contact.01/07The technology and customer magazine

Multi-functional PRK 25BMosca AG appreciates cost-to-performance ratio

Paulaner backs Leuze electronicTop optosensor technology meets the ancient brewer’s art

BCL 500iWith integrated connectivity

Dear readers,

It is our very great pleasure to present not just one but a whole range of new developments with this issue of our customer magazine. For instance the next-generation barcode readers of our BCL 500i family with a whole range of exciting performance features including ultra-fast scanning rates, code reconstruction technology and integrated fi eld bus connectivity. Also featured are our new ODS 96B optical laser distance sensors. With a capacity for unusually fast measurement cycles, these sensors are capable of detecting highly dynamic processes, and as well as conventional interfaces they come already fi tted with an inte-grated IO link interface. When it comes to safety technology, the AS-i safety monitor ASM2 is also on hand to take control of data transmission between the AS-i master and AS-i actuators.

A particular highlight of the year is without doubt the presentation of these and a wide range of other innovations at the Hanover Fair from April 16 – 20. It is our very great pleasure to welcome you to our stand, where we can promise you another exciting innovation: In order to more accurately portray the effi ciency and performance associated with the name of Leuze electronic, we have made some changes to the way we communicate our brand image. In future, we will be appearing with a standardized logo accompanied by the slogan “the sensor people” in a bid to high-light the our company’s focal asset: The ability of each and every member of our committed and qualifi ed workforce to achieve excellence in what they do.

We hope that this magazine and a visit to our stand in Hanover will inspire you with new and profi table ideas for your business.

Yours truly

Dr. Harald Grübel Michael Heyne

Editorial

Index

Leuze electronic in Practice

Leuze electronic Produkt News

High-tech optosensor technology supportingthe age-old brewer’s art.

Multifunctional PRK 25B

Millimetre-precise positioning under the streets of Munich

In-line tube labelling with Leuze electronic

Mini sensor technology for mini-baguettes

BCL 34 PROFIBUS for professionals

04

05

06

07

07

08

Next-generation barcode reader with integrated connectivity

Optical distance sensors supply data in two millisecond cycle

Failsafe actuators in the AS-i network

09

10

11

Munich . To ensure that the excel-lent brews produced by the Paulaner Brewery in Munich reach beer lovers everywhere, the art of excellent brew-ing alone is no longer enough without the benefi ts of high tech.As well as a thorough understanding of the age-old art of brewing, the brewing experts working at Nockher-berg in Munich need to be able to rely on modern technology. Optosensory engineering from Leuze has an impor-tant role to play here, starting with the wooden barrel washing system where SOLID-4 light grids safeguard the areas surrounding the barrel delivery system (Fig. 01) and the automatic conveyor transporting the barrels from the washer to the barrel fi lling station.

Leuze optosensors continue to play an indispensable role in monitoring the subsequent bottle and barrel fi lling processes. Downstream from the bottle fi lling station, for instance, series 18 retro-refl ective photoelectric sensors (Fig. 02) are used for reliable tailback control.The PRK 18/4 (Fig. 03) is used as a trigger photoelectric sensor to initiate a downstream inspection system.

Repeated interruptions occurred in the past during the transportation of crown caps. This is now a thing of the past, as the technicians at Paulaner have come up with the ideal solution in the form of laser sensor PRKL 8-24 (Fig. 04). On the magnetic conveyor belt used to transport the crown caps,

the PRKL 8-24 with its small light spot is able to detect the gaps, allow-ing the caps to reach the fi ller without congestion or jamming. The PRK 97 (Fig. 05) plays a major role in control-ling the transportation of barrels. It prevents a tailback from forming and initiates the ejection command.

Helmut Gerstlauer, in charge of elec-trotechnical engineering in the fi lling department, emphasized:“The individual terms of reference called for the use of different sensors.We were able to source all of these from Leuze as a one-stop supplier, which has had a very positive effect on our safety and automation concept.”

Leuze electronic in Practice

High-tech optosensor technology supporting the age-old brewer’s art

04

Fig. 01 Fig. 05 Fig. 02 Fig. 04

Fig. 03

Leuze electronic in Practice

Strümpfelbrunn . When it comesto leadership of the strapping techno-logy market, the name Gerd Mosca AG springs to mind as one of the sector’s premier suppliers. So it is hardly surprising that the technology leader has been using optosensory technology from Leuze successful-ly for a number of years. MOSCA systems can be used for strapping building materials, graphic products, wood, corrugated cardboard, food items, beverages and countless other products.

Since as long ago as 2003, series 25 sensors have been used on a variety of the company’s machines.The new sensor generation in this size category, the PRK 25B, now holds an impressive track record on the auto-matic plastic tape strapping machine KCK 131.The PRK 25B (Fig. 01) permits not only pallet recognition but also pallet height scanning and positioning. This is a benefi t highly appreciated by Markus Haas, Head of Electric Design for Corrugated Cardboard and Pallet Strapping: “Alongside the increased range, we were also impressed with the cost-to-performance ratio. For us, the PRK 25B is a direct successor to the 25 series, particularly as we were able to carry out a simple one-to-one exchange”.

Another factor speaking out in favour of the PRK 25B was the scope it offers for simple, fast adjustment on the basis of “brightVision®”. This technology places the emphasis on simple sensor alignment with the aid of a visible light spot and convenient operation using bright display diodes with all-round visibility. According to Markus Haas, seen on the right tal-king to Leuze fi eld sales team mem-ber Dirk Heep, MOSCA will be making increased use of this sensor model with its M8 and M12 connector.

At the pallet packaging press(Fig. 03), the PRK 25B is supported by an HRT 96 which scans the pallet towards the front. The PRK 25K per-forms a muting function at the pallet outfeed (Fig. 02), where the danger area is safeguarded by safety light grid COMPACT CPRT 500/2.

Multifunctional PRK 25B

05

Fig. 01 Fig. 02

Fig. 03

Munich . Parking spaces, parti-cularly near the city centre, are in ever shorter supply. The situation is no different in Munich’s Neuhausen district. In a bid to address this gro-wing problem, urban planners opted for a smart and innovative solution in Donnersbergstrasse: Parking below street level.The company WAP Wöhr Autopark-systeme based in Friolzheim planned and constructed an automatic under-ground carpark to accommodate 284 cars for local residents. Optical data transmission with the DDLS 200 (Fig. 01) and barcode positioning system BPS 37 (Fig. 02) from Leuze were in-tegral to the concept. These products help ensure fast, reliable entry and removal of cars into and out of the underground “storage rack”.

Authorized parkers log in by means of a transponder chip at the park box above ground. The gate opens and the vehicle is guided into the box by the driver, who then secures the vehi-cle and leaves the transfer station. At the control panel, the user confi rms the parking process, the gate closes and the car is entered into storage. Car removal takes place in reverse sequence.

The car positioning process under-ground depends upon pin-point precision. The barcode positioning system BPS 37 at the traction sy-stem (Fig. 03) which moves the rack handling (Fig.04) device horizontally ensures that the pallet containing the car is stored in its compartment with millimetre precision.

For fast data transfer from the PLC to the rack handling device, optical data transmission system DDLS 200 was selected. It transmits data to the mo-ving parts of the system free of wear and practically without disturbing in-terference up to a distance of 500 m. This automatic underground carpark has solved the problem of parking in the district, as the 284 cars using the facility no longer clog up the streets.

06

Millimetre-precise positioningunder the streets of Munich

Leuze electronic in Practice

Fig. 01 Fig. 02

Fig. 03

Fig. 04

07

Leuze electronic in Practice

Aichtal . The labelling system fi rm PAGO Etikettierungssystem from Aichtal uses sensor technology from Leuze for its new inline tube labelling machine iDT.The project makes use of PAGO’s expertise in the fi eld of high-perfor-mance labelling machines to turn the Pagomat 6/2 into a complete system including handling unit for tube trans-port and precision guidance.The transparent labels are quickly and accurately dispensed with the aid of ultrasound fork sensor GSU 14.

Because it uses the functional princi-ple of ultrasound, the GSU 14 allows almost any customary material com-binations (transparent, paper, metal-lized) to be reliably detected. Where destination labelling is required, this can be achieved by means of the recessed grips integrated in the tube lids using multicolour contrast scan-ner KRTM 20.

With its three-fronted transmitting LED, the KRTM 20 also achieves ex-cellent contrast conditions even with diffi cult materials. The thermotransfer printer integrated in the complete

system allows batch data to be fl e-xibly printed on the labels, while the correctness and legibility of the EAN codes are reliably checked by the BCL 20 bar code reader.

This machine solution testifi es to Leuze’s competence in the fi eld of labelling technology. As a one-stop supplier in the fi eld of optical sensory technology, Leuze offers a wide pro-duct spectrum for the labelling and packaging sector.

In-line tube labelling with Leuze electronic

Bologna . The Italian fi rm of Grandi SA in Bologna has been constructing packaging machines and systems for over three decades, largely destined for applications in the food industry. Grandi is experienced in the fi eld of specially engineered customer solutions, and its machines and systems are in widespread use around the world. Packaging machines used for counting and packaging mini-baguettes were supplied to an industrial bakery in Central Africa. The baguettes are fed to the individual infeed channels, where they are counted and the correct number of units is collated for the relevant packaging unit. In total

there is a fl eet of four machines in operation with a throughput of 16000 baguettes per hour. When selecting the optosensory system to install, Sensorline Automation decided to opt for the Leuze red light scanner HRTR 3 with background suppression, as the sensor with its elongated light spot is able to reliably detect objects of different sizes and with structured surfaces. With a light spot of 3 x 40 mm (at a distance of 50 mm), it is able to detect objects located at varying positions within the light spot area, ensuring troublefree grouping and packaging of baguettes. The HRTR 3 with its excellent background sup-pression properties also ensures that

that interference from surrounding and disturbing machine contours is suppressed, allowing the system to be used even where machine space conditions are restricted.

Perfect detection of mini baguettes

system allows batch data to be fl e-xibly printed on the labels, while the correctness and legibility of the EAN codes are reliably checked by the

packaging sector.

Balingen . Balingen in the Swa-bian region of Southwest Germany is home to a wealth of major brands. Images broadcast from the hand-ball World Championships are still a recent memory, depicting the German team sporting their Kempa jerseys. The German basketball scene is almost entirely kitted out with the Spalding brand. And the company Uhlsport has developed as a cohesive football brand on the strength of the goalkeeper niche.

For the internationally oriented sports article supplier, all this makes effi cient turnover of merchandise crucial. To ensure that professionals and ama-teurs alike receive their kit in good time, planning and construction of the entire conveying technology outfi t is in the capable hands of ddintra.NET Indoor Logistic based in Ravenstein.

In a warehouse storage area of 9000 m2, up to 40000 articles are turned over every day. This calls for a future-oriented solution involving identifi -cation components which prevent any possibility of bottlenecks in the transmission of data.

A case in point here is the BCL 34, whose integrated PROFIBUS link permits ultra high-speed data com-munication in logistics systems. At Uhlsport GmbH, the BCL 34 is used for merchandise control, making available the maximum PROFIBUS data transmission rate of 12 Mbit/s. The direct data fl ow between BCL 34 and the PROFIBUS Master ensures maximum utilization of the BCL 34’s outstanding effi ciency. The BCL 34 is used at 15 order picking stations, where it identifi es the barcode printed on the transport containers.

The other benefi t: No parameteriza-tion tools are required. In addition, all important parameters can be directly set via the PROFIBUS.

Head of Logistics Heiner Löffl er is enthusiastic about the effi cient inter-action between conveying technology and optosensory engineering: “I need to be able to rely on optimum system availability. Goods ordered today have to reach the customer by tomorrow.”

Dariusz Dziwosz from ddintra.NET also expressed his satisfaction with the system: “The minimal mounting depth of the BCL 34 and the extremely short reading distance permits installati-on in almost any optional location. As a result, we are able to achieve extremely economical plant layouts.”

08

BCL 34 PROFIBUS for professionals

Leuze electronic in Practice

09

Leuze electronic Product News

Next-generation barcode reader with integrated connectivity .

The Leuze electronic barcode reader family has just been increased to include the BCL 500/i, a new product series featuring a range of more sophisticated performance features. An adjustable scanning rate of 800 to 1200 scans per second and a reading fi eld of 200 by 1600 millimetres places the new models in the category of high-speed scanners for extremely fast processes. Special features of the series include code reconstruction technology (CRT) and integrated fi eld bus connectivity.

A high-performance lens wasdeveloped specifi cally for use in the BCL 500i barcode reader.A ±30° asymmetrical optical angle of aperture provides scope for an ex-tensive scanning fi eld aperture even at close range. The devices provide high depth of fi eld and are available in three models: N (high-density lens),M (medium-density lens) and F (low-density lens) for module widths of 250µm, -1.0µm. All three models are available with identical scanning fi elds as line scanners and also in the form of the latest-generation swivel mirror or defl ecting mirror versions.

Innovative code reconstruction technology (CRT) guarantees extreme scanning reliability even for high-speedprocesses. In simple scanning systems, a full bar code is picked up by a continuous scanning line. CRT technology permits codes in extreme skewed positions relative to the central axis to still be reliably scanned. This entails the individual code fragments from several scans being reconstructed by the software to recreate a complete code.The benefi ts of this technology are brought to bear in decoding labels which are applied skewed, have mini-mal heights or are damaged or dirty.

The new devices offer the same two serial interfaces for RS 232 or RS 422 and RS 485 as before, but now supplemented by four communi-cation channels which can each be confi gured individually as a real-time Ethernet or fi eld bus interface.

The new units will be on show at the Hanover Fair 2007 with PROFI-BUS, the most popularly requested platform to date, with additional ETHERNET variants to follow during the course of the year. In addition, Leuze’s own multiNet will be availa-ble for networking applications. The nerve centre for directly integrated communication in the BCL 500i is a HighEnd 32-bit network controller. Integration of the communication interface in the device offers direct benefi ts to the user in the form of highly simplifi ed wiring and a higher data rate in practically every case, as it eliminates the bottleneck caused by additional interfacing units or gateways.

As customary in the PROFIBUS environment, the device can be fully parameterized using this fi eld bus standard directly via the control sy-stem. In addition, it can be addressed via a USB interface. As the parame-terization software “WEB-Confi g” features comprehensive menu and operator prompting, the device is capable of communication with any optional WEB browser.

For the user, this does away with the effort involved in maintaining and up-dating external parameterization and confi guration software on service lap-tops. The interface is conditioned in such a way that a USB memory stick can be used as an external parameter memory with simultaneous capability for performing documentation and monitoring functions.

The BCL 500i is operated by the user via a high-resolution display which provides a clearly arranged, transpa-rent depiction of scanned measured values, set parameters, device status and warning messages. Operation is self-explanatory and is performed using four function keys with stored explanatory texts.

T

F

M

Your ContactIvana Bechtle

+49 | 70 21 | 573 - 202

+49 | 70 21 | 9 85 09 50

ivana.bechtle@leuze.de

Leuze electronic Product News

Optical distance sensors supply datain two millisecond cycle .

With its ODS 96B, Leuze electronic is launching a new generation of optical distance sensors designed to permit the detection of highly dynamic processes by performing unusually high-frequency measurements.

10

The ODS 96B is an optical laser distance sensor featuring CCD tech-nology from Leuze electronic, which is designed to perform dynamic product measurement processes on conveyors, for positioning assign-ments and gripper applications. The new version of the ODS 96 B covers a measurement range from 60 to 2000 millimetres. Measurement times of two milliseconds permit dynamic pro-cesses to be measured up to 5 times faster than comparable products. This means a more tightly-meshed grid, i.e. more fi nely graduated and precise information coupled with more stable measured values, resulting in enhan-ced process effi ciency particularly for applications involving high-gloss, structured or dark surfaces and where there are fl uctuations in temperature.

Faster measurement sequences mean that the units offer a higher level of precision. The measurement accuracy of the ODS 96B is around ±1% with a repeat accuracy of ±0.5%. Precisemeasurement also cuts the time required for readjustment and setting processes.

An easily legible LED display with membrane keypad simplifi es visu-alization and operation. It indicates measured values in millimetres which are still easily legible even under the infl uence of strong sunlight. The complete appliance confi guration of switching points and measurement ranges through to fi lter settings for pre-fi ltration of measurement data directly at the device are all possi-ble with the aid of menu prompting. This includes also the selection of operating modes such as shine, pre-cision or speed. A diagnostic routine can also be performed directly at the device, requiring neither cables, software or cable adapters.All these are integrated features.

One of the special features of the compact ODS 96B alongside theconventional interfaces RS 232 and RS 485 is an integrated IO-Link inter-face. This is used as a serial bidirec-tional communication interface for point-to-point connections.

The new ODS 96B units are the result of interaction between state-of-the-art software and hardware technologies and many years of application know-how. They offer a unique combination of measurement speed and precision even over long distances.

ced process effi ciency particularly for applications involving high-gloss, structured or dark surfaces and where there are fl uctuations in temperature.

Faster measurement sequences mean that the units offer a higher level of precision. The measurement accuracy of the ODS 96B is around ±1% with a repeat accuracy of ±0.5%. Precisemeasurement also cuts the time required for readjustment and setting processes.

Your ContactStefanie Seufert

T

F

M

+49 | 70 21 | 573 - 287

+49 | 70 21 | 9 85 09 11

stefanie.seufert@leuze.de

11

Failsafe actuators in the AS-i network .

The AS-i safety monitor ASM2 from Leuze lumifl ex has now also taken charge of data transmission monitoring between the AS-i master and AS-i actuators, with ASM2 functioning as signal trans-mitter and the failsafe AS-i actuator-slave as signal receiver.

Actuator group formation

For each safety monitor, actuators can be collated to form groups with the same failsafe address. It is also possible to implement a number of actuator groups within an AS-i net-work using additional safety monitors ASM2. This set-up always permits both immediate and also delayed switch-off of the failsafe AS-i actuator. In the event of a fault, a reset only has to be performed for the reported actuator and not for the entire group of actuators in the system.

Economical networking

The failsafe output of the ASM2 can also be used for direct link-up to a second AS-i network, making this a highly economical option as the link works exclusively via the already existing AS-i cable. For diagnostic purposes, the status information of the failsafe outputs and signal out-puts can be accessed from the other network by the ASM2.

Effi cient maintenance

If required, both the AS-i safety mo-nitor ASM2 and the failsafe actuator slaves can be simply exchanged without PC. The confi guration data of the safety monitor being exchanged is transmitted to the replacement unit by linking the two devices with a data cable. When exchanging the failsafe actuator slave, the failsafe address is simply assigned manually using a handheld unit.

Editorial Offi ceRudi Dölfel (head),Susanne Heth, Markus Henkel

EditorLeuze electronic GmbH + Co. KGMarketing and CommunicationPostfach 11 11D-73277 Owen

TFMI

Designbloesch-partner.de

PrintFischbach Druck GmbH72764 Reutlingen

Masthead

switch-off of the failsafe AS-i actuator. In the event of a fault, a reset only has to be performed for the reported actuator and not for the entire group of actuators in the system.

slaves can be simply exchanged without PC. The confi guration data of the safety monitor being exchanged is transmitted to the replacement unit by linking the two devices with a data cable. When exchanging the failsafe actuator slave, the failsafe address is simply assigned manually using a handheld unit.

Your ContactMargarita Neufeld

T

F

M

+49 | 70 21 | 573 - 370

+49 | 70 21 | 9 85 09 11

margarita.neufeld@leuze.de

+ 49 | 70 21 | 573 - 0+ 49 | 70 21 | 573 - 199info@leuze.dewww.leuze.de

Barcodeleser

BCL 500iThe new generation withintegrated interface versatility