sensor solutions for the automotive industry[1]

8/6/2019 Sensor Solutions for the Automotive Industry[1]

1/56

Process Optimisation in Every Detail

I N D U S T R Y G U I D E

Sensor Solutions

for the Automotive Industry


2/56

Becoming better, together.

Leading-edge sensor technology

for the entire production process

2 A U T O M O T I V E I N D U S T R Y | S I C K

The optimisation of operations in automotive production is a

continuous task. After all, global competition and price pressures

do not disappear. Therefore, every detail is always crucial.

SICK sensor technology helps to exploit potential efficiencies.

As an independent and world-leading developer and manufacturer

of intelligent sensor systems SICK has for many years made a vital

contribution to process optimisation in the automotive industry.

SICK sensor solutions are part and parcel of making the entire pro-

duction environment safer, faster and more transparent. Hazards

and problem sources are systematically eliminated; individual pro-

duction steps are accelerated by increasingly accurate, sensor-based

controls. Thus, with its comprehensive sensor competence, SICK

provides convincing solutions in quality assurance and maximum

manufacturing transparency.

All of this to make you one of the first in the global race within

the automotive industry.

Complete Sensor Supplier

Global Presence

Leading Innovator

Service Solutions

Online Partner Portal for

the Automotive Industry


3/56

S I C K | A U T O M O T I V E I N D U S T R Y 3

Sensor benchmarks

for the automotive industry

On the following pages, you will find an

overview of SICKs capabilities and

the most common sensor applications

in all stages of automotive production.

Lets concentrate on the areas in which

SICK Sensor Intelligence can make

your production even more efficient.

Together, we can discover your optimi-

sation potential and develop individual

solutions with you for increased compe-

titiveness.

C O N V I N C I N G P E R F O R M A N C E

Global Presence 04

Complete Supplier 06

Sensor Milestones 08

International Service Solutions 10Online Partner Portal 12

E X E M P L A R Y

S E N S O R S O L U T I O N S

Press Room Sensors 18

Body in White Sensors 28

Sensors in Final Assembly 36

Sensors in Engine

and Gearbox Production 44

Network Technology 52


4/56

Because the industry knows no limits


Global presence.

In the automotive industry, its the global perspective

that counts. Thus, SICK are represented worldwide too.

As an independent partner, we are always on your side

and quickly available. No matter where in the world you

are. SICK is near you: with more than 40 national and

international subsidiaries, many agencies and partner-

ships.

In addition to distribution and service, SICK is geared to

international production and development strategically

placed and customer-oriented, across Germany, Italy,

Sweden, Japan and the USA making us even closer to

many different industry developments.

As an innovative complete sensor supplier with worldwide

leadership, we are thus committed to our self-image and

to our customers: always one step ahead in technology,

around the world.

Benefit from SICKs worldwide presence. Always and

everywhere.


5/56

Around the World

Europe

Austria

Belgium

Czech Republic

Denmark

Finland

France

Germany

Great Britain Hungary

Italy

Luxembourg

Netherlands

Norway

Poland

Portugal

Romania

Russia

Slovakia

Slovenia

Spain

Sweden

Switzerland

Turkey

Asia

China

India

Indonesia

Japan

Korea

Malaysia

Singapore

Taiwan Thailand

Australia

America

Argentina

Brazil

Canada

Chile

Mexico

USA

Venezuela

Africa

South Africa


W O R L D - C L A S S L O G I S T I C S

In essence, our own logistics are

among our best references

where we show how complex

distribution can operate using

intelligent sensor solutions and

sophisticated concepts.

The international SICK logisticscentre reduces delivery times,

service and storage costs.

We take components and spares

to the right place, at the right

time to you. And to your benefit!


6/56


SICK has long recognised the key role sensors play in fac-

tory automation and have developed application-oriented

sensor products. Meanwhile, this has evolved into highly

complex sensor solutions which are more than mere

signal transducers. Our claim is innovative Sensor

Intelligence, for good reasons: complete systems which

combine safety and control functions.

This integration is perfectly illustrated for the automotive

industry, e.g. by UE1000 series safety bus modules:

solutions for machines and systems with a high degree

of networking. A SICK innovation from the Industrial Safety

Systems Division. However, developments also continue

in the two other SICK Divisions of Industrial Sensors and

Auto Ident and with ever-increasing speed.

This, of course, is of particular benefit to you. With Sensor

Intelligence, your processes achieve a degree of optimi-

sation unheard of only a few years ago. And you have all

the positives on your side: quality, efficiency and manufac-

turing transparency.

Combine safety and control to achieve complete inte-

gration with systems, products and services from SICK.

Sensor Intelligence, integrated

The complete supplier for complex solutions.

I N D U S T R I A L S E N S O R S

Encoders, ultrasonic sensors, inductive, capacitive

and magnetic proximity sensors as well as magnetic

cylinder sensors, photoelectric switches, contrast

and luminescence scanners, colour sensors, fork

sensors, light grids, distance sensors, data trans-

mission systems, vision sensors, position finders

and split-beam sensors


7/56


I N D U S T R I A L S A F E T Y S Y S T E M S

Photoelectric safety switches, safety light curtains,

safety laser scanners, safe camera systems, safety

switches and safety software. The range comprises

commissioning, safety checks, repair and exchange

service, stop time measurements, technical con-

sultancy, education und training

A U T O I D E N T

Stationary 2D code and bar code scanners, hand-

held scanners for mobile and stationary use,

omnidirectional bar code reading systems, indoor

and outdoor laser measuring systems, evaluation

electronics, bus connection systems, software

tools, engineering

Photo:DaimlerChryslerAG


8/56


Technology does not evolve by itself. Progress only comes

about when we constantly go beyond what is known, deve-

lop new ideas and take them to the market.

Such as at SICK!

SICK has always invested more than most in research and

development. They are the engine of sensor development

and our worldwide success. The results are impressive:

sensor milestones which have opened up ever-new oppor-

tunities for process optimisation in automotive construc-

tion. Innovations which deserve their names and have

made a decisive contribution to the technological progress

in the automotive industry.

Something which in 1950 began with the first practical

photoelectric switch, based on the autocollimation prin-

ciple, has certainly not finished with the most recent

generation of milestones laser scanners, light curtains,

smart cameras and image code readers.

Trust the leading innovator for complete sensor solutions.

With SICK your production will set benchmarks for the

whole industry too.

Sensor milestones

The S3000 safety laser scanner sets

new standards in measurement accu-

racy and variety of use. It can be used

for the protection of horizontal and

vertical hazardous points, hazardous

areas and access according to type 3

of IEC/EN 61496-3.

S 3 0 0 0 P I O N E E R O F A

N E W D I M E N S I O N I N L A S E R

M E A S U R I N G T E C H N O L O G Y

Protecting

Preventing collisions

Navigating

Measuring

Positioning

Identifying

Sorting

Picking

Integrating

L E A D I N G

I N E A C H D I S C I P L I N E

SICK highlights in the Automotive Industry.


9/56


C 4 0 0 0

S E L F - T E A C H I N G

S A F E T Y L I G H T C U R TA I N

I V C - 2 D / 3 D

H I G H - T E C H

I M A G E P R O C E S S I N G S Y S T E M S

I C R 8 5 0

2 D C O D E S C A N N E R

W I T H H I G H E R A C C U R A C Y

Simply efficient: With the use of the

C4000 Entry/Exit system one sensor

pair reliably distinguishes between

man and machines. Add to this the

self-teaching variety of functions and

easy commissioning and this reduces

assembly and running costs by up

to 40 % compared with conventional

systems.

The ICR850 Image Code Reader does

not require a code that is positioned

exactly or a code-related trigger signal

and no additional lighting. Thanks

to high resolution of 2,048 pixels, it

is able to recognise codes down to a

few mm2 in size something that did

not exist before.

All-in-one and for the first time also in

3D: The freely programmable IVC-3D

smart camera sets standards for qua-

lity assessments on assembly lines,

robotic and handling processes. With

a comprehensive library and sophis-

ticated image processing, it opens up

new, flexible and above all econo-

mical solutions.


10/56

The particular issue of safety is certainly not completed

with fitting first-class SICK sensor technology. It begins

long before assembly and then just continues. After all,

safety with Sensor Intelligence is a continuous process

over the whole life cycle of machines and systems: from

planning and operation to modernisation.

With the International Service Solutions from SICK you

benefit at every stage. From the worldwide know-how of

the market leader in safety to the experience from various

industries and countless applications.

Use the International Service Solutions for more safety

and efficiency over the entire machine life cycle. More on

www.sick.com

1 0 A U T O M O T I V E I N D U S T R Y | S I C K

From planning and operation

to modernisation

Service over the lifetime of a machine.

T R A I N I N G &

E D U C A T I O N

We have to know technology to use

it safely and fully benefit from the pos-

sibilities it offers. Learn about every-

thing through SICK training from

the basics of safety technology to the

implementation of complex safety

solutions.

C O N T I N U O U S

P R O C E S S O P T I M I S A T I O N

We accompany you permanently. As

soon as there are better solutions for

an area of your production, we will

suggest them to you. Thus, we always

maximise your sensor efficiency.

T H E O N L Y A C C R E D I T E D

M A N U F A C T U R E R

SICK is the only manufacturer of sen-

sor technology accredited to perform

safety inspections of machinery and

systems ... one of the most coveted

official quality certifications.


11/56

S I C K | A U T O M O T I V E I N D U S T R Y 1 1

SICK Safety in All Phases of Factory Automation

SICK INTERNATIONAL SERVICE SOLUTIONS

A P P L I C A T I O N S U P P O R T

S A F E T Y A N A LY S I S


U P G R A D E S E R V I C E S


T R A I N I N G & E D U C A T I O N


P R O D U C T S U P P O R T

During the whole machine life cycle

OPERATION

MACHINE

LIFE CYCLE

MODIFI-

CATION

PLANNING

ENGINEERING

DESIGN

COMMIS-

SIONING

SIGN OFF


I N S P E C T I O N S

S T O P T I M E M E A S U R E M E N T

S E R V I C E C O N T R A C T S


C O M M I S S I O N I N G

S U P P O R T

T E C H N I C A L S I G N - O F F

Commissioning check

S A F E T Y S I G N O F F

Inspection prior to first

commissioning


12/56

The Online Portal is a must where efficiency and fast pro-

cessing, in every detail, are paramount such as in the auto-

motive industry! At www.mysick.com you will find compre-

hensive eCommerce tools and information for your sensor

planning: complete project management from availability

check, quotations, ordering terms and conditions to order

placement/status. The SICK Partner Portal supports your

workflow, with the individual allocation of user rights.

With easy online access to sample applications as well as

the downloading of technical data, drawings and graphics,

your sensor planning is accelerated effectively.

Sensor planning online in the SICK Partner Portal


www.mysick.com

Your Sensor Partner Portal

Clear:

Under the menu items of Products,

Information and My Applications

you will find everything you need foryour sensor planning.

Available 24 hours:

No matter where in the world you are

or when you want to know something.

At www.mysick.com, everything is only

a click away. Anytime!

Secure:

Your data is password-protected and

can only be seen by you. Using the in-

dividual user management, you can

define who is allowed to see what data

and what action to take!

www.mysick.com

Working even more efficiently, online!

The big online product catalogue:

www.sick.com/productfinder


13/56


Price and availability query:

Simply and quickly deter-

mine the price and the de-

livery date of the products

required.

Quotation enquiry:

You can enter a reference number for

your quotation. The quotations are

available to you online. Each quotation

is confirmed to you by email.

Ordering online:

In a few steps, you can perform the process

of ordering equipment.

Your work becomes even more efficient online

The user management supports your workflow

Product availability is shown immediately

All operations are significantly accelerated,

e.g. price enquiries, quotations, orders

Finding products, applications, circuits and

accessories is even faster

Product search. Products and comprehensive

information technically linked

All operations at a glance: product search,quotation, order status etc.

Exclusive download options: technical data,

drawings, graphics etc.

Go online right away!

Y O U R B E N E F I T SI N T H E S I C K P A R T N E R P O R T A L


14/56

Selected solutions to problems

for the Automotive Industry.


T H E 4 P R O C E S S S T E P S A N O V E R V I E W 1 6

1 ST P R O C E S S S T E P : P R E S S R O O M 1 8

Focus 1: Directing, controlling and protecting stacker cranes

Focus 2: Directing, regulating and monitoring the uncoiling operation

Focus 3: Protecting, positioning and monitoring body presses

Focus 4: Protecting, controlling and identifying in robot applications

2 ND P R O C E S S S T E P : B O D I E S I N W H I T E 2 8

Focus 1: Protecting and controlling turntables

Focus 2: Protecting and positioning in the area of vehicle floor assembly

Focus 3: Protecting, positioning and identifying in the area of robot cells

3 RD P R O C E S S S T E P : F I N A L A S S E M B LY 3 6

Focus 1: Work guidance and body identification in interior fitting

Focus 2: Protecting access to the assembly cell, locational and positional

control of rear/front screensFocus 3: Positional control and collision protection on scissor lifts, backup control

and identification for the supply of wheels

4 TH P R O C E S S S T E P : E N G I N E A N D G E A R B O X P R O D U C T I O N 4 4

Focus 1: Protecting of processing machines and automatic loading stations

Controlling and monitoring of robot grabbers and workholders

Focus 2: Hazardous point protection of assembly robots

Lubricant control and component identification for quality assurance

Focus 3: Entry protecting of robot cells

Positioning and indicating of workpiece carriers

N E T W O R K T E C H N O L O G Y 5 2

A P P L I C A T I O N S


15/56


A P P L I C A T I O N S

Discover, step by step, how SICK

Sensor Intelligence makes your

operations even faster, more effi-

cient and safer.

We have illustrated the entire

production process. Using selected

examples, demonstrations of the

many different possibilities offered

by intelligent sensor solutions can

be shown. Be stimulated and find

out about your optimisation poten-

tial.

SICK support you in this.

The following applications only show the solution of

the tasks, schematically. Selecting the device types,

their arrangement and assembly must, especially in

areas of safety engineering, be matched to the task

and the conditions at the point of use. The represen-

tation of applications, the product properties given

and technical data do not constitute a warranty de-

claration.


16/56

SICK offers sensor solutions

for all areas of automotive production.

T H E 4 P R O C E S S S T E P S A N O V E R V I E W


2 . B O D I E S I N W H I T E

1 . P R E S S R O O M


17/56

4 . E N G I N E A N D G E A R -

B O X P R O D U C T I O N

T H E 4 P R O C E S S S T E P S A N O V E R V I E W


3 . F I N A L A S S E M B L Y


18/56

In the production of body parts, quality and throughput targets must be right. Therefore,

SICK sensors are used in nearly all areas of the press room with its many automated

press lines and robot assembly areas. They ensure maximum readiness to deliver and

direct the components and ready-to-fit systems to the production lines at the correct

point in time.

Storing sheet metal coils

Taking coils out of storage

Uncoiling the sheet metal

Cutting sheet metal panels

Punching and pressing

body parts

Placing the punched

parts in racks


1. Press room:

Assuring quality and meeting throughput targets

whilst maximising protection for man and machine.

F O C U S 1

F O C U S 2


19/56


P R E S S R O O M

F O C U S 3

F O C U S 4


20/56

Press room, focus 1:

Directing, controlling and protecting

stacker cranes.

2 0


21/56

The DME distance sensor determines the

horizontal position of the trolley of a

gantry crane. The vertical position of the

positive lifting gear is determined by an

ATM60 absolute multiturn encoder. The

IN4000 inductive safety sensor indicates

when the trolley has reached the limit

of the automatic range. Outside this range,a worker controls the trolley and lifting

gear, by hand. All measuring sensors are

networked with the central control, via

Profibus.

The stacker crane is protected by S3000

safety laser scanners, in both directions

of travel. The protection (red) and warning

fields (yellow) have their size dynamically

adapted to the speed. The protection and

warning fields are switched over if the

direction of travel changes. The X axis is

positioned by the DME3000/5000 dis-

tance measuring device. Fine positioning

in the X and Y axes is performed by means

of a DMP position finder. The ISD300 data

photoelectric switch facilitates the stacker

crane/computer data exchange.

The DS60 distance sensor indicates that

a rack bin is occupied. It is insensitive to

reflections and features a particularly large

scanning distance.

The DMP2 position finder facilitates the

fine positioning of the stacker crane.

It allows the stacker crane to follow until

its receiver array is centrally lit by the

reflected light.

The i1000 safety switch locks the door to

the working cell. Opening the door triggers

a stop command for the stacker crane.For long stacker crane stopping distances,

the locking device of the safety switch is

maintained by means of a safety time relay

until the stacker crane has come to a

standstill. This switch is designed for par-

ticularly arduous operating environments

and heavy doors.

A U T O M O T I V E I N D U S T R Y | S IC K 2 1

P R E S S R O O M


22/56


Directing, regulating and monitoring

the uncoiling operation.

2 2


23/56

The DS60 distance sensor indicates the

presence of a sheet metal coil.

Identifying the sheet metal coil prior to

processing, with the CLV450 code reader.

For instance, the type of material, sheet

thickness (gauge), web width etc. are

coded. The code reader, equipped with a

swivelling mirror, recognises the code in

a wide field of vision.

The DMT10 distance measuring device

continuously measures the diameter of

the coil. The measured values serve to

optimise the pull-off speed and start the

automatic coil changeover.


P R E S S R O O M

The MLG1 modular light grid recognises

a hole > 15 mm, with which a weld is

marked. It signals the position of the weldto the plate shear control.

The MLG1 modular light grid detects the

sag of the sheet web for loop control:

adjustment of uncoiling speed and pull-off

speed. The beam coverage is output via an

RS485 interface.


24/56


Protecting, positioning and monitoring

body presses.

2 4


25/56

The M4000 multiple light beam safety

device, consisting of sender and receiver

unit, protects the access to a hazardous

area. Three sides of a dangerous area can

be protected with two deflector mirrors.

The interruption of one beam or several

beams stops the hazardous movement

(here: movement of the press table).A reset device positioned outside the

hazardous area enables the protective

field. This enables the restart of the press

table.

IQ40 inductive proximity sensors indicate

the correct positioning of the tool on the

press table, enabling automatic locking.

The IM30 inductive proximity sensor indica-

tes that the press tool is closed and can be

changed.

The i100P safety position switch indicates

the opening and closing of a sliding gate.

The use of high quality materials guaran-

tees reliable operation even in arduous

environments.

The S3000 safety scanner protects the area

in front of the press between two tool gates.

If there is a person or an object in this area,

extension or retraction of the tools is not

possible.

Two OD displacement sensors determine,

very precisely, the thickness of the sheet,

and report thickness deviations and double

sheets. In a subsequent control unit, the

measured values are evaluated. On the one

hand, the correct sheet thickness is checked

and, on the other hand, tool damage at

the following processing station is avoided

through double-sheet recognition.

Component control with a WT12 laser

photoelectric proximity switch. It indicates

that the part has been removed.


P R E S S R O O M


26/56


Protecting, controlling and identifying

in robot applications.

2 6


27/56

The rack station in front of a robot cell is

access-protected by a C4000 safety light

curtain. If the rack is changed or if a per-

son steps through the light curtain, there

will be enforced interruption of the light

curtain and the robot will stop. However,

the C4000 is bridged, for the robot to be

able to continue work at another location,during rack changeover. Simultaneously,

a second access protection behind the

rack station is primed and takes over the

safety function. It consists of an M4000

multiple light beam safety device and a

deflector mirror. If the M4000s lightbeams

are interrupted, too, then the robot is

stopped. C4000 light curtain and M4000

multiple light beam safety device are also

mutually active.

Two WT9-2 photoelectric proximity switches

and four IM12 inductive proximity sensors

control the grabber of a robot for locating

a body part. MTZ1 magnetic cylinder

sensors recognise the piston position in

the pneumatic cylinders, with which the

grabber is closed or opened.

A CLV490 bar code scanner identifies a rack

which the robot loads with body parts.

The code reader supplies the data to a cen-tral computer, for the further working .


P R E S S R O O M


28/56

The construction of body in white is one of the vital production steps in automotive

construction. This is where the various components are put together for a strong

and homogeneous vehicle base. The foundation of the vehicle the body evolves.

SICK sensor solutions contribute to matching precision with speed and safety.

Completion of body parts

Assembling the body in white

Insertion of bonnet and tailgate

Checking the body


2. Body in white:

SICK combines precision, speed and safety

for productive solutions.

F O C U S 1

F O C U S 2


29/56


B O D Y I N W H I T E

F O C U S 3


30/56

Body in white, focus 1:

Protecting and controlling turntables.

3 0


31/56

Protection of hazardous points/hazardous

areas in front of a turntable with C4000

safety light curtain and S3000 safety

scanner. The C4000 stops the rotational

movement of the table if there is an inter-

vention in its protective field. Its height

prevents reaching above. Here, the S3000

serves as point-of-operation guarding, alsocapable of protecting a non-rectangular

room. The protective field of the S3000

can be freely programmed within a radius

of 7 m and thus adapted to the spatial

conditions.

On the UE4150 bus node for Profibus, all

safety sensors of a workstation including

emergency stops and signal transducers

can be installed and communicated to,

via the bus. All connected devices can be

analysed and visualised. Simple installati-

on by means of pre-programming and cost-

effective upgrade of systems is possible.

The IVC-2D Industrial Vision Camera mo-

nitors whether the nuts placed on the sheet

part have been correctly positioned and

welded. The working process is continued

only when the camera confirms this. The

data supplied by the IVC is saved, for quali-

ty assurance.

On the turntable, small parts (bolts, lugs)

are welded to a body part. The robot

places a body part in the clamping device

on the turntable. The IQ18 inductive

proximity sensor confirms the presence,

whereupon the clamping device closes and

the table rotates by 180. The operatorplaces bolts and lugs into/onto the body

part. The WT12L-2 laser photoelectric

proximity switches indicate their presence.

If all parts are present, the rotating

movement of the table into the robot cell

is started. The robot welds the parts.




32/56


Protecting and positioning

in the area of vehicle floor assembly.

3 2


33/56

Access to the robot cell is protected by a

C4000 Entry/Exit safety light curtain.

This light curtain is used where material is

automatically transported into the hazar-

dous area of a system and, simultaneously,

entry of people must be securely preven-

ted. The C4000 Entry/Exit checks the pat-

tern produced by the skid moving throughthe light curtain, and thus can distinguish

between man and material. Additional sen-

sor components such as muting sensors

or swing doors are as unnecessary as addi-

tional inputs or safety relays in the control.

The solution offers great potential savings

in terms of costs for engineering, assembly

and operation.

T400C non-contact safety locks monitor

the swing doors at the infeed/outfeed

station of a robot cell. If a door is opened,

the switch stops the robots working

process. T4000C units have non-wearing

solid-state outputs and a feature is simple

installation.

UE10 safety relays support safe automati-

on. They are the link between photoelectric

safety switches and the machine. They

offer the advantages of the classic relay

and modern switching technology. They are

used to link several deactivation areas or

to monitor door switches, two-hand control

circuits and enabling switches.

The IN3000 inductive safety sensor con-

trols, at the foot of a robot, its axis 1

position. This information is passed to the

vehicle control: The start of the automated

guided system (AGS) is permitted only when

the unloading operation is completed.




34/56


Protecting, positioning and identifying

in the area of robot cells.

3 4


35/56

The muting system, consisting of a multiple

light beam safety device with integrated

M4000 Advanced muting module and

4 distance sensors (DS60, ObSB [object

between sensor and background]), monitors

the lock to a portal robot. The special

arrangement of the DS60 distance sensors

The position of the lifter platform is deter-

mined with a BTF13 wire draw encoder,

which is directly linked to the frequency

converter of the lifter via an SSI interface.

The correct position of the skid on the lifter

is monitored by a photoelectric proximity

switch. The rear photoelectric reflex switch

on the lifter indicates any overtravel tothe correct position; there is also an emer-

gency stop. On the upper level, the first

photoelectric switch indicates that a skid

is positioned in the waiting position. The

second photoelectric switch indicates an

overtravel of the correct position: emer-

gency stop. The light paths of the second

photoelectric reflex switch at the upper

level and the front photoelectric switch on

the lifter as well as the photoelectric switch

at the lower level must be unobscured, for

the lifter to start.

The CLV490 barcode scanner identifies the

body and ensures the correct allocation of

bonnet and tailgate. Thanks to autofocus,the reader has an extremely large depth of

focus.

WT12L laser photoelectric proximity swit-

ches and DS60 distance sensors check a

body for the presence of special recesses,holes, brackets and equipment: optoelec-

tronic quality assurance.



ensures that the vehicle body is safely

recognised on the skid as such, that the

M4000 is muted and that the skid can

move into the cell without the system being

stopped. If, however, a person enters the

cell, the system is stopped.


36/56

This is the basic principle of final assembly. It centres on logistics and quality. Only thus can

the car, as a product, be produced perfectly and in accordance with the customers wishes.

Whether identifying bodies, inserting screens, collision protection on suspended conveyors,

supplying the wheels and many other applications: SICK sensors are everywhere, to ensure

fluid processes.

Painting of the body

Interior fitting

Assembly of front and rear screens

Marriage of body and chassis

with engine

Assembly of wheels

Assembly and

final inspection


3. Final assembly:

The right components and modules,

at the right time, in the right place.

F O C U S 1


37/56


F I N A L A S S E M B L Y

F O C U S 2

F O C U S 3


38/56

Final assembly, focus 1:

Operator guidance and body identification

in interior fitting.

3 8


39/56

Each storage shelf for small parts is, on its

pick-off side, equipped with a Pick2Light

light grid (PLG). The green job lamp indi-

cates the operator from which bin to take

a component: worker guidance (also called

Pick to Light or Poka-Yoke). If the worker

accidentally reaches into a wrong bin, this

will be shown optically and acoustically.

Here, instead of the light grids (see above),

an LMS sensing laser scanner takes over

the monitoring of the correct picking of

parts, with a pulsed laser beam sweeping

the area to be monitored. According to the

principle of pulse run-time measurement,

the position of the location where the

emitted laser beam is reflected (the opera-

tors hand, in this instance) is determined.

The storage bin co-ordinates are displayed

for the operator, by means of lamps.

The signal lamp above the shelf shows

red, and an acoustic signal sounds, if

he or she reaches into a wrong bin.

The IT5620 hand-held scanner reads data

for further equipping the body. The data is

wirelessly transmitted to its ST2020 base

station and, from there, to a central com-

puter.



The CLV450 compact bar code scanner

identifies a body prior to assembly. The

code reader is designed for applications

requiring a long reading distance. It also

features dynamic focus adjustment.


40/56


Protecting access to the assembly cell,

locational and positional control of rear/front screens.

4 0


41/56

The rack station in front of a robot cell is

access-protected by a C4000 safety light

curtain. If the rack is changed or if a per-

son steps through the light curtain, there

will be an enforced interruption of the light

curtain and the robot will stop. However,

the C4000 is muted, for the robot to be

able to continue work in its cell. Simulta-neously, a second access protection

behind the rack station, consisting of an

S3000 safety laser scanner, is primed

and takes over the safety function. If the

S3000s light beams are interrupted, too,

then the robot is stopped. C4000 light

curtain and S3000 laser scanner are also

mutually active.

The robot takes a front screen from the

rack, with four WT24 photoelectric proximi-

ty switches taking over the exact positio-

ning of the grabber. This is attained when

all four recognise the black coating at the

edge of the screen. To insert the screen,

the robot then moves to the approximate

position over the bodys front screen cut-

out. It moves its grabbing arm over the

fitting position until the two OD100 dis-

tance sensors capture the bodys edge and

both have determined exactly the same

distance. Thus, the X, Y and Z co-ordinates

for the position of the robot arm in relation

to the body have been determined. They

are saved. The screen is accurately inser-

ted.

Here, a WF100 fork sensor takes over the

job of the two OD100 distance sensors

(see position 1). With it, to determine the

position, two dedicated points in the bodys

screen cut-out are approached, and thus

the X, Y and Z co-ordinates for the position

of the robot arm in relation to the body are

determined.



The skid with the body can thus pass with-

out triggering a signal. Swing doors are

not needed since the protective fields of

the S3000 units are always active on the

sides. If a person interrupts one of the

protective fields, the transport track and

the robot movements are stopped.

The entry into the assembly cell is protec-

ted by two S3000 proximity laser scanners.

Here, two devices were used to avoid

shadows and thus monitoring gaps next to

the body and the transport track. The two

protection fields are adjusted to the body

profile in steps, via IQ40 inductive proximity

sensors arranged along the transport track.


42/56


Positional control and collision protection on scissor lifts,

backup control and identification for the supply of wheels.

4 2


43/56


On the suspended conveyor, IQ40 induc-

tive proximity sensors over the runner

serve to position the scissor lifts for cor-

rectly positioning the vehicles for wheel

assembly. DS60 distance sensors ensure

the correct distance of the suspended

vehicles with scissor lifts. They monitor

their relative distance: collision protection.The devices have two switching points

which can be allocated at certain distan-

ces. When reaching switching point 1,

the suspended vehicle switches to creep

mode, with a stop at switching point 2.

The IQ40 inductive proximity sensor on

the scissor lift switches if the scissors are

closed, and thus permits e.g. the exit from

the assembly cell.

The ICR890 camera system identifies tyres

prior to storage or prior to assembly onto

wheels. The bar code to be read is attached

to the tyre bead and can no longer be seen

after pulling onto the wheel. The identifi-

cation ensures that the right tyre is taken

to the right storage location or allocated

to a particular wheel. The information read

can be saved on a central computer, for

quality assurance.

WLR1 photoelectric reflex switches con-

trol the supply of wheels to the assembly

station. The devices are conceived for

so-called backup conveyors. They are

equipped with solenoid valves. The trans-

port track is divided into segments, at the

end of which there is always one WLR1

mounted with a reflector. The internal logic

of the devices ensures a controlled flow of

materials, for the onward transport of the

wheels to be started or stopped at defined

segments.


The OPS290 omnidirectional bar code rea-

ding system identifies wheels prior to auto-

matic assembly and thus ensures that the

correct wheels with the correct tyres are

fitted to the vehicle. The system consists of

two CLV490 autofocus bar

code scanners with swivelling mirrors and

an OTC Omni Tracking Controller. The two

reading lines cross and move over the

object to be scanned, to thus be able to

reliably recognise codings irrespective of

their positions.


44/56

To ensure that engine components form a perfect whole, SICK sensors perform vital

monitoring, control and safety tasks in all areas of the power train. For example,

in checking for the presence of workpieces, control of gantry robots, lubricants control

in the engine or control of the workpiece carriers on transfer lines and, last but not

least, in protecting hazardous points and areas.

Machining of cylinder head and engine block

Assembly of the cylinder head

Assembly of the engine block

Marriage of engine block and cylinder head

Assembly of accessories


4. Engine and gearbox production:

SICK sensor solutions ensure precision and safety.

F O C U S 3


45/56


E N G I N E A N D G E A R B O X P R O D U C T I ON

F O C U S 2

S 1


46/56

46

Engine and gearbox production, focus 1:

Protecting of processing machines and automatic

loading stations. Controlling and monitoring of grabbers.


47/56


The loading station before the machining

line is access-protected from people using

C4000 safety light curtains and M4000

multiple light beam safety device. Both

safety devices are switched as a lock.

If an empty rack is brought into the station

or if a filled one is collected, the C4000

light curtain is interrupted, the M4000multiple light beam safety device then

takes over the protective function: the por-

tal robot can continue to work. It is stop-

ped only if the M4000 is interrupted too.

After the rack change, the C4000 safety

light curtain again takes over the access

protection. Now the rack can interrupt the

M4000 multiple light beam safety device

without the gantry loader being switched

off. The safety devices can be switched

via a safety PLC or a UE s afety interface.

Two IQ40 inductive proximity sensors indi-

cate that a filled rack is standing in the

collection station. The CLV490 bar code

scanner passes the data of the machined

cylinder heads to a central computer.

E N G I N E A N D G E A R B O X P R O D U C T I O N

The i16 safety switch safeguards the sliding

door on an encapsulated processing ma-

chine. The machine is stopped instantlywhen the door is opened. Machines with

long stopping times are protected by

safety switches with locking devices, e.g.

i100 Lock. The safety switch allows the

sliding door to be opened only when the

machine has stopped.

The ATM absolute multiturn encoder re-

ports the horizontal position of the lifting

mechanism to the control system. It canbe integrated into the control system, via

different interfaces (SSI, RS422, Profibus,

DeviceNet, CANopen).

The IM18 inductive proximity sensor in-

dicates the presence of the workpiece to

the control unit of the processing machineand releases it for machining. The IM30

proximity sensor (top centre) signals the

opening of the clamp device for the auto-

matic removal of the cylinder head.


48/56


Hazardous point protection of assembly robots. Lubricant

control and component identification for quality assurance.

4 8


49/56

Following assembly, the cylinder head is

sprayed with lubricant. It provides the first

supply when the engine is started. The

LUT3 luminescence scanner checks the

presence. It emits ultraviolet light, which

converts the luminophors in the lubricant

to visible light, which is received by the

LUT3. The onward transport of the cylinder

head is stopped if no lubrication film is

present.

Hazardous point protection on a robot sta-

tion (handling robot) with C4000 safety light

curtains. It is possible to step behind the ver-

tically arranged safety light curtain, as pre-

sently fitted. To protect the operator from

this, another short C4000 is mounted below

the vertically attached light curtain. Both

safety light curtains are serially connectedwith one another (cascading): The vertically

arranged C4000 serves as host, the horizon-

tally arranged one as guest. Any intervention

in the protective fields stops the handling

robot. The UE470 safety controller deals

with the machines entire safety technology.

Emergency stop and safety switches, light

grids as well as the signals of the machine

for controlling the bottom/top dead centre

process are directly connected to the UE470.

Various programs, required for different

operations, are saved in the UE470. These

can be called via a program change-over

switch. It is also used to select the process-

dependent safety functions. Using the UE470

negates the wiring of several safety relays

in the control cabinet. Costs for installation,

assembly as well as commissioning are

reduced.

The IVC-2D Industrial Vision Camera checks

the presence of lubricant in the groove of

the bearing shell. The lubricant is supplied

to the bearings when the engine is first

started. If the IVC communicates that there

is no lubricant, this will be indicated.

The ICR850 code reader reads the two-

dimensional code on the camshaft and thus

checks whether the correct camshaft is

fitted. It passes the information to a central

computer, for quality assurance.

The OD100 distance sensor checks the

correct camshaft position, prior to placing

the drive chain.

The data of the fully assembled cylinder

head is transmitted to the quality manage-

ment system, via an IT5620 hand-held

scanner with wireless data transmission

(ST2020).




50/56


Entry protection of robot cells.

Positioning and indicating of workpiece carriers.

5 0


51/56

The C4000 safety light curtain protects the

material lock to the assembly cell. Four

IQ40 inductive proximity sensors act as

muting sensors. Their special arrangement

ensures that the workpiece carrier with

its engine is admitted without interrupting

the robots working process. If, however,

a person enters the cell, he or she will bedetected by the C4000 safety light curtain

and the system stopped.

A cylinder head enters the assembly cell on

its workpiece carrier. The transfer system

is controlled via three IQ40 inductive proxi-

mity sensors which indicate the position of

the workpiece carrier: the workpiece carrier

is stopped at the handover station.

The UC12 ultrasonic proximity sensor in-

dicates the presence of a cylinder head.

The robot grabs it and places it on the

engine block. The four binary sensors,

the photoelectric proximity switch and the

three proximity sensors (see above) are

cost-effectively networked, via an AS inter-

face field module, with the first bus level.

(Actuator Sensor Interface = lowest field

bus level).




52/56

5 2

Network technology:

Fieldbus integration, platform- and system-neutral.

F O C U S 1


53/56

As a one-stop supplier, SICK takes a neutral stance regarding the subject

of fieldbus integration. SICK sensors offer connectivity options for almost

all known fieldbus systems: PROFIBUS and PROFIsafe, AS-Interface and AS-

Interface Safety at Work, DeviceNet and DeviceNet Safety as well as Ethernet.

Beyond the mere connection, SICK also offers complete automation. For the

AS-Interface and DeviceNet system worlds, standalone and configurable con-

trols are available in addition to the sensor integration. This enables solutions

to automation tasks and the creation of flexible and cost-effective monolithic

complete solutions.

The user determines which integration will be implemented. In each case, they

can use the benefits of fieldbus technology, e.g. reduced hardware, less system

planning through the modular fieldbus design or optimisation of machine main-

tenance by reducing the choice/variety of units, remote maintenance, diagno-

stics and parameter download.


N E T W O R K T E C H N O L O G Y

F O C U S 2

Open for all bus systems.


54/56

5 4

IVC-2D Industrial

Vision Camera

I/O link

CLV420

bar code scanner

Connecting module

for CDM400

bar code scanner

PROFIBUS, PROFIsafe

PROFINET

DeviceNet, DeviceNet Safety

Ethernet, Ethernet/IP

AS-i, AS-i Safety at Work

SICK CAN Scanner-Network

SICK sensors from the Divisions of

Industrial Sensors, Industrial Safety

Systems and Auto Ident can be used

on almost all system platforms.

Connecting module

for CDB400

bar code scanner

Base station

IT5620

hand-held scanner

OPS400

OMNI-Portal Scanner

CLX490

omnidirectional bar

code reading system

ATM60/90 absolute

multiturn encoder

The available integration options in

control engineering, based on world-

wide standards, make each and every

solution a longterm future investment.

DME5000

distance sensor

W12-3 photo-

electric switch

W27-3 photo-

electric switch

IM18 inductive

proximity sensor

MLG automation

light grid


55/56


N E T W O R K T E C H N O L O G Y

OPC Server

Status and diagnostics directly

to the HMI (Human Machine Inter-

face) and via company network

Remote maintenance from every

site, and into the protective field

Information management: confi-

guration backup stored centrally

With a few mouse clicks, Active-X

enables a representation of protec-

tive fields in the OPC Client.

SNC Safety Network

Controller

W12-2 photo-

electric switch

W27-2 photo-

electric switch

AS-i fieldbus module AS-i Safety at Work

Slave UE4200

PROFIsafe safety

bus module UE4100

DeviceNet

safety bus module

UE4400

Safety positioning

switch

M4000

multiple light

beam safety

device

S3000 safety

laser scannerSafety switch

C4000

safety light curtain

FDT/DTM Technology

Standardised Style Guide:

Different device tools can be ope-

rated using the same philosophy.

Central data storage: The configu-

ration data of the individual device

manufacturers, the DMTs (Device

Type Manager), are stored centrally

in the FDT (Field Device Tool).

Uniform access point: Only the FDT

makes the connection to the device

via the field level.


56/56

I N D U S T R I A L S A F E T Y S Y S T E M S

Comprehensive safeguarding ofboth personnel and machinery!

As specialists in Sensor Techno-

logy, SICK develops and manu-

factures pioneering products for

providing protection in hazardous

zones, dangerous locations and

for safeguarding access points.

By providing services, which en-

compass all aspects of machine

safety and security, SICK is

setting new standards in Safety

Technology.

A U T O I D E N T

Whether the tasks involveidentification, handling, classifi-

cation or volume measurement,

innovative Auto Ident systems

and laser measuring systems

function extremely reliably, even

under rapid cycle times. They

conform to the latest Standards

and can be simply and speedily

integrated in all industrial en-

vironments and external appli-

cations.

ANALYZERS AND PROCESSINSTRUMENTATION

System control, maintainingsetpoints, optimising process

control and monitoring the flow

of materials the instruments

and services for Analysis and

Process Measurement, supplied

by SICK MAIHAK, are setting

the standards for these appli-

cations in terms of Technology

and Quality.

I N D U S T R I A L S E N S O R S

Our complete range of sensorsprovides answers to suit any

application in the field of auto-

mation. Even under rugged

ambient conditions objects are

reliably detected, counted and

positioned in respect of their

form, location and surface

finish, as well as their distances

established with pin-point accu-

racy.

R A N G E O F E X P E R T I S E

8009329/11-05MRH/FDPrintedinGermany(12-05)

Subjecttochangewithoutnotice00WBint25 Worldwide present with

subsidiaries in the following

countries:

Please find the detailed

addresses and more represen-

tatives and agencies in all

major industrial nations at

www.sick.com

Schweiz

Singapore

Republic of Korea

Republika Slovenija

Suomi

Sverige

Taiwan

Trkiye

USA/Canada/Mxico

Australia

Belgium/Luxembourg

Brasil

Cesk Republika

China

Danmark

Deutschland

Espaa

France

Great Britain

India

Italia

Japan

Nederlands

Norge

sterreich

Polska

Russia

sensor solutions for the automotive industry[1]

Documents