookreturnwithoutmomentofshock

: ApplicationsDetection of fluorescent substances

29

Further product information:www.mysick.com/applicationsMore about the customer:www.ljunghall.se

Further product information:www.mysick.com/applicationsMore about the customer:www.trionag.ch

important to Trion in opting for this light curtain. Thus, the combined stick design for sender and receiver as well as the use of standard connection technology common in industry reduce the expens­es at Trion in procurement, warehousing, and service logistics. Added to this are extensive customer service and prompt reaction to any questions. “Markus Bühl­mann, our contact at SICK, is very quick to help when needed, and almost al­ways he manages to provide a very good technical solution,” confirms Richard Ja­worsky. “On top of that, there is SICK’s worldwide presence. Nearly anywhere, suitable devices are available within a few hours, something particularly appre­ciated by our final customers.”

Small wonder, therefore, that Trion uses other sensor technology from SICK as well: inductive sensors for monitor­ing the positions of sorter protective hoods and for controlling the speed of the sliding panels, WL100 compact

Offer praise for the comprehensive cus-tomer service by SICK and prompt reac-tion to any questions: Richard Jaworsky, Deputy Head of Production, and Thomas Steiner, Head of Production at the Swiss Trion AG in Dübendorf near Zürich

photoelectric sensors to detect media at module interfaces in conveyor sys­tems, ELG automation light grids and – in case of confined installation space – WLL190T­2 fiber­optic photoelectric sensors for detecting objects when cy­cling through the facility.

>> In Sweden, the automotive supplier Metallfabriken Ljunghäll AB was facing precisely this problem in its production plant. For reasons of process and qual­ity control, it was essential to guaran­tee the presence of the application of transparent glue on components with a metal surface. Important secondary conditions: Added to the adhesive are luminophores that become visible when excited to illuminate by a light source fea­turing UV emitted light. However, the use of “classic” luminescence scanners nev­ertheless had to be ruled out, since com­plete distribution of the adhesive within an area needed to be detected.

Luminescence vision sensor on glue patrolThe task was solved using the Inspec­tor I40­LUT. The UV lighting integrated into the vision sensor causes the glue to glow in bright, long­wave light, ensuring in this way the necessary contrast to the background. Focused not on a spot but instead on an area, the I40­LUT can reli­

Detecting something transparent on shiny surfaces is not par­ticularly easy in the first place. When, on top of that, the location where a glue application needs to be present is not clear, it’s a case for the Inspector I40­LUT.

ably detect the presence and quantity of the glue application – while simultane­ously carrying out additional inspection tasks on the part.

Tested briefly, sold quickly, detecting reliably in the long termAfter being presented with the applica­tion, a sales representative from SICK proposed the Inspector I40­LUT and simply brought the device along for the customer call. The test demonstration carried out directly on the object was convincing – and in no time, several vi­sion sensors were sold. Installed and parameterized quickly and easily, they have since proven an inspection solution guaranteeing reliable detection – as ex­pected.

When luminous power is decisive

On patrol with the Luminescence Inspector

The I40-LUT detects the presence and quantity of transparent glue

01� 2011

Feed station for the pallets loaded with Euro-format stacking crates at the Migros Aare Cooperative

30

: Applications Object�detection

Further�product�information:www.mysick.com/applicationsMore�about�the�customer:www.migros.chwww.kaiser-engineering.ch

In�its�empties�return�station,�the�Migros�Aare�Cooperative�ben-efits�from�SICK’s�new�WL27-3�Reflex�Array�photoelectric�sensor�featuring�a�light�array�50�mm�in�height.�During�peak�hours,�this�plant�extension�carried�out�by�Kaiser�Engineering�in�Rheinfelden�nearly�doubles�the�throughput�in�the�pallet�feed�station.�

>>� The� Migros� Aare� Cooperative,� with�a� staff� of� about� 80,000� and� sales�amounting� to� 5.2� billion� Swiss� francs,�is� Switzerland’s� largest� chain� of� retail�stores.� In� the� economic� area� of� the��Migros� Aare� Cooperative,� more� than�120� Migros� retail� stores� are� supplied.�Every� hour,� dozens� of� trucks� are� pull-ing� in� and� out.� At� the� empties� return�station,� things� are� really� busy,� as� up�to�4,000�pallets�are�placed�by� forklifts�on� the� appropriate� feed� stations.� This�corresponds�to�moving�approx.�70,000�Euro-format� stacking� crates� for� subse-quent� sorting.� At� peak� periods,� Easter�and� Christmas,� the� number� of� Euro�stacking�crates�delivered�even�reaches�

about�130,000�a�day.�“In�that�scenario,�every� second� counts� when� unloading�the� trucks� and� loading� the� feed� sta-tion,”�stresses�Anton�Loosli,�the�Head�of�Maintenance�Delta�at�Migros�Aare.

Solution with the WL27-3 Reflex Array increases productivityAt�the�empties�return�station,�the�pallets�are�unloaded�from�the�trucks�and�set�on�the�feed�stations�by�a�forklift.�Following�this,�the�pallets�loaded�with�Euro�stack-ing�crates�are�transported�to�the�sorting�facility� by� a� chain� conveyor.� The� bottle-neck�in�this�transport�chain�was�the�feed�station.�After�a�pallet�had�been�set�down�and�its�presence�checked�by�a�“classic”�

Photoelectric sensor with light array

Throughput�in�empties�return��station�at�Migros�doubled

The WL27-3 Reflex Array increases throughput at the feed station in a cost-effective way; Detection of objects > 12 mm indepen-dent of location within the 50-mm light array

photoelectric� retro-reflective� sensor� us-ing� a� point-shaped� light� spot,� a�waiting�period�of�approx.�10�seconds�passed�be-fore�the�pallet�was�transported�onward.�Time�and�again,� this� resulted� in�unnec-essary�waits�for�the�forklift�drivers,�since�they� were� not� able� to� unload� the� next�pallet� yet,� as� the� space� was� still� occu-pied.�The�Kaiser�Engineering�Company�in�Rheinfelden� had�worked� out� a� convinc-ing� solution� with� SICK� AG,� Switzerland,�using� the� new� WL27-3� photoelectric�sensor.�By�combining�the�bright�red�light�PinPoint�LED�with�special�optics,�the�sen-sor�generates�a�nearly�constantly�50�mm�high� light� array� between� the� photoelec-tric� sensor� and� the� reflector.� Objects�>�12�mm�are�detected�reliably�within�the�light�array� independent�of� location.�The�Reflex�Array�sensor�and�the�reflector�are�integrated�into�the�lateral�guidance�sys-tems�in�the�front�area�of�the�feed�station.�As�a�result,� the� fork�of� the� forklift� truck�can�be�detected�reliably.�Now�the�start-ing�signal� for� transporting� the�pallets� is�triggered�by�the�detection�of�the�truck’s�fork,�shortening�the�waiting�times�to�ap-prox.� 3� seconds.� In� this� way,� the� clear-ance� signal� for� transporting� the� pallet�further� is� linked� directly� to� moving� the�forklift’s� fork� out� from� the� pallet.� “This�measure�heightens�the�drivers’�safety�in�order�to�avoid�collisions�as�well�as�overall�plant�safety,”�says�Anton�Loosli,�and�“On�top�of�that,�it�increases�throughput�at�the�feed�station�enormously.”

: applicationsGasanalysis

31

Furtherproductinformation:www.mysick.com/applications

>> The growthof theplants canbe in-creased considerably in a natural andecologicallyhealthyway,byusingcleanincineration exhaust to enrich the airwithCO2 in the tomatogreenhouse.Ni-tric oxides from the exhaust can evenbereusedasfertilizersundercontrolledconditions. With its gas analyzing sys-tem,SICKmonitors thenitric oxide val-ues foroptimal “feeding”of theplants,combiningeconomywithenvironmentalprotection.

Smallpowerstationsareoftenusedforthegenerationofpowerandthehea-tingofgreenhouses.Theirexhaustscanbereusedinanenvironmentallyfriendlywayiftheyarecleanedoftoxics.There-foreincinerationgasesaredirectedinto

flue gaspurificationplants so they canbeusedforfertilization.

Brilliant gas measurementThe nitric oxide content has to bemeasured continuously for the obser-vation of the legally binding emissionlimits and the limit monitoring of theexhaust ducts into the greenhouse.The GMS800 DEFOR by SICK, the UVspecialist for selective NOx measure-ment,doesthisjob.Eveninthesmall-estmeasuring ranges itmeasuresex-cellently:measuring ranges from0 to50mg/m³NOandNO2canbepreciselymade.ThesummationofNO+NO2toNOx is carried out directly in the ana-lyzer. The special measuring methoddoesnot require aNOx converter. Thecomplete extractive measurementsystemMAC800 consists of a heatedextraction probe, the heated measur-ing gas line, a measuring gas cooler,a measuring gas pump, the analyzerGMS800DEFOR and a device for thetestgasadmission.

Controlled greenhouse fertilization with SICK gas analyzers

GrowingwithCO2

Inordertogrow,plantstrans-formcarbondioxideintostarchby photosynthesis. They can,however, “digest”muchmorethanambientairoffers.

Profitable safetyTheuseof the suitability-testedanalyz-ingsystembySICKensuresahighlevelof safety for people and plants in thegreenhouse. Furthermore, the reliablemeasurement supports ecological andeconomic aspects. The measuring sys-temiseasy tomaintain,offers low-costservices,andmeasureswithhighavail-ability. The NOx measurement providesreliable instantenous values. Therefore,plant control can be optimized in anenvironment-friendly way. The costs forthe exhaust purification are minimizedand tomatoes with as little CO2 emis-sionsaspossibleareproduced.

01 201132

: applications In-companytraining

Attractive,modern,andfuture-proof–this ishowyoungpeopleimaginetheirin-companytraining.Hands-onexperienceandinde-pendentworkingarecalledfor–andcutting-edgetechnologies.IthappensjustthiswayintechnicalvocationaltrainingatSEW-EURODRIVE, where trainees integrate safety technology fromSICKintotheirprojectwork.

>> In timesofacuteshortageof skilledlabor,nothingismoreessentialthancom-petent and practically oriented trainingofemployees.Andparticularlyleadersintechnologylikethemanufacturerofdrivetechnology, SEW-EURODRIVE, and SICKhaveidealopportunitiesbywayofin-com-pany training to familiarize their futureemployees with subsequent demandsand tasks. “Learning directly on themodel, literally grasping the practicallyorientedimplementationoftechnicalbutalsoeconomicalrequirements,aswellasindependent work during training maketraineesinterestingtomanydepartmentsinourcompanyaftertheendoftheirtrain-ingperiod,”saysNorbertSteltz,HeadofElectronicsTrainingatSEW-EURODRIVE.

Company contract as practical final exam Thisisbroughthome,forinstance,bythetraining program for electronic engineerfordevicesandsystems.Apart fromthecorrespondingtheory,theexamadminis-

teredbytheIHK(ChamberofCommerceand Industry) also involves a practicalcomponent.“Intechnicalvocationaltrain-ing,we realize this requirement throughwork on so-called company contracts,”

explains Gregor Wohlfart, the TrainingCommissioner Technology in Sales andUniversityMarketingatSEW-EURODRIVE.“To this end, the young people are tocarry out a defined project contracton their own.” Like Gabriel Currle andSaschaOberst,whojustcompletedtheirtraining successfully. In connection withtheir exam, they were given the task ofprotecting, fromthreesidesandwithoutcontact, theworkspacearoundamodelofanautomatichoistingdevicewiththreesynchronous servo lifting axles. “As wesearchedforthesuitablesensortechnol-ogy, we decided in favor of SICK,” saysGabrielCurrle.“Herewewereabletousethree fundamentally different technolo-giesforprotection:theV300safecame-rasystem,anS300safetylaserscanner,and theminiTwin safety light curtain.” Itwasclearlynodisadvantage in thiscon-nection that SEW-EURODRIVE and SICKhad already been cooperating for yearsintheareaoffurthertrainingandqualifi-cationofemployeesandcustomers.“Mr.WohlfartestablishedcontactforustothekeyaccountmanagerfromSICKrespon-sible for SEW, Volker Neuenhaus, withwhomwesettledthetechnicalquestionsinadvance,”saysSaschaOberst.“Subse-quently,wevisitedSICKattheSPS/IPC/

Safety technology in in company training at SeW-euroDrIVe

Learningwiththehelpofthelatesttechnologies

Freddy Heinzelmann, Gregor Wohlfart, Sascha Oberst, and Norbert Steltz from SEW-EURODRIVE; Volker Neuenhaus, SICK, and Gabriel Currle from SEW-EURODRIVE (from left to right)

: applicationsQualitycontrol

33

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.haas.com

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.sew-eurodrive.de

High temperatures, harsh ambient conditions, and challengingtasksmakeveryhighdemandsonopticalsensors in industrialbaking machines. Here, sensors from SICK are the preferredchoice, e.g. at Franz Haas Waffel- und Keksanlagen-IndustrieGmbHintheAustriantownofLeobendorf.

>>“NearlyallofHaas’waferandbiscuitbakingplantsarehigh-performanceso-lutionsforfullyautomatedbakingofwa-fersheetsindifferentsizes,biscuitandcake products, wafer cones, and pan-cakes in large-scale industrial produc-tion processes,” explains Martin Kopf(BSc. Eng.), Head of Electric Construc-tionatFranzHaasWaffel-undKeksanla-gen-IndustrieGmbH. In termsofsensortechnology, this means recognizing themostdiversebakedgoods– i.e.copingwithdifferentshapes, sizes,degreesofbrowning,andsurfacestructures.“Fromthe perspective of automation technol-ogy, the objective is, despite a greatproduct variety andmanydifferent pro-cessing steps and ambient conditions,to identify ruggedand low-maintenancesensorsolutionsthatcanbeusedacrossfacilities ifpossible,”MartinKopfsumsupthesituation.

two product families of photoelectric sensors for diverse detection tasks When detecting dough strands, pre-formed dough pieces, wafer sheets,cookies or cones, Haas has been rely-ing primarily on two product familiesof photoelectric sensors from SICK formany years: WTB12-3 and W12L-2 La-ser.“Aboveall,thisisduetothesensors’superb detection behavior with regardtoourdifferentproducts,whichassuresusofhighproductoutput,aswellasthesimpleoperationandcommissioning,forwhich we do not require any specialistpersonnel,”explainsMartinKopf.Thefa-cilityenvironmentandthebakedgoodsdeterminewhichsensor isused.“If, forinstance, chocolate cookiesneed tobedetectedonalightconveyorbelt,wewilluse a photoelectric sensor with back-ground suppression,” elucidatesMartinKopf. “For flatwafers or lye breadwithitsdark,shinysurface,sensorswithfore-groundsuppressionarethebestchoice.”With respect to the ruggedness of the

sensors,ECOLABatteststothesensorsoftheWTB12-3andW12L-2Laserprod-uct family that they reliablyandperma-nentlyfulfilltherequirementsofmaterialstabilitysuchthoseentailedincleaningand disinfecting processes in the foodenvironment.

The bottom line: By using the sen-sors from the WTB12-3 product familyin two versions as well as the W12L-2

Photoelectric sensors for wafer and biscuit baking plants

RobustsensorsforfancypastriesDRIVEStradefairinNuremberg,receivingexplanationsaboutthefunctioningofthedeviceswiththehelpoftheexhibits.Forcommissioning,thetechnicalservicehot-lineofSICKVertriebs-GmbHinDüsseldorfhelpedusout,”addsGabrielCurrle.

Inadditiontoselectingandintegrat-ing the technical solutions, the com-mercial handling was also part of thecompany contract. “To this end, theDriveAcademy, acting as the customer,issued a separate project number. Thetwo trainees then had to calculate theprojectinbusinessterms,checkingthattheywerewithinthescopeoftheirtimeandcoststructureregardingintegrationaswell,”explainsGregorWohlfart.“Theymastered this brilliantly and gatheredvaluableexperience.”

Perfectly prepared for practiceThe example demonstrates how in-com-pany training, especially in the technicalskilledtrades,haschangedawayfromtheschool orientation toward practical learn-ing on themodel. “And for this purpose,oneneedscooperationwithpartnerswhonotonlyhavethesametrainingphilosophybut also rank among the technologicalandmarketleaders,”saysFreddyHeinzel-mann,ProductManagerFunctionalSafetyat SEW-EURODRIVE. “On top of that, inthe automotive industry, for example, orin warehousing and conveying facilities,nearlyeverywhereweencounterSICKasa supplier of sensor and safety technol-ogy.EmployeeswhohavealreadyworkedwithdevicesoronoperatorinterfacesfromSICKinthecourseoftheirtrainingcanim-mediatelycontributetheirexpertise.”

Inthisway,thingshavecomefullcir-cle.Attractive,modern,andindependenttraining guarantees not only a future toyoungpeoplebutalsotothetrainingcom-pany acting as a future employer. How-ever, the use of innovative technologiesnotonlycreatesthedesiredwin-winsitu-ationfortraineesandtrainersbutalsoforcustomers,astheycancountonqualifiedanswers to their questions and tasks.Therefore, Gabriel Currle’s and SaschaOberst’s safe lifting axle model, whichtheDriveAcademywilluseforpurposesoftrainingandfurthereducation,willnotbethe last joint trainingproject carriedoutbySEW-EURODRIVEandSICK.

Laser, the Haas Company manages tosolve reliably the most diverse tasksassociatedwith the detection of bakedgoods in the high-performance bakingmachines. “The sensors enjoy a highdegreeofacceptanceworldwideamongendusers.Moreover,becauseofSICK’sglobalpresence,areplacementdeviceisquicklyonsiteifworstcomestoworst,”MartinKopfsummarizestheadvantagesthatthephotoelectricsensorsfromSICKofferhim.

01 201134

: applications Qualitycontrol

Furtherproductinformation:www.mysick.com/applicationsMoreaboutthecustomer:www.adbro.co.uk

Adbro Controls has integrated SICK’s revolutionary new 3D andcolor imaging camera, the ColorRanger E, in an extremely high-speedconveyor-basedqualitycontrolandhighspeedrejectsystem.

>>Designedprimarilyforthefoodindus-try,thisinnovativesolutioncaneasilybeintegratedwithexistinginstallations.

Adbro engineer, Nicky Brian, com-ments: “The ColorRanger E has en-abledustodeliveracompletepaletteofinspectionparametersforcriticalQCtasks. Size, height, shape and somesurface defects have been possiblewith previous profiling scanning cam-eras; however, the new system caninspect for colordefectsaswell.Withallthedatacombined,thesystemcanreplacemanualQCinspection,itoffersprecision inspection down to 0.3 mmdiameter, at speeds up to 1ma sec-ond,ona600mmwidebelt.”

A typical systemwould involve theintegration of the ColorRanger E andPLC which tracks the exact positionof goods on a conveyor belt. The PLCcomparesscanneddefectsagainstthe

pre-programmed range of ideal itemsfor approval, or rejection, it deliversthe informationtoapneumaticnozzlewhichthenblowsthefaultyitemoffthebeltwithcompressedair.Otherusefuldata such as trends and defect typesarealsorecorded.Thesystemcouldbeeasilyandquicklyattachedtoexistingconveyorsystems,andintegratedwithprocesscontrolwithoutrequiringtotal-lynewinstallations.

Nicky Brian adds: “We have com-prehensivelytestedthesystemanditscapabilities, with trials on a range offooditems,suchasbreadrolls,sweets,and biscuits. We have extensive pro-duction and process experience, andthe ColorRanger E system fromAdbroandSICKissimpletoinstallonexistingprocess lines,and toscaleup insize.It can easily replace existing sensors,and black and white cameras, and

doesn’t require new conveyor installa-tions or extensive downtime, makingitacost-effectivemethodofimprovingcriticalqualitycontrol.”

Adbro’sworkingdemonstrationandtrialunitdemonstratesatypicalsystemwithColorRangerE.Lightsandprofilinglasersareinanenclosedunit,withthearrayofpneumaticnozzlesoveragapbetweenthebelts.Defectiveitemsaredetected, tracked, and rejected by ablast of directed air blowing the iteminto the gap between the belts. Thedisplay screen offers process controleitherattheapplicationorremotely.

adbro delivers extra quality control with

SICK3Dcolorcamera

: TechnologyIntegration concept for automatical identification

35

With IDpro, SICK introduces for the first time a cross-technology platform and portfolio strategy for all automatical identification technologies. IDpro permits an application-specific selection of suit-able automatical identification products from a single producer.

>> Investing in the suitable automatical identification solution in a future-proof way is not always easy from a business perspective. Technical requirements can often be realized using different tech-nologies such as bar codes, 2D codes, and RFID. Practice shows that there is no single correct identification technol-ogy – what matters throughout is the application and its basic technical and economic conditions. However, indus-try demands standard integration and operating platforms. Behind this lies the desire to be able to use the mark-ing technology appropriate in each case without having to invest great sums for integration and training. This is where SICK comes in with IDpro.

IDpro – three technologies, one integration conceptWith IDpro, SICK offers a portfolio strat-egy across technologies for the CLV6xx, LECTOR®620, and RFH620 product fam-ilies. All of the IDpro devices stand out due to industry-compatible design, and they can be connected, configured, and parameterized in the same way. Conse-quently, one can realize solutions for cli-ents that are cost-effective and a secure investment.

By means of the IDpro platform, it is possible to develop hidden potentials for more effectiveness and economic efficiency. Generally, machine and plant builders have defined an in-house con-trol and software structure. Therefore, conversion to a different automatical identification technology is quite often associated with substantial adjustment expenses. In future, using IDpro will allow applying the most suitable auto-matical identification technology on an order-by-order basis. Thus, when using 2D codes or RFID transponders, one can continue to apply the existing en-gineering and expertise, since one has automatically familiarized oneself also with 2D and RFID devices during train-

ing for, e.g. bar code technology. In this way, reduced training and documenta-tion effort is also reflected positively in economic terms.

To integrators, IDpro affords secu-rity in planning and investment because their designs are not rendered worthless by a change in technology. They will al-ways be able to use the basic concept of the solution, adapting the data capture on the object to the respective condi-tions and orders without having to carry out complex changes to the IT processes. A case in point confirming this is Laetus GmbH in the Hessian town of Alsbach-Hähnlein. The Laetus Company special-izes in the development, production, and sales of advanced control systems for checking pharmaceutical packag-ing materials. “Building on the current network of CLV6xx bar code scanners, the new LECTOR®620 will now be inte-grated into the existing structure,” says Günter Rodeck , BSc. Eng., Director Prod-uct Management Standard Systems,

Three technologies – one integration concept

Integrating intelligently using IDproMarketing & Business Development at Laetus. “Due to the fact that in the in-tegration of LECTOR®620 we were able to build on the existing IDpro platform, expenses for integration and training de-creased considerably thanks to the stan-dardized parameterization software and operator interface.”

IDpro – investment in the suitable solution with an assured future Currently, SICK is the only supplier in the area of automatical identification that carries all three technologies – bar code, 2D, and RFID – in its portfolio, developing and manufacturing them in-house and having created a standard platform, i.e. continuous operator interfaces, process interfaces, and connecting options. This allows the planning of specific applica-tions far in advance of having to settle the question of identification technology. In selecting the optimum technology for the respective application, SICK provides all of the information from a single source using IDpro: across technologies, compre-hensively, and neutrally.

Further product information:www.sick-idpro.comMore about the customer:www.laetus.com

01� 201136

: Know-how Muting

To� allow� automatic� material� transport� in� intralogistical� pro-cesses� into�protected�hazardous�areas,� reliable�differentiation�of�humans��and�material,�of�persons�and�pallets,� is�necessary.�For�this�purpose,�SICK�offers�interesting�solutions�with�its�safety�capable��sensor�and�control�technology.�

Muting and pattern recognition

Safe�ways�through��the�“hole”�in�the�fence

>>� Production� facilities� in� automotive�manufacturing� or� at� logistics� centers�are�typical�examples�of�highly�automat-ed�plant�processes�that�nevertheless�in-volve� numerous� persons� possibly� stay-ing� there,� e.g.� plant� operators,� service�technicians,� or� maintenance� workers.�All� of� them� have� to� be� protected� from�the� hazards� of� automatically� operated�facilities.� Usually,� however,� complete�fencing,� e.g.� of� a� robot� or� a� vertical�transfer�car,�is�out�of�the�question,�since�they� are� integrated� into� an� automated�material�flow.�Therefore,�the�“hole�in�the�fence”� necessary� for� transporting� ma-terial� to� and� from� the� dangerous� area�must� be�monitored� in� such�a�way� that�pallets�can�pass�while�persons�are�de-tected�reliably,�causing�the�machine�or�facility�to�switch�off.�

Application-specific alternatives The� C4000� Palletizer� or� the� C4000��Fusion� safety� light� curtain,� and� the�M4000� multiple� light� beam� safety� de-vice�are�available�for�this�purpose.�Com-bination�with�the�UE403�safety�modules�or�the�Flexi�Classic�and�Flexi�Soft�safety�controllers� results� in� possible� solutions�featuring�top�reliability�and�economic�ef-ficiency�–�either� through�muting�or�pat-tern�recognition.�

The well-designed combination is what matters Which� one� of� countless� combinations�of�sensor�and�control�technology�consti-tutes� the� best� solution� for� a� particular�application� depends� on� many� factors,�among� others,� space� available� in� the�

Muting station with M4000 Advanced in combination with UE403 in intralogistics

Material yes Person no

: Know-how

37

muting solutions using: ue403 safety module

Flexi Classic (ue410-mm)

Flexi Soft Solutions with special functions

Mutingonsite(IP65) yes --- --- self-teachingpatternrecognition

Mutingincontrolcabinet(IP20)

--- yes yes notrequired

Connectiblesafetylightcurtains/multiplelightbeamsafetydevices

productfamilyM4000Advanced

productfamiliesM4000Standard,M2000C4000/C2000miniTwin

productfamiliesM4000Standard/Advanced,M2000C4000/C2000miniTwin

C4000Palletizer/C4000Fusion

2-sensormutingcrossedarrangement

yes yes yes self-teachingpatternrecognition

2-sensormutingserialarrangement(2sensorsinhazardousarea)

yes yes,inconnectionwithXUmodule

yes self-teachingpatternrecognition

4-sensormuting yes yes yes self-teachingpatternrecognition

Mutingwithoutmutingsensors

--- --- --- yes

Integrationoffurthersafetyapplications

--- yes yes ---

Concurrencemonitoringofthemutingsensors

yes yes,inconnectionwithMDImodule

yes ---

Override/bypassintegrated

override override,inconnectionwithMDImodule

override/bypass bypass

Addedvalueofthesolution

simpleandfastwiring simpleanduniversal simpleanduniversal nomutingsensorsrequired

universallyusablemutingapplication

expandableinamodularway

expandableinamodularway,noadditionalsafetycontrollersrequired

self-teaching

machine,thetypeandfeedingofobjectsandautomation-relatedadditional func-tionstobecarriedoutbytherespectivesensororsafetycontroller.

Muting is the “mother of all solu-tions”foraccessprotection inautomat-edmaterialtransports.Amutingstationconsists, e.g., of muting sensors, anM4000 multiple light beam safety de-vice,theUE403safetymodule,at leastone muting signal transmitter, e.g. amutingLED,andsometimesalsoswingdoors.Whenanobjectpassesthemut-ingstationprior toentering thehazard-ous area, the chronological and logicalsequence of the muting signals is re-cordedandevaluated.

Alternatively, themethod of patternrecognitionmonitors, on the one hand,thesizeandclosedshapeofanobject,e.g. the goods on a pallet, while it canalso, on the other hand, recognize the

sizeandnumberofseveralobjects,e.g.the strutsof ameshboxor pallet and,respectively, the individualgoods trans-portedatconsistentintervals.Sinceper-sons within the protective field alwaysgenerate a different pattern than theobject patterns, one can thus achievea safe differentiation between humansandmaterial.

The following table illustrates thepossible combinations of electro-sensi-tiveprotectivedevicesand safe controltechnology.

Object pattern recognition by C4000 Palletizer on a pallet conveyor

38

: Products

Freely programmable and thus available quickly and flexible touse–thesearethebenefitsprovidedbytheprogrammableabso-luteandincrementalencodersfromSICK.

>> When it comes to possible cost re-ductions in procurement, warehousing,and service logistics, too, the DFS60incrementalencoders,theAFS60abso-lutesingleturnencodersandtheAFM60absolutemultiturn encoders from SICKarea“well-rounded”affairformanydrivemanufacturers, machine builders, andsystemintegrators.

encoders become usable universally thanks to programmingIn many places, the freely programma-ble encoders fromSICK provide crucialadded benefits beyond their technicalfunctionality. Due to the continuouslyvariable setting of the number of linesdesired, they can be adjusted as accu-rately as never before. Moreover, it ispossible to define the zero-pulse widthdepending on the application. Finally,theDFS60offers thepossibilityof indi-vidually adjusting the voltage levels oftheTTLor,respectively,theHTLinterfac-esattheoutputside.Overall,therefore,everyprogrammableencodercanbesetexactly as required for a given applica-tion–anddirectlyexwarehouseatthat,which ensures availability and usabilityatshortnotice.

Programmable in a user-friendly way – even when already installed Inorderfortheaddedbenefitofthever-satileencodersfromSICKtobeavailabletomachinebuildersandintegratorswith-outanyadditionalexpense,greatimpor-tance was attached to easy-to-operateprogrammingofthenumberoflines,ze-ro-pulsewidth,zeroset,andoutputlevel.Programming takes place by means ofthestandardoutputlineoftheencoders–whetherusing thePC-supportedPGT-08-S standard programming tool or –particularlyinthecaseofmaintenance,service,oradjustmentwork–usingthepocket-sized stand-alone PGT-10-S pro-gramming tool. Both tools even permitthecloningofsettingsoncedeterminedtoasmanyencodersasdesired–anes-sentialsavingoflaborwhenitcomestoapplicationsrecurringregularly.

Particularlywiththeencodersinstalledinparticular,thepossibilityofbeingabletoactuate theencodersbymeansof theirRS485standard interface constitutesadecisive advantage. By contrast, in thecase of devices with DIP switches, pro-grammingviathecontrollerisjustasim-possibleasthecloningofconfigurations.Moreover,dependingonthedevice,therearecumbersomehandlingofPGconnec-torsanddifficult-to-reach programmingplugs–bothverytime-consuming.

Source code availableOEMsandmachinebuilderswhowishtocarryoutprogrammingdirectlybymeansof the HMI of their equipment can re-questthesourcecodefromSICKforin-tegration.

Thebottomline:flexibility,fastavail-ability, straightforward service options,efficientmaterialmanagement– in thisway,theDFS60,AFS60,andtheAFM60are “programmed” for success in theyearsaheadaswell.

universal solutions for rotary path measurement

Programmableencodersgainingground

Furtherproductinformation:www.mysick.com/products

Encoders

39

: Products

Smallcodes,omnidirectionalorientation,differentcontrastsandresolutions,largefieldofview,changingreadingdistances–theimage-basedcodereaderICR849-2LFlexLensfromSICKoffersutmostflexibilityinpracticaluse.

>>TheICR849-2LFlexLensdeliverscon-vincingperformanceduetosuperbread-ing characteristics. On the one hand,theseareachievedbymeansof the in-tegrated four-megapixel CMOS imager,which allows, for example, reaching aresolutionof0.35mminafieldofviewmeasuring 300mm x 300mm. In thisway,onecan reliablydetectacode thesizeofapinheadonanareagreaterthanA4format(roughlyUSlettersize).Inad-dition, C-mount interchangeable lensespermit flexible adaptation of the codereader to the respective reading situa-tion.Apartfromthat,theimageprocess-ingsetsnewstandards.Withitsdynamicparameter switching, the integratedde-coderensureswithonlyonesettingreli-abledecodingoflow-contrastordirectlymarkedcodesinanyorientation.

Industry-compatible integrationIntermsofbothmechanicsandcontroltechnology, the ICR849-2L FlexLensmeets all the requirements of industry-compatibleintegration.Themetalhous-

ing with an IP 65 enclosure rating isvery easy to mount; configuration ofthedevice issimpleandthussavestime and costs by means of liveimage and auto setup. The M12Ethernet connection technologyfor fast imageanddata transmis-sion constitutes the standard inmany user industries. In addition,thecode reader isequippedwithaserial interface.ViaCAN,one isabletoconnectseveraldevicestoformonenetwork–practicalwhenrequiringmulti-sided reading. By way of external con-nectionmodules,fieldbusenvironmentssuch as PROFINET, PROFIBUS, andDe-viceNetarealsoopentotheICR849-2LFlexLens.

object identification, retraceability, and product piracy protectionDue to its performance characteristics,thecodereaderistheidealsolutionforvarious tasks in logistics automation.One particular focus of use is goodsidentification in automated medicine

Four-megapixel code reader for pharmaceutical, logistics and automotive industries

Idealforsmallcodesinalargefieldofview

Furtherproductinformation:www.mysick.com/products

Image-basedcodereaders

storage systems: Here, the device sup-ports both uninterrupted retraceabilityand effective protection from productpiracywithrespecttomedicines.

40

: Products

Alarmwithout intruder, intruderwithout alarm– for thedesignof exteriorperimeterprotection, it is essential to ruleoutboth.The LMS53x laser measurement sensor from SICK featuringmulti-echo technology provides the decisive performance edgefortheseapplications.

>>TheLMS53xisa2Dlasermeasure-ment sensor designed specifically forsecurity applications with long rangesin the outdoor area. For holistic secu-rity, particular importance is attachedtoearlydetectionwhen it comes tope-rimeter protection. Horizontal surfaces,e.g.yards,accessroads,orroofs,canbemonitored by the sensor just the sameasverticalplanessuchaswalls,fences,or façades. The LMS53xmeets the re-quirements of Environmental Class IVofEN50131(VDE0830),inaccordancewith the test methods of EN 50130-5,i.e. thedevice canbe installed for two-dimensional monitoring of an exteriorperimeterfullyexposedtoweather.How-ever,itisalsosuitedformonitoringtasksin interior areas having harsh ambientconditions.

modular system structure, high-performance opticsThe system consists of three compo-nents:thesensorheadwiththesender-

receiver optics and data evaluation, aplug-insecurityapplicationmodule,eachfeaturingspecific,individuallyadjustablesettingsandparameterization,aswellasanintegratedparametermemory.Thesecomponents permit simple and quickconnectionor replacementof adevice.Withitsnovel,particularlylight-intensivesenderoptics,onecandetect intrudersradially at long ranges common for ex-teriorperimetersupto65m.Even low-re-flective“shadycharacters”arevisible

Security laser scanner featuring multi-echo technology

Reliableexteriorperimeterprotectionwithoutaflaw

>> multi-pulse technology

Themulti-pulse technology improves the tried and tested pulse-time-of-flightmeasurementandiscapableofcarryingoutanevaluationofuptofivereturnimpulsesafteranemittedpulseatscanningspeedsofupto100Hz.Indoingso,theLMS53xgeneratesmoremeasurementdataforpositionanddistancedetection that is evenmoreprecise. Furthermore, due to theaddedamountofmeasuredvaluesperanglebeam,themeasurementanddetectionresultsbecomeindependentofweatherandotherambientconditionstoanextentnotachievedpreviously.Thus,itispossibletoeffectfastandreliabledetectionofstationaryaswellasmovingobjectseveninpoorvisibilitycausedbyrain,fog,ordust.

Lasermeasurementtechnology

41

: Products

With stoptime detection as a motion control function block, SICK extends the portfolio of safety control solutions by an easy-to-inte-grate and economical solution for safe drive monitoring.

>> Machines such as palletizers, mixers, and packaging and milling machines are kept moving by drives. The function block of stoptime detection determines the end of a coastdown/braking action of a drive. The signal generated by the function block can be used to unlock safety gates or prevent the restart of the drive. This is the task carried out by stop-time detection, the new function block of motion control.

Integrated flexibly into Flexi Soft Stoptime detection is available as a func-tion block in the new free-of-charge Flexi Soft Designer. Using the logic editor of the Flexi Soft Designer software, it can be integrated directly into safety control projects featuring Flexi Soft without any additional module. It is possible to con-nect up to four sensor or encoder sig-nals (24 V signals) to a function block for monitoring the motion of a drive. These HTL signals require no additional spe-cial hardware but are instead introduced on digital input cards into the controller, thus allowing a very efficient way of imple-menting a 1b Stop category. Activation of the function block takes place by means

of its drive control input. In this way, the motion control function guarantees a high level of machine availability, increases in productivity through faster and yet pro-tected intervention into the machine, as well as safe access to the equipment in the case of set-up and maintenance mea-sures. Just download Flexi Soft Designer at www.sens-control.com and use the simple, intuitive programming interface featuring the new function block of stop-time detection.

Stoptime detection with the Flexi Soft safety controller

Motion Control: monitoring zero-speed safely

to the scanner up to 40 m. Given appro-priate positioning, it is possible to reach ranges within the detection diameter of up to 130 m or, respectively, up to 80 m at an object reflectance of 10 %.

Using multi-echo technology against nuisance or false alarmsThe decisive element for the perfor-mance edge in security applications is the new multi-echo technology. It enables the laser sensor to detect reliably any ob-ject- or weather-related interference or multiple reflections, thus reducing sub-stantially the rate of both nuisance and false alarms – something confirmed so far by TÜV’s ongoing acid test.

Ideal for alarm verification This high level of reliability makes the LMS53x a very efficient, dependable, and universal detection solution. Moreover, the device is cut out for being the ideal supplemental or alarm-verification sys-tem which can be combined with detec-tion methods that are physically different, e.g. thermal imaging cameras, motion detection video technology, radar, capaci-tive proximity detectors, ground detection and fence protection systems, as well as electromechanical detector solutions. Whether as stand-alone technology or in combination – using the LMS53x guar-antees reliable and economical exterior perimeter protection.

Further product information:www.mysick.com/products

Further product information:www.mysick.com/products

The LMS53xx laser measurement sen-sor from SICK

Safe control solutions

Diagram: function block of stoptime detection

+ More information on page 45

+

42

: Products

Immediately available in all markets: the automation light grid MLG Up-grade. It provides convincing performancebecause of numerous innova-tions, including integratedCANbus, two analog outputs, and a softwaresolutionforuniversalpalletidentification.

>>ThemodularlightgridMLGUpgradeisaversatileautomationsolutionconfigu-rableinamodularwayforbothswitchingandmeasuring2Dobjectdetection.Thenew system delivers convincing perfor-mancedue to improvedeaseof opera-tion and integration. A refined teach-in

methodpermits a choicebetweenhighsensitivityandhighfunctionalreserveorteach-inusingtheautomaticmode.TheCANbus intheMLGUpgradesimplifieswiringandallowscost-effectivenetworkintegration. The two analog outputssparetheeffortofseparatelyevaluating

upgrade of the mLg automation light grid

Newfeatures,newpossibilities

SICKextendstheportfolioofinductivesafetyswitcheswiththeIN3000Directproductfamily.Featuringtwocylindri-calversions,twoOSSDsafetycapableoutputsandapprovalforperformanceleveld,thedeviceshavewhatittakesas ideal solutions for safe positionmonitoring.

>> Inductivesafetyswitchesdetect thepresence or absence of metal, thusrecognizing,whether themachine com-ponents are in a safe position or havealready moved beyond it. In terms oftechnology,theyarerightinlinewithcur-rent developments, since due to theirnon-contactprinciple,theyarefreefromwearand–particularlyinharshenviron-ments– requiresignificantly lessmain-tenance than electro-mechanical posi-tionswitches,forinstance.However,the

IN3000Direct serieshasevenmore toofferthan“only”areliablefunction.

easy integration, fast responseThe IN3000 Direct inductive safetyswitches are available in small and ro-bust M12 and M18 cylinder housings

with 4-pin M12 plug connectors. Theypresentthepossibilityofflushandnon-flushmountingpositionsandaresuitedfor operating distances up to 8 mm.LEDsvisualize thesensorstatus,allow-ing quick functional diagnosis on loca-tion.Theirresponsetimeisevenfaster:Itispossible,inlessthanamillisecond,tooutputdirectsignals toasafetycon-trollerbymeansofthetwoOSSDswitch-ing outputs, thus stopping dangerousmachinemovements.

Inductive safety switches: innovative series introduced

Cylindricalconstructionwithafuture

themeasuring results. The12-pinM12connectorprovidesmanyoutputsforset-tingupdifferentmeasuringzones.Inthisway,onecansolveevencomplexappli-cationswithoutaddedspecialsoftware.

universal pallet verification integrated For height detection and checking forprojections in material handling andwarehousingsystems,theMLGUpgradeprovidesefficientsoftwareforpalletveri-fication.Itissuitedforthemostdiverse

Highendautomationlightgrids|Non-contactsafetyswitches

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extremely rugged TheIN3000Directproductfamilystandsoutduetoitshighlevelofinsensitivitytoshocksandvibrations.Afactorcontribut-ingtothelongservicelifeofthesensorsis that they are easy to clean – par-ticularly important foruse inareaswithheavy contamination or high hygienicstandards.

PL d and SIL2All safety sensors of the product fam-ilymeetPLd inaccordance theseriesmeet PL d in accordance with EN ISO13849-1 and SIL2 in accordance withIEC 61508 or, respectively, SILCL2 inaccordancewithEN62061.Inthisway,theIN3000Directbecomeaneconomi-callyattractivesolutionwherevertheriskanalysis does not stipulate the highestsafetycategories.

Rugged,smallindesignandversatileinapplication,thenewW8Inoxminiaturephotoelectricsensorshavetheirsightssetparticularlyonapplicationsinthefood,beverage,andpharmaceuticalsegmentsaswellasinmachinetools.

>> TheW8Inoxisthelogicalcomplementtotheportfolioofstainlesssteelsensorsfrom SICK. The product family includesthrough-beam and photoelectric retro-reflectivesensors,energeticphotoelectricsensors,aswellasthosefeaturingback-ground suppression–depending on theapplicationusedforcloseorfarranges.

rugged sensors for harsh applications The sensors of the W8 Inox productfamily are verywell prepared for clean-ing processes, rinsing and disinfectionagents, as well as drilling water anddrillingoilsthataffectconventionalsen-sorsadversely. Thehigh-quality1.4404(316L)stainless-steelhousingfeaturingan IP 69K enclosure rating, the chemi-callyandthermallyresistantfrontscreenmadeof PPSU, aswell as the operatorcontrol–mechanicallyveryresistantduetothePEEKhigh-performanceplastic–withstandeven theharshest loadsdur-ingproductionandcleaning.

Specialized in space-saving and simple installationThe W8 Inox sensors permit space-savingandsimple installation:Theyarecompatible with the mounting system

Photoelectric sensors: Inox portfolio complemented

Stronginconfined,harshenvironmenttypes of pallets, is more precise andeasier to integrate thanmultiplephoto-electricsensors,andensures fastcom-municationwithplantcontrol.

Protected against deflectionsFor tasks in vertical lift systems,whichduetotheirmechanicaldesignbeartheriskofdeflections,SICKhasreducedtheapertureangleonthereceiverbyapprox.70%. In thisway, one can dependablyavoidfalsemeasurementsandswitchingsignals, achieving a high level of avail-ability.

new: detection of internal and external contoursDetection of internal and external con-tourswasdevelopedspecificallyforusein paint installations. This approachmakes it possible to control the paintinstallationor,respectively,alignapaint-ingrobotinsuchawaythatpaintisap-plied onlywhere paint is required. Thisoptimizes processing time and savespaintconsumption.

Furtherproductinformation:www.mysick.com/products

Furtherproductinformation:www.mysick.com/products

Furtherproductinformation:www.mysick.com/products

usingaM3threadthathasbeenestab-lishedinthemarketandpossessamin-iaturehousingthatisnearlyidenticaltothatoftheW8Plastic.Evenwhenspaceisscarceonthemachine, theoptionofconnection technology either as a 2-mcable,anM8plugora300-mmconnect-ing cable with an M12 plug guaranteefast installation. The same applies tocommissioning: After just a few adjust-ments, also depicted graphically in theoperatingmanual,thesensorsarereadyfor operation. Thanks to high-perfor-manceLEDtechnology,perfectdetectionresultsareensuredduringoperation.

The W8 Inox product family for diverseusesoffersruggednessandavailabilityinmanyapplications.

Miniaturephotoelectricsensors

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AlongwiththesuccessoftheInspectorproductfamilyinabroadrangeofapplicationscamecallsfromcustomersforversionsforspecialuse.

>> What took shape as a result aretwo new device versions as well as anetwork-capabletoolformonitoringmul-tipleInspectorsforimprovedqualityandthroughput.

Well-positioned to guide your applica-tionsPositiondetection forcounting,picking,oraligningparts,aswellasvisualguid-ance for robots, gripper and handlingdevices,butalsothepositioningofauto-matedguidedvehiclesorliftinggearonaislestackersusingreferencemarksaretypicalapplicationsofthenewInspectorP30.Thevisionsensorfeaturesvariousso-called “locator tools,” ensuring topdetectionreliabilitywithrespect tobothobjectsthataretaughtinorthatvaryinshape.Dataregardingthepositionorori-entationare recordedhighlyaccurately,withoutputmadepossibleviaEthernetand direct digital outputs. This allowsmachinestocarryoutrapidworkingpro-cesses,e.g.whengrippingandseparate-

ly packaging sweets.Dependingon theoperatingenvironment,differentoptical,filter,andlightingversionsareavailable.

Powerful luminescent inspection with 2D visionThe Inspector I40-LUT does not oper-ate with visible light but with UV lightinstead. Its task involves detecting lu-minescent material – so-called lumi-nophores–withinaspaceofdefinablesize. Luminophores can be applied oraddedeconomically during the processof manufacturing goods, e.g. to adhe-sivesandpaintsinfurnitureproduction,asacuttingmarkonwoodandtextiles,or as an invisible productmarker usedtoprotectfromproductandbrandnamepiracy.During inspectionby the Inspec-torI40-LUT,thelightsourceofthevisionsensorutilizesUVemittedlighttoexcitethe luminophores to illuminate, i.e. toreflect light in the visible spectrum be-tweenapprox.420nmand750nm.Thegreat advantage of the I40-LUT is thefactthatitcandetectthemarkswithinalargerareaandindependentofposition

Positioning, visual guidance, luminescence detection, and network

NewversionsoftheInspectorvisionsensor

andorientation.Ontopofthat,thevisionsensoriscapableofevaluatingboththepatternsandamountof luminophorousmarks, thusenabling it toprovideaddi-tionalinformationonthequalityandtypeofatestobject.IntegrationtoaPLCus-ingEtherNet/IPaswellastheoptionoftransmitting images continuously to anexternalFTPserverpermitindustry-com-patibleincorporationintotherespectiveproductionenvironment.

advanced monitoring of InspectorsInspector Viewer is the new accessorythat allows advanced monitoring of In-spector vision sensors networked to-gether. However, it does not end there:In addition to live visualization, for in-stance, when checking labels or logos,theInspectorViewer,operablebymeansofatouchscreen,alsopermitsrapidad-justmentornewteach-inofthedevicesas well as cloning and transferring ofconfigurationseffectedpreviously.More-over, the InspectorViewer iscapableofcarryingoutstatisticalevaluationoftestresult and trends. It is possible to con-nect all variant types of the Inspectorproductfamily.TheInspectorViewermayalsoserveasanFTPserver,continuouslysavingtheimagestransmittedbytheIn-spector sensors. Network integrationtakesplaceusingEthernet–aUSB in-terface for reading out image data orconfigurationsisalsoavailable.

P30,I40-LUT,andViewer–thevisionsen-sorproductfamilyisgrowingalongwithcustomers’ requirements and wishes.WhatwouldyouhaveanInspectorinves-tigateforyou?

Furtherproductinformation:www.mysick.com/products

P30, I40-LUT, and Viewer – the new Inspector versions

Visionsensors

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Flexi Link, the new extension function of the Flexi Soft safety controller from SICK, permits the interlinking of up to four Flexi Soft stations – thus making it the safe solution for complex applications.

>> When modules become machines, often their individual safety solutions also have to be combined into a safe whole. Flexi Link fulfills this function by making it possible to configure, emulate, manage, and diagnose up to four Flexi Soft stations by means of a network. This is achieved with the help of the Flexi Soft Designer parameterization tool – and thus without any additional hardware and the associated wiring expenses.

Safety configuration in accordance with plant progressThrough the modular concept, Flexi Link enables the machine builder to plan a full development of the plant, to incor-porate it completely in the safety appli-cation, and yet put only individual parts into operation. Plant components can be both integrated into a combination of machines following completion of the configuration or uncoupled temporar-ily, e.g. for maintenance purposes. This approach allows planning projects in advance while commissioning individual machine components later or, respec-tively, again after uncoupling – without

renewed adjustment on location. In mod-ular machine building, this makes com-plete commissioning in case of a plant extension redundant, permitting continu-ous diagnosis of the integrated Flexi Link system. The fast evaluation and preven-tive error detection thus possible lead to increases in productivity both for the ma-chine manufacturer and for the end user.

Flexi Link is the innovative solution for enabling machine components with Flexi Soft controllers to exchange safety in-formation. In this way, one achieves the greatest possible flexibility, particularly when it comes to complex projects. You may find more information on Flexi Link at www.sens-control.com

Further product information:www.mysick.com/products

Ideal for flexible machine designs and interlinked facilities

Flexi Link: networking safety controllers reliably

Safe control solutions+ More information on page 41

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Screwin,connect,readytogo–that’showsimplelevelmeasure-mentisusingtheMHF15opticallevelswitchfromSICK.Thesen-sor is ideallysuitedfordetectingwater-basedmedia inprocesstanks,containers,andpipes.

>>TheMHF15 isanopticallyscanninglevelswitchthatstandsoutduetoasim-ple, rugged, and solid sensor construc-tion.ThankstoitsstainlesssteelhousingfeaturinganIP69Kenclosurerating,thesensor’stipmadeofrobustpolysulfone,andthehigh-qualityworkmanship,eventhemostadverseconditionsbothinsideandoutsideofcontainersandpipescan-notdamagethesensor.

uniquely easy to install Hardlyany levelswitch isaseasy to in-stall and commission as the MHF15.Thesensor,thesizeofathumb,evenfitsinto themost cramped installation set-tingsandwithitsG1/2"threadfeaturesa common process connector. Oncescrewed in, all that’s left is connectingthe MHF15 electrically. Matching themediumwhencommissioning is justasunnecessaryas repeated recalibrationsin long-termoperation.Thisplug&play

Compact, corrosion-resistant, and cost-effective

Leveldetection,plug&play

Detectinginductively,evaluatinganalogously–inmanyprocesses,onerequirespreciselythiscombination.TheresponsefromSICKiscalledIMA.Thenewproductfamilyofinductiveanalogsensorsisconvincingduetoextremelyhighdetectionrangesandprecisepositiondetection.

When intermediate positions are of interest as well

Inductiveplusanalog>>Whetherintensilestressmonitoringoffilmsandpaper,continuouspollingoflinear movements, absolute angles ordistancedetection,or ingapand thick-nessmeasurement – inmany automa-tionprocessesbinarydataoftendonotsuffice. Inthiscontext, the IMAproductfamilyfromSICKprovidescustom-madesensorsolutionsforanalogdetectioninyourapplication.

High sensor-based performance potentialDetection ranges between 4 mm and40mmwithoutblind-zonearea, resolu-tions insomecasesof lessthan1µm,highrepeataccuraciesbetween0.3mmand 0.6 mm at minimum temperaturedrift – the sensors of the IMA product

Levelsensors

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designensuresminimumcostsfor inte-gration,operation,andmaintenance.

Better optically: level detection, dry-running and pump protectionSimple, compact, and rugged, theMHF15istheidealsensorformaximum-minimummonitoring in tanks and con-tainersanddry-runningaswellaspumpprotectioninpipes.Thelevelswitchcanbe used at process temperature of upto+55°Candprocesspressuresupto16bar (1,600kPa).Easyhandlingandgreat cost benefitsmake theMHF15aconvincing alternative to mechanicallevel sensors such as electrodes, floatswitches,orvibrationswitches.

Optimum because optical: level detec-tionwiththeMHF15.

Furtherproductinformation:www.mysick.com/products

Furtherproductinformation:www.mysick.com/products

family combine large detection rangesand extremely small tolerances. In thisway,itispossibletodetectreliablyevenlongerpathswithoutanyaddedmechan-ical components. Furthermore, the IMAdevices require significantly less spacethanconventionalanalogsensorswhileofferingidenticaloperatingdistances.

Construction sizes for any sequence of movement desired Six construction sizes are available fordifferenttasksandsequencesofmove-ment:M8andM12withananalogvolt-agesignalfrom0to10VaswellastwoM18andM30versions,eachwithanad-ditionalpoweroutput from4to20mA.With their output signal proportional todistance, the IMA product family offersthepossibilityofsolvingthemostdiverseautomationtasksboth inapreciseandeconomicallyreasonableway.

Inductive sensors for any machine design

Flat,compact,andruggedWhenthingsbecomecrampedinsideamachine,theycomeintoplay:theIQFlatinductivesensorsfromSICK.Flatindesign,theyareconvincingbecauseofsimple installation, ruggedconstruc-tion,andincreasedoperatingranges.

Inductiveproximitysensors

>> The IQ Flat product family consistsoffoursensorvariantsoverall,featuringconstructionheightsbetween4mmand10mm.IQ04andIQ06inaplastichous-ing have operating ranges of 1.5 mmand3mm,respectively,andtheycanbemountedusingonlyonebolt.Forbothofthem, readjustment is justasunneces-saryasinthecaseoftheIQ20andtheIQ25. The latter are particularly ruggedduetotheirmetalhousingandsuitableforoperatingrangesof7mmand5mm,respectively.

Easy tomountandreliable–aboveall,however, being flat and compact – thesensorsoftheIQFlatproductfamilyaresuitedforextremelyspace-criticaltasks.Checking for presence in handling sys-tems that are becoming increasinglymorecrampedisjustasmuchpartofthejobaspositioningofcomponentcarriersinelectronicsproductionordetectionofworkpiecesinpressesandmolds.

Furtherproductinformation:www.mysick.com/products

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Furtherproductinformation:www.mysick.com/products

Motorfeedbacksystems

Fewer costs, reduced space requirements,more security of in-vestmentsandmachinesafety–theEKS36andEKM36motorfeedbacksystemsfromSICKwithHIPERFACEDSL®(digitalservolink)openupnewpossibilitiesforthearchitectureofservodrivesystems.

>> In the future, it will be possible bymeans of the HIPERFACE DSL® protocol,purelydigitalforthefirsttime,torealizeen-codercommunicationusingonlytwowiresintegratedintothemotorcable.Thisoffersaseriesofbenefits.

HIPerFaCe DSL® – here’s what’s behind it HIPERFACE® is an asynchronous half-duplex interface that has becomeestab-lished in themarket formanyyearsasastandard, used today by more than 70drivemanufacturers.Theirservodrivesys-

temsconsistoftwoseparatecomponents,the controller, and the motor. Until now,twoseparateconnectioncablesforenergysupply and data transmission connectedthemtoeachother.IntegratingbothcablesandthusbeingabletodowithoutoneofthetwoM23connectionplugseachwasawishexpressedfrequentlybymanymanu-facturersofmotorsandcontrollers.

Now this wish comes true withHIPERFACEDSL®.The interfacepermitsinterference-free data transmission be-tweencontrollerandmotorviatwolinesintegrateddirectly into themotorcable.

Datacommunication ismodulatedontothesupplyvoltage.Specialmethodsandtheuseofpulsetransformersmakesurethat the encoder signal is decoupledfrom interference on the motor outputcable, allowing transmission for up to100m.

Cost-effective, safe for machines, and future-proofThedata transmission, certified in termsof safety technology in accordance withSIL3 (IEC 61508) or performance levele (EN ISO13849-1), saves the separatemotorfeedbackcableandoneM23con-nectionplugeachonthemotoraswellasthecontroller.Thiscutsconnectioncostsbutalsowarehousingexpensesformotormanufacturers and machine builders inhalf, also reducing the space necessaryon the motor and the controller. Finally,asamarket-orientedsolution,HIPERFACEDSL®offershighsecurityofinvestmentforelectric drive technology – especially astheconstructionoftheEKS36andEKM36motor feedback systems features the36-mm housing diameter customary inthemarket–thusrequiringnomechanicalmodifications.

electric drive technology: motor feedback purely digital

NewdrivearchitecturesbymeansofHIPERFACEDSL®digitalinterface

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Anevolutioninsize,coupledwitharevolutionofapplicationopti-mizationandflexibility–that’sthenewcompactsafetylaserscan-nersoftheS300MiniproductfamilyfromSICK.

>>Theconstructionheightofonly116mm makes the S300 Mini the world’smost compact safety laser scanner ofits kind. The “space miracle in yellow”allows installationwithminimumspacerequired, while at the same time it isdesigned so flexibly as tomeet thede-mands of the most diverse operatingconditions and user wishes. Moreover,obviouslytheS300Miniseriesfulfillsnotonly the technical safety requirementsof performance level d in accordancewith EN ISO 13849 as well as SIL2 inaccordance with IEC 61508, but alsothe demands on opto-electronic safetyequipmentinaccordancewithType3ofIEC61496.

Safety in pure form: the S300 mini StandardSICKdesignedtheS300MiniStandardasabasictechnicalsolution.Therangeofthe270°protectivefieldis2m,with-inwhichone canprograma triple fieldsetwithoneprotectiveandtwowarningzones. The device features one pair ofOSSDs(outputsignalswitchtingdevice)serving as a direct switching output.Safety in pure form as provided by the

S300Miniisrequiredinnumeroussim-pletaskswheneconomicefficiencymat-ters, for instance, using the S300MiniStandardasawear-freereplacementof

tactilepressuresensitivemats,andasasafetysensorforprotectingsimpleAGVs.

Safety “deluxe”: S300 mini remoteWhen there is minimal installationspace,combinedwiththerequirementsofcomplexsafetyapplications,theS300MiniRemotesafetylaserscanneristheappropriate solution. By using this de-vice,onecanrealizeupto16triplefieldsets–ideale.g.forAGVapplicationsbutalsoforautomatedforklifttrucksorrail-mounted transverse distribution cars.On top of that, by means of the latestgenerationoftheEFI(enhancedfunctioninterface), and by using the Flexi SoftsafetycontrollerfromSICK,itispossibleto combine up to four electro-sensitiveprotective devices, e.g. two S3000 Ex-pertsandtwoS300MiniRemotes,intoanetwork.Bydoingso,onecaneasilyim-plementevencomplexprotectivetasks.

Whether in area protection on sta-tionarymachinesor indetectingobsta-clesinthecaseofautonomousvehicles– inboth instances, theS300Minide-liversconvincingperformanceduetoitshigh level of flexibility, ease of integra-tion,andreliability.

Safety laser scanner in miniature design

Smallbutselect

>> S3000 expert

ThenewS3000Expert checkmates safety gaps. Featuring64 fields, up to32monitoringcases,andanextremelylongprotectivefieldrangeof7.0m,thedeviceisaveryflexibleandthusperfecthigh-endsolutionforcountlessapplicationsinintralogistics,inwarehousesandshippingcompanies,aswellasforloadingandshippingareasinvolvingheavy-dutyvehicles.IncombinationwithFlexiSoftsafetycontrollersfromSICK,onecanalsoconfigureanefficientsystemofscanners.

Furtherproductinformation:www.sick.com/S300mini

Safetylaserscanners

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User-friendly,reasonablypriced,andprecise–thatishowthenewWFSforksensorfromSICKpresentsitself.Theslenderconstruc-tion,simplesetting,andshort response timesallow topperfor-mancedetectingthemostdiverselabels.

>> By introducing theWFS, SICK com-pletestheportfolioof forksensorswithaproductthatisdesignedspecificallyfordetecting non-transparent labels on di-versecarriermaterialsaswellasfordou-ble sheet detection. TheWFS achievesspecialprocessaccuracybyitsposition-ing directly on the dispenser edge of alabelfeedingmechanismandduetotheshortresponsetimeofonly50µs.

extremely easy to integrateTheWFS – fork depth of 42mm, forkwidth of 3 mm – delivers convincingperformance due to reliable detectioneven in the case ofmin l signal differ-encesbetweenthelabelandthecarriermaterialandbecauseofeasyintegrationand operation. The slender fork shapepermits optimum process and space-relatedmountingsolutions–ifrequiredusing a specialmounting rod. Commis-sioning is fast and simple, as settingoccursbymeansofdynamicandstaticteach-in–eitherusingtwopushbuttonsonthedevicethatcanalsobeusedforfine-tuning, or via the control line. Dur-ingthisexternalteach-in,onecanadjust

thetaught-inswitchingthresholdaccord-ing toneed,guaranteeing reliable labeldetection at any time. Special feature:theswitchingoutput isactiveevendur-ingtheteach-inprocess,ensuringnotasinglelabelis“missed.”

The WFS is the reliable and economi-calsolutionwhen itcomes todetectingthemostdiverselabelsdependablyandaccurately even at high speed butwithminimaladjustmentexpense.

new fork sensor: lithe and lissome and more

Labeldetectionmadeeasy

Furtherproductinformation:www.mysick.com/products

Forksensors

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Precise, easy to operate, and fast – the redesignedWL12G-3small photoelectric sensor sets thenewstandard for detectingtransparentobjectssuchasglass,PETbottles,andfilms.

>>Byreliablydetectingtransparentob-jects–rangingfromthin-walledPETbot-tlestohighlytransparentfilm–the“old”W12G from SICK has already set the“best-in-glass” standard for detectingtransparent materials. The redesignedWL12G-3smallphotoelectricsensorre-mainstruetothisbenchmark.

robust and compatible in terms of connectionsOntheoutside,thenewWL12G-3relieson tried and tested virtues. The metalhousingaswellastheconnectiontech-nologyare identical to theW12-3prod-uctfamily.Fornumerouscustomers,thismechanical and electrical compatibilityfacilitates switching to the new photo-electricsensorforglassdetection.

ease of operation is of high importanceCommissioningofaWL12G-3isfastandsimple:aligntheWL12G-3tothereflec-tor,push thebutton, finished!–settingsensitivity by means of teach-in savestime. Foroptimumadjustment toappli-cation conditions, one can choose twooperatingmodesviateach-in.The360°statusLEDs,visiblefromallsides,guar-antee fast polling of the sensor statusandthusfacilitated,moreeffectivesen-sordiagnosis.

Device availability in adverse, extreme operating conditions!Whether faced with damp settings orsplash water, ambient light, or strongelectromagnetic fields– theWL12G-3sare very reliable and extensively inde-pendent of influences from the envi-ronment. The switching frequency wasincreasedto1.5kHz–idealforhighma-chinespeeds.Theruggedhousing–withanoptionalTefloncoating–providesthe

stability that guarantees sensor avail-ability in an industrial setting and en-suresuninterruptedproduction.

Seeing the application through the “eyes” of the sensor The WL12G-3 is available optionallyas an I/O variant. Integration of theWL12G-3 at the sensor/actuator levelinto automation systems allows the re-alizationofpreventivemaintenanceandrepairmeasures.

WL12G-3 – “crystal-clearly” the bestsolutionforreliabledetection,counting,andsortingoutoftransparentobjects.

The photoelectric sensor for transparent materials

Detectinga“hintofnothingness”reliably

Furtherproductinformation:www.mysick.com/products

Smallphotoelectricsensors

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>> The S700 extractive gas analyzerbelongs to the most successful pro-ductsofSICK’sprocessautomation.Thesuccessful series has been completelyrevised and enlarged. The successorGMS800usesthemeasuringprinciplesNDIR, thermal conductibility, O2 mea-surement as well as UV resonance ab-sorptionspectrometry(UVRAS)andnondispersive UV photometry (NDUV) in aflexible way.With currently six analyzermodules,onegasmodule, I/Omodulesand different housing types, the low-maintenance system can cover a hugerange of extractivemeasurement tasksandsituations.Thankstotheverylatestinsoftware,theGMS800offersnowallnecessary interfaces to allow the con-nectionwithaprocesscontrolsystemoraremotecontrol.Theuseofthedeviceinfacilitiessubject toapproval isnoprob-

Furtherproductinformation:www.mysick.com/products

lem thanks to the qualification test ac-cordingtoEN15267-3.

TheGMS800 canmeasure individu-allyover60gascomponents in thepro-cessgasesofchemicalandpetrochemi-calplants. Itcandetect forexample theconcentrationofhydrogensulfide(H2S)inreactiveorsourgases.BymonitoringCOthesystemcanbesettoallowtheearlydetectionoffireincoalmillsandsilosandmonitorsthedangerofexplosionbystackgasinfurnacesorcokeovens.Inthehy-drogen production theGMS800 recordseven the smallest concentrations of COinH2.

The new all-rounder is suitable forthemonitoringof lowest toxics inpower,cementandwasteincinerationplantsaswell as in the pulp and paper industry.WiththeUVanalyzerDEFOR,theGMS800isidealforgasturbines,inpowerplants,DeNOx plants or desulfurization plantstomeasure the smallest concentrationsofSO2,NOandNO2.NOxiscontrolledbymeasuring NO and NO2 directly and byadding it up toNOx in the analyzing de-vice.ThiswayCLDanalyzersorNO2con-vertersbecomeunnecessary.

Gasanalyzers

WiththesuccessorGMS800,SICKhasnotablyenlargedthefieldofapplicationoftheapprovedextractiveall-rounderS700intheareaofgasanalysis.Partofthenewproductfamilyis,forexample,themultifunctionalDEFORphotometermoduleformeasurementsin theUVrange.With thisproducteventhesmallestconcentra-tionsofNO,NO2andSO2,–forexampleintheexhaustofgastur-bines–canbedetected.TheverylatestinevaluationelectronicsandtheEthernetconnectionfordatatransferandremotecontrolmaketheGMS800evenmoreinterestingforequipmentandsys-temmanufacturers.

the new gas analyzer system gmS800 performs even better than its predecessor

Oneforall

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: Service & Support

Furtherinformation:www.sick.com/safety/en

The highest quality standards, consistent and documentableprocedures,aswellas independentevaluationarewhatdistin-guishestheaccreditedsafetyservicesSICKoffers,amongotherthings,forfulfillingtherequirementsoftheGermanOrdinanceonIndustrialSafetyandHealth(German:Betriebssicherheitsverord-nung–BetrSichV).

>>Theexperts’trainedeyesmissneithersafetydeficitsnorpotentialimprovementsrelatedtoprocessesandefficiency.

machinery Directive (mD) and BetrSichV constitute the basis The item relevant above all for manu-facturersistheEUDirectiveonMachin-ery. It describes abstract requirementsconcerning the safety of machineryand plants that are defined clearly byEN standards: However, operators, too,must pay attention to theMD. First, inthe case of essential changes to exist-ingmachines and plants, they becomethemselves manufacturers as definedby the Machinery Directive, i.e. theymust takecareof theentireprocessofCEmarking.Secondly,operatorscannotplead that by usingmachines conform-ingtoCE,theywerereleasedfromtheirresponsibility by the manufacturer, fortheymustascertainor,respectively,havesomeone ascertain that the equipment

used in theiroperation is ingoodorderfrom a safety perspective. The founda-tionofthisistheOrdinanceonIndustrialSafety andHealth (BetrSichV). Suitableprotective measures and checks areessential basic elements of the safetyconceptsetdown in theBetrSichV.Themeasurescalledforinparticularincludechecks prior to commissioning as wellas recurring checks of safety featuresonmachines.Inthiscontext,theregula-tionsspecifythatonlypersonsqualifiedtodosocancarryouttheseinspections.

SICK: accredited safety and decades of experience SICKisaccreditedbytheDAkkS,theGer-manAccreditationBody,asaninspectioncenterinaccordancewithIECor,respec-tively,ENISO17020andthuscapableofcarryingouttechnicalsafetyinspectionsand approvals if new, redesigned, andmodernized machines and plants andofcertifyingthiswithSICK’sowninspec-

tionseal.Morethan100trainedsafetyexperts worldwide are endowed withwide-rangingapplicationknowledgeanddue to theexpertisederived frommorethan15,000safetyinspectionsannually,theyarewellversedintheapplicationoftherelevantdirectivesandstandards.Aspersonsathomeinthefield, theyhavecommand of the skills needed for ma-chinedesignthatconformstodirectivesand standards, and the expert knowl-edgerequiredfortheiroperation.

Particularly interesting for operators: plant walk-through With a view to the requirements of theBetrSichV, the so-called plant walk-throughforoperatorsisparticularlyvalu-able.DevelopedbySICK,thisprocedureprovidesasimpleandquickassessmentofthecurrentsafetystatusofmachinesand facilities operating in production.ThesafetyexpertsfromSICKidentifythemost importantsafetyaspectsonallofthemachinesandfacilitieswithinapro-duction plant, subsequently prioritizingthemaccordingtoriskpotentialandfor-mulatingrecommendationsforeffectivesafetystrategies.Usingthisplanningin-strument,whichinadditioncanbeusedforcooperationwiththesupervisoryau-thorities,allowsimprovingmachinesafe-tyspecificallyaswellaspreventingrisksofinjuryforemployeesandliabilityrisksforthoseresponsibleinthecompany.

Whether manufacturer or operator,whether EU Machinery Directive or theBetrSichV –with the portfolio of safetyproductsandservices,SICKmanagestoreconcilethedemandsbycustomersforproductivitywiththesafetyofpersonnelandmachines.

Safety inspections

Withaccreditationandatrainedeye

Safetyinspections

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: SICK tour

Aqualitybrand:SICK–SensorIntelligence.Since2002,SICKSTEGMANNGmbH(Inc.)hasbeenpartofSICK’sGroupofCompanies,completingwithinnovativeproductsSICK’srangeofservices.Sofar,theencodersandmotorfeedbacksystemshadbeenmarketedsuccess-fullyundertheSICK-STEGMANNbrandname.

35 years of SICK USA founded 24 March 1976

20 years of SICK Singaporefounded 28 June 1991

20 years of SICK Finland founded 16 October 1991

>>More than100 invitedguests fromGermanyandabroadtookinaprogramofevents featuringmanyculturalhigh-lights. The guests were welcomed on“Brühl’s Terrace,” where they enjoyed

Twentyyearsago,SICKEngineeringGmbHinOttendorf-OkrillanearDres-denwasfounded.Agoodreasonforcelebrating in style the anniversaryof the subsidiary that specializesin flowmeasurement and emissionmonitoring.

>> In the future, the consistent mar-ket presence under the SICK umbrellabrand will emphasize the affiliation ofSICK STEGMANN GmbH with the SICKGroupevenmoreclearly.Alongwiththisadjustmentofthebrandname,theprod-uctsofSICKSTEGMANNGmbHwillalsointegratecompletelyintoSICK’sportfolio

in terms of appearance. This ensuresconveyingahomogenousappearanceofastrongandinnovativecorporategroup,particularlyfromasalesperspective.

The legaldesignationofSICKSTEG-MANNGmbHisunaffectedbythis.Alloftheproductapprovalsandcertificatesre-mainineffect.

>> As of 1 December 2010, SICK AGhas been present in South Africa withits own subsidiary. SICK AutomationSouthernAfrica(Pty)Ltd.inRoodepoortnearJohannesburgoffersclientstheen-tirerangeofsensors,systemtechnology,industry expertise, and services of theSICKGroup.

SICKfoundssubsid-iaryinSouthAfrica

thegrandviewoftheElbeRiveratnightoveraglassofmulledwine.Duringthesubsequentwelcomedinnerat theHil-ton in Dresden, they all had a chancetoget toknoweachother ina friendlyget-together and raise a glass to theanniversary.Theeveningwassetasidefor the highlight of the festivities: ThehistoricbuildingensembleofDeutscheWerkstätten Hellerau in Dresden pro-vided the atmospheric setting for anevening event to which managementofSICKEngineeringGmbHwarmlywel-comedallemployeesandguests.

Subsidiariescelebrate!

ThehighgrowthratesintheprocessingindustryaswellassteadygrowthoftheSouthAfricaneconomyoverallmakethecountry an interesting market for thehigh-qualityproductsfromSICK.Thede-cision to cooperatewithM&MSystemsAutomation–oneofSICK’sdistributorstodate–informingthejointventureofSICK Automation Southern Africa, wasthereforeboth logical and forward-look-ing.Thenewlyfoundedcompanyaimsatdevelopingthemarketonabroadbasisbyutilizingexpertise,applicationknowl-edge,andservices.

SICK is present in South Africa as well

Birthday party in Dresden

SICKEngineeringGmbHcelebrates20thanniversary

55

: SICK tour

>> On the initiative of SICK and withactive help from “Industrial Safety Sys-tems,” an information day took place

on 4 November at the VDMA (Associa-tion of German Mechanical Engineer-ing Institutes) in Frankfurt dealing with

“SafetyDocumentation.”Thehighlytopi-cal issue drew 135 interested design-ersfromdifferentsegmentsofmachinebuilding toFrankfurt. The focuswasonthe essential planning steps aswell asobligationsfordocumentationfortheCEmarkingofamachine.With thehelpofthesafetyPLUStradefairmachinefromSICK,participantsactivelydiscussedthestepsfromriskassessmenttopreparingasafetyconceptandall theway to theconcluding evaluation of conformity. Intheexhibitionaccompanyingthesubject,theexperts hada chance to check outforthemselvesSICK’srangeofservices–startingwithproductsolutionsall thewayto“safetyservices.”Theunanimoustenoroftheeventwas:successfuloverallconceptwithinterestingspecialistcontri-butionsandentertainingpresentation.

ActingashostoftheAnnualGeneralMeetingofPEMA(PortEquipmentManu-facturersAssociation), inFebruarySICKinvitedinternationalportequipmentmanufacturerstotheCustomerCenterofSICKAGinWaldkirch.Recentyearssawtheestablishmentofthreenewcommitteesforsafety,technology,anden-vironmentintheportindustry.Inthecontextofthemeeting,thesecommitteesaddressedtopicssuchas“Safetystandardsandguidelinesonquaycranes.”

>> Efficient sensor solutions for thepro-ductionofsemiconductors,printedcircuitboards,solarmodules,andthin-filmsolarcells are the themesonwhich the latestSICK Industry Guide informs. Featuringnumerousapplicationexamplesandprod-uctrecommendations,itgivesanexcellenttechnicaloverviewofautomationoptionsintheareaofelectronicsandthesolarin-dustry.NowavailableinEnglish.

Acopycanbeorderedat:Kundenservice@sick.deorasadownloadatwww.sick.com

neW: Industry guide

ElectronicsandSolarIndustry

>>SincetheendofFebruary2010,SICKhasbeenamemberofPEMA,whichin-cludes not only system integrators butalsoconsultantsfortheportindustry.Asa result, SICKwas able to welcome in-ternationalcompanies likeKonecranes,Cargotec, Terex, Baltkran, Hans Künz,Cavotec,ConductixWampfler,Vahle,TTSPortEquipment, IdentecSolutions,APSTechnology,AME,ABB,Siemens,TMEICGE, RAM, Bromma, Stinis, and others

to Waldkirch. Among the participantswasalsotheICHCA(InternationalCargoHandling Coordination Association) aswell as additional guest speakers deal-ingwithenvironmentalandsafetytopics.Overall, the event proved a resoundingsuccess– it turnedout to be almost afamily get-together of port equipmentmanufacturers, integrators, andconsul-tants,allofwhomwerenetworkedverywellwitheachother.

SICKhostedPEMA

VDma Information Day

“SafetyDocumentation”featuringsafetyPLUS®machine

No one making it to Fort Myers, Florida, on business or plea-sure, should miss a visit to Edison & Ford Winter Estates . After all, this place witnessed the writing of a chapter in the history of automobile development.

Automobile development under bamboos and palms

When geniuses vacation together

>> Thomas Alva Edison has earnedworld fame with his more than 2,000inventionsandover1,100patents.Theitems sprung from his brainwaves andresearch work include, among others,thetoaster,therecordplayer,themoviecamera,thefurtherdevelopmentofthelight bulb, and the telephone. To takea break from his labors, in 1885 Edi-son bought a property on the Caloosa-hatcheeRiverinFortMyers.Thedecisivecriterioninthiswasbamboogrowingonthe land. Edison then examined the fi-bersaspartofhisrecreationalactivitiesforsuitabilityasconductingfilamentsforlightbulbs.

Edisonwasnotonlyaninventorbutalsomanagedhisownlarge-sizedenter-prises, such as the Edison IlluminatingCompany.Oneof hismost famousem-ployeeswasHenryFord,whostartedup

hisownbusiness,however,basedonhishobby, automobile engineering. Closebusiness cooperation between the twomenresultedinanequallyclosefriend-ship, causing Henry Ford to purchasehis own villa in 1916 next to Edison’s‘SeminoleLodge,’called‘TheMangoes,’namedafterthecountlessmangotreesontheproperty.Thus,theywereabletojoinforcesevenduringtheirholidaystopursue ideas regarding automotive de-velopment.HenryFordandhisvehicleswere not the only ones benefiting fromEdison’sthirstforaction;sodidacertainHarvey Firestone. In the 1920s of the20thcentury,thetwobroughthundredsof rubber trees from all corners of theworld toFortMyers inorder toconductresearch into a source for natural rub-berthatcouldbecultivatedandusedinAmerica.TogetherwithHenryFord,they

founded the Edison Botanic ResearchCompany in 1928. Today, the first tree– a Ficus benghalenis,which Firestonegave to Edison in 1925 as a four-footseedling, is reportedly the second larg-estspecimenworldwide.

At the Edison & Ford Winter Estates in Florida, one finds a series of innovations from the past

: SICKinsight[plus]

01 201156

“Homes, gardens, laboratory,museum”–whenvisitingtheEdison&FordWinterEstates, one is surroundedby theauraof a special place. Southernmansions,hundreds of trees serving not just forrelaxationbutalso for research, aparkwithoneof the first swimmingpools inthe United States, a landing stage andbenches with magnificent views over-looking the Caloosahatchee – and aplethoraofexhibitsfromEdisonandalsoafewvehiclesfromFord,e.g.thefamousModelTasapickupandasacamper.Worthavisit…

www.edisonfordwinterestates.org

Subsidiaries

australia Phone+61394974100·+1800334802–tollfreesales@sick.com.auaustriaPhone+43223662288-0office@sick.atBelgium/LuxembourgPhone+3224665566info@sick.beBrazilPhone+551132154900sac@sick.com.brChinaPhone+85227636966ghk@sick.com.hkCzech republicPhone+420257911850sick@sick.czDenmarkPhone+4545826400sick@sick.dkFinlandPhone+3589-2515800sick@sick.fiFrancePhone+33164623500info@sick.frgermanyPhone+492115301-301kundenservice@sick.degreat BritainPhone+441727-831121info@sick.co.ukHungaryPhone+3613712680office@sick.huIndiaPhone+912240338333info@sick-india.comIsraelPhone+97249990590info@sick-sensors.comItalyPhone+3902274341info@sick.itJapanPhone+81333581341support@sick.jpnetherlandsPhone+31302292544info@sick.nlnorwayPhone+4767815000austefjord@sick.noPolandPhone+48228374050info@sick.plrepublic of KoreaPhone+8227866321/4info@sickkorea.netromaniaPhone+40356171120office@sick.rorussiaPhone+74957750530info@sick.ruSingaporePhone+6567443732admin@sicksgp.com.sgSloveniaPhone+386(0)1-4769990office@sick.siSouth africa Phone+27114723737info@sickautomation.co.zaSpainPhone+34934803100info@sick.esSwedenPhone+4686806450info@sick.seSwitzerlandPhone+41416192939contact@sick.chtaiwanPhone+886223756288sales@sick.com.twturkeyPhone+902165285000info@sick.com.trunited arab emirates Phone+97148865878info@sick.aeuSaPhone+1(952)9416780info@sickusa.comMoreatwww.sick.com

>> Imprint

: InfoTradefairs·Imprint·Contacts

>> Visit SICK at the trade Fair!

trade fair dates germanyTradefair Location Date2011Cemat Hanover 05/02–05/06Control Stuttgart 05/03–05/06interpack Düsseldorf 05/12–05/18Sonepar-Partnertreff nord-ost Hanover 05/14–05/15PVSeC Hamburg 09/05–09/09PoSt-eXPo Stuttgart 09/27–09/29moteK Stuttgart 10/10–10/13inter airport Munich 10/11–10/14Fakuma Friedrichshafen 10/18–10/22VISIon Stuttgart 11/08–11/10FmB – zuliefermesse maschinenbau BadSalzuflen 11/09–11/11Productronica Munich 11/15–11/18SPS/IPC/DrIVeS Nuremberg 11/22–11/24

trade fair dates europeTradefair Location Date2011Indumation Brussels,BE 05/18–05/20SPS/IPC/DrIVeS Italia Parma,IT 05/24–05/26Vision & robotics Veldhofen,NL 05/25–05/26swisst.fair Zurich,CH 06/16–06/17Verpackung & Logistik austria Vienna,AT 09/21–09/22PPma show Birmingham,UK 09/27–09/29

trade fair dates worldwideTradefair Location Date2011national Postal Forum SanDiego,US 05/01–05/04CaneCt 2011 Toronto,CA 05/16–05/18rosupak 2011 Moskow,RU 06/14–06/18Cemat – asia 2011 Shanghai,CN 10/24–10/27Industrial automation Show 2011 Shanghai,CN 11/01–11/05

FurthertradefairdateswithSICKworldwideatwww.sick.com/fairs

Publisher:SICKAG·Postfach310·79177Waldkirch·Germany·www.sick.comPhone+497681202-0·Fax+497681202-3863·info@sick.de

Project management:StephanieRott·Stephanie.Rott@sick.de

Specialist editors:TOPMEDIA·DirkS.Heyden·69469Weinheim·info@topmedia-weinheim.depr-bürohensel·RolandHensel·90571Schwaig·pr-hensel@t-online.de

Layout:ad:johnsonKommunikation·76133Karlsruhe·info@adjohnson.de

translator:Dr.ErwinD.Fink·79106Freiburg·info@transmedia-translations.com

Printing:DruckereiFurtwängler·77211Denzlingen·info@druckerei-furtwaengler.de

Pictures:SICKAG,www.ausloeser-fotodesign.de,fotolia,iStock

Individualcontributionsmaybereproducedafterpriorconsent.Pleasecontactusat:Phone+497681202-3878·Errorsexcepted·Subjecttotechnicalchange

SICKAG·Erwin-Sick-Str.179183Waldkirch·GermanyPhone+497681202-0Fax+497681202-3863info@sick.de·www.sick.com

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

Reliable documentation, modern packaging

Everything is in motion – both in complex packaging lines, as in downstream processes. SICK offers 2D code readers, RFID reading devices, and 2D & 3D camera sensors and camera systems for sorting, documentation and product tracing during material flow. They detect the important detailed information, so that products and packaging are reliably identified and distributed into the modern goods economy.

Profitable logistical chainsthrough tracing

Seeing details, understanding the big picture

11283_Branchen-AZ_Verpackung_210x279-4_wf.indd 1 04.03.11 11:06

OrderN

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