insight

The building security laser measurement system

LD PDS – protects valuablesand prevents vandalism

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2 0 0 4www.sick.com2 SICK’s customer magazine

TPM servo actuators from WITTENSTEIN

Perfect positioning with theSRM 50 motor feedback system

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Curtains down!The vertical protective field of

the S 3000 safety laser scanner

Curtains down!The vertical protective field of

the S 3000 safety laser scannerPage 06

10 years’ success in the Middle Kingdom

It is exactly one decade since SICK turned its attention to the Chinese marketwith its SICK Hong Kong subsidiary. It all started in Guangzhou with the first of-fice, which was soon followed by another in Hong Kong itself. What originally be-gan with just four personnel has since developed into a company with almost 60 employees at a total of four sites – Beijing and Shanghai came later.

The quality of the products, the enormous industrialisation boom of recent years,and the support received from the German headquarters in Waldkirch meeting allour technical and commercial needs, were undoubtedly of decisive importance inthis success. But also of decisive importance was, and remains, the fact that ba-sically it is the Chinese who run the business in China and Hong Kong. Thus thementality interface, with all its challenges, remains within the company – commu-nication in the Group, instead of a clash of cultures in customer contacts.

In the next decade, too, China – the Middle Kingdom – will remain a market of di-verse challenges. What SICK Hong Kong began ten years ago will be continued bySICK Optic-Electronic Co. Ltd., Guangzhou China, founded last year: the success-ful opening up of one of the world’s largest markets for industrial sensors. Wethank all those who have accompanied us along the path up to now, and allthose who will help shape our future path.

With best wishes from the Far East

Danny Chan, Managing Director, SICK Hong Kong and SICK China

03Editorial

insightTELEGRAM++ New Safexpert 4.2 update of CE-software –Straightforward adaptation of hazard analyses:checklists, lists of hazards, cross-references,etc. – The Check and Acceptance Assistant –Simple checks complying with the MachineDirective or German Safety at Work Legisla-tion (BetrSichVer) – EN 292 withdrawn andreplaced by EN ISO 12100 – Info on new stan-dard and Safexpert www.sick.de/safexpert++ Three wide-awake trainees at SICK AG de-

velop pulse-controlled sleeping aid for tinnituspatients – Win “Jugend forscht” competition(for young researchers) – Appear on televisionand receive “Gallileo Prize” from Pro7 TVchannel – Prize: a new Toyota “Prius” ++ Inter-esting info on “Year of Technology 2004” fromFederal Ministry for Education and Researchat www.bmbf.de and www.jahr-der-technik.de– Reports, events and brochures on allaspects of technology and the future ++

Product spotlight ..................... 28+29

UE 440/470 safety controllers:flexible, compact and reliable......... 30

New W 190L series of laser photoelectric switches ..................... 31

SICK IVP – innovative cameras for industrial image processing ........... 32

The IN 4000 safety system switches on metal ......................... 33

The KT 3 Laser compact contrast scanner ........................... 34

The IT 3810 hand-held scanner: bar codes in focus ........... 34

The DKS 40 incremental encoder – the compact and robust cost-cutter.......................... 35

UM 18 – when space is limited ...... 35

Reliable image processing on press brakes.................................. 36

The KT 5 contrast scanner display: a “straight back” for comfortable use............................. 37

The ELG 1 short range – the reason-ably priced automation light grid ..... 38

Automatic counting of persons with LD PeCo ................................. 38

DT 500/DS 500 distance scanners offer long range and great accuracy 39

LD PDS – protects valuablesand prevents vandalism .................. 40

Large-format colour detectionwith the CVS 1 ............................... 41

SICK supports standardised teach-in 42

Parameterisation and diagnosis via Bluetooth................................. 42

Autoworld in Brussels.................... 43

Company founded in Turkey............ 44

DeviceNet Safety on the march....... 44

ecatalog.sick.com...........................45

10 years’ SICK Hong Kong............. 45

“Eat that frog” ............................. 46

Imprint/Service ............................. 47

Trade fair dates ............................. 47

................................................... 03

Valéo validates “vertical” S 3000 Standard............................ 06

S 3000 – double safety for travelling production gantry............ 07

S 3000 – Vertical protective field for safety on wafer robots.............. 07

Encoders in blue kit regulate knitting machines.......................... 08

Phoenix – commissioningrises from the ashes ...................... 09

Safer punching machines with greater productivity ........................ 09

The DRS 60 encoder: printing and packaging in tandem................ 10

SICK sensors dominate at Hansen Transmissions .................. 11

Perfect positioning with the SRM 50motor feedback system ................. 12

Staying on the go with the driverless metro............................ 13

LMS 400 – top pot-picking ............. 14

Whether cheese sticks or contact lenses – into the box with them...... 15

Machine safety with ATEX light curtains................................. 16

Coca Cola Beverages Polska checks with the CM 30 .................. 17

Protective field “zapping” with the DME 5000 ...................... 17

On the right path with illuminated guidance ....................................... 18

Stationary and mobile bar code read-ers control recycling process.......... 19

SICK sensors control automatic egg labelling .................. 20

Seamless identification of sutures 21

The ATM 60 absolute encoder: the robust solution for a harshenvironment .................................. 22

LMS 200 laser measurementsystems detect projecting car parts 23

DT 500 – laying it on the line for mattresses............................ 24

WL 2S handles auto-filling shelves.. 24

Device and product safety legislation (GPSG) clears up uncertainties........ 25

In conversation with Dr. WernerJansen of the BGFE....................... 26

SICK insight 2/200404 Contents

Book corner

Products

Standards

Info

06Curtains down! The S 3000 sets standards

The ATM 60 absolute encoder: the robust solution for harsh conditions

The V 4000 Press Brake optimises safety and processes

22

SICK insight in conversation with Dr. Werner Jansen of the BGFE

26

36 Interview

Museum

Applications

SICK Tour

Editorial

Know-how

SICK insight 2/2004

05News in brief

insightBOOK CORNER

Brian Tracy

Eat that frogEat a frog? Not particularly appetisingat first glance. What’s it all about? Isthis a book offering advice on unusu-al delicacies? The puzzle is solved onPage 46.

Corn fields as far as the eye can see.But there’s no 500-tonne monster of a combine harvester in sight. Just a small, smart, high-tech robot – with an LMS Laser Measurement System for navigation.

The agBot (agricultural robot) wasdeveloped at the University of Illinois,USA. As industrious as an ant, it worksthrough fields row by row, and will soonbe used for weeding, watching out forharmful insects and taking soil sam-ples. Its LMS Laser Measurement Sys-tem ensures that the agBot stays strict-ly on path, doesn’t run anything overand, at the end of the field, easily

Free download service from SICK

Laser classes:greater clarity forusersThose who produce or distribute lasersensors or other devices with point-form-ing light sources must comply with standards such as IEC 60825 or EN 60826. But users must also observeother regulations. In Germany theseprincipally include the Trade Associa-tion’s BGV B2 regulation and its BGI 832 information sheet.

Both works, however, not only referto more detailed sub-divisions within theindividual laser classes, but also includea range of secondary content. For usersthis raises the concrete question: “Whatis of relevance to me, and what do I re-ally have to comply with?”

The comprehensive, practical de-scriptions and graphic explanations inthe article “Laser classes and their ap-plication for users of laser devices” pro-vide answers to questions on all aspectsof the classification and use of lasers.It is available at www.sick.de/infopoolas a free download.

Current trade fair info:From 23–25 November in Nuremberg...... as usual, SICK is offering an overview of its productrange at this year’s SPS/IPC/DRIVES. We are looking for-ward to your visit at

Stand 7-370 in Hall 7See our special trade fair page at: www.sick.de/sps2004General information direct from the organisers at:www.mesago.de

From 6–10 December in Paris...... the biennial international ELEC fair: with a new design,and integrating MESUCORA for the first time. Drop in andvisit us at

Stand 13k4 in Hall 6 Further information on the trade fair at: www.eleclive.com

A-MAIZE-ing achievement from the land of unlimited opportunity

Watchful robots tend cornfields

moves into the next aisle between theplants with two elegant 90° turns. Theultimate goal will be to check plants in-dividually and perhaps protect themfrom pests by precision-spitting pesti-cides where necessary. “Our farm robotonly costs US$ 7,000”, agricultural en-gineer Tony Grift is proud of the elec-tronic farm helper that is very reason-ably priced despite its high level oftechnological sophistication.

LMS in agriculture – another task CORNered!

www.gizmodo.com, search for: agbotsINFO 201

SICK insight 2/2004

Title topic: The vertical protective field of the S 3000 safety laser scanner06 Applications

When unhindered machine access is essential

Valéo validates “vertical” S 3000 Standard

The French automotive supplier Valéo has validated the S 3000 Stan-dard safety laser scanner for vertical machine protection in several ap-plications at their La Suze sur Sarthe works. Apart from its SafetyCategory 3 according to EN 954-1, the possibility of unhindered ma-chine access for operators was the decisive argument.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 202or on the Internet at:www.sick.de/S3000More about the customer:www.valeo.com

Vertical machine protection with thenon-contact electro-sensitive S 3000safety laser scanner at Valéo in FranceTI

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>> With sales of over EUR 9 bn. andmore than 68,000 employees at almost130 production sites in 26 countries,Valéo is one of the leaders in the auto-motive supplier market. The productprogramme – split into ten application-specific divisions – enjoys a high-techreputation. Correspondingly, productionat the various sites not only exploits thelatest production technologies, but alsoutilises safety technology of the higheststandards.

Manual handling of parts requires free accessThe machines protected with the S 3000 at Valéo require the manual in-sertion and removal of workpieces.“This immediately ruled out a mechani-cal protective system”, reports ThierryPouchol of SICK France, who providedsupport for the project. The S 3000non-contact safety laser scanner simul-

taneously safeguards the work area andraises machine performance.

The first choice for vertical usethanks to contour monitoringResponse time: 60 ms, resolution: 30 mm, protective field height: about 2 m, with 450 mm distance to the haz-ardous machine area – these are thefacts of the application at Valéo. In prac-tice, this task was only soluble becausethe S 3000 had the necessary auxiliary“contour as reference” function. With-out this it would have been impossibleto gain certification for vertical use incompliance with EN 61496-3. The scan-ner exploits this function to reliably de-tect when a protective field edge, in thiscase the floor of the hall, changes itsrelative position to the scanner. This re-liably detects any mechanical misalign-ment of the scanner, and thus any un-guarded access to the hazardous area.

The device immediately switches off theprotected plant if the actual contour de-viates from the reference contour be-cause of any re-alignment of the sensorin its supporting bracket.

Thus the S 3000 offers Valéo andother users a currently unique, real leadin vertical machine protection.

SICK insight 2/2004

07Applications

Wing production for the Airbus A380

S 3000 – double safety for travelling production gantry

>> The plants produced by the Spanishcompany M. Torres join carbon fibretape together, layer for layer, for theproduction of wings and other compo-nents of the Airbus A380. As a result ofthe size of the wings – they are, after

Only the S 3000 could do it

Vertical protective field for safety on wafer robotsWith its reliable view from above, an S 3000 Standardprotects the operators of a wafer-polishing plant fromreaching into the workspace of the handling robot. Onlythe S 3000 could solve this task because it is the onlysafety scanner of its type to be approved for vertical pro-tection.

all, 40 m long – the processing tooltravels over the aeroplane part underproduction by means of a gantry.

Four S 3000s for the drive pathTwo S 3000 laser scanners per direc-

tion of transport ensure that no per-sons or objects are present on thetracks along which the gantry moves.An automatic switching of the two scan-ner pairs takes place to match the di-rection of gantry movement.

Four S 3000s for the productionzoneEmployees put down layers of the car-bon fibre tape while the gantry is in mo-tion. The application tool on the gantrythen applies a glue-like material to jointhe individual carbon fibre tape layerstogether. Four further S 3000s form aninvisible protective barrier around thetool’s operating area in order to protectworkers.

Eight S 3000s for the Airbus A380 –not an everyday application.

>> Peter Wolters Surface TechnologiesGmbH & Co. KG in Rendsburg, one of theleading producers of highly accurate fine-smoothing and polishing machine toolsystems, was looking for a reliable solu-tion that prevented operators reachinginto the robot’s workspace during opera-tion but did not hinder access to the dou-ble-sided wafer polishing plant. The S 3000 Standard was best suited for the

machine conditions. The device is in-stalled on the upper section of the ma-chine framework with a sufficient safetydistance. With its resolution of 30 mmthe scanner instantly detects if a handreaches into the machine. The haz-ardous movement of the robot in the pol-ishing plant is then immediately halted.Vertical monitoring with the S 3000 – the perpendicular safety solution.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 202or on the Internet at:www.sick.de/S3000More about the customer:www.peter-wolters.com

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 202or on the Internet at:www.sick.de/S3000More about the customer:www.mtorres.es

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Polishing plant protected with the S 3000

Eight safety laser scanners in use on a production gantry for Airbus components in Spain

S 3000 safety laser scanners not only monitor the 50 m long and 11 mwide path of a giant production gantry for Airbus components – they al-so protect employees who are working below the gantry.

SICK insight 2/2004

Incremental encoders in automated machines for warp-knitted fabrics at Karl Mayer08 Applications

For jerseys and lingerie

Encoders in blue kit regulate knitting machines

>> Almost any textile application, fromthe finest lace to materials for lingerie,girdles and sports clothing, from hometextiles to carrier materials for reinforc-ing concrete, can be economically pro-duced with the computer-controlledhigh-performance automatic warp-knit-ting machines.

Three areas of use – one encoder typeThe driven components of HKS 2 warp-knitting machines (particularly suitablefor producing heavy velour and lightertulle net, as well as materials for jer-seys) are the machine’s main shaft,the roller system for output of the

Automated machines for warp-knitted fabrics (otherwise known as tricotmachines) are one of the main areas of production at Karl Mayer’s tex-tile machine works in Obertshausen, Germany. DGS 60 series incremen-tal encoders from SICK-STEGMANN detect the number of revolutionsand the positions of various machine shafts rotating at speeds of up to3,500 r.p.m. – allowing nifty knitting process control by the computer.

goods, the rolling-up attachment, andthe two so-called warp beams with thereels of yarn. Although the power andthe number of revolutions of the indi-vidual drives vary, the same version ofthe DGS 60 is used for each of them.This keeps purchasing and storagecosts down to a minimum and simpli-fies rapid encoder replacement shouldit become necessary. The encoderscover three different functions on themachine. First they are used as themain encoder for the thread guide com-puter (as the machine’s control systemis called) on the machine’s main shaft– rotating at speeds of up to3,500 r.p.m. The second function is

regulating the number of revolutions inconnection with the drive amplifiers.The DGS 60’s third task on the warp-knitting machines is to regulate posi-tion for process control by the threadguide computer. The circumferences ofthe warp beams’ reels of yarn de-crease as they are unwound from full toempty (known as “beam travel” in thetrade). The thread guide computer cor-respondingly modifies the rate of driverevolutions up to 3,000 r.p.m. to en-sure constant, and thus error-free, ma-terial feed to the knitting process withminimum thread tensions.

Encoders for the world’s “quickest” bathing suitsThe DGS 60 is also an important com-ponent of the world’s quickest warp-knitting machine (also developed byKarl Mayer) that produces material forbathing suits at record speeds far ex-ceeding 3,300 r.p.m.

Nifty knitting processes – with the DGS 60 encoder.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 203or on the Internet at:www.sick.de/insight/enMore about the customer:www.karlmayer.de

Encoders detect the number of rotations and positions of rotating machine shafts onKarl Mayer’s high-performance automated machines for warp-knitted fabrics

A variety of materials are produced onthe warp-knitting machines

SICK insight 2/2004

Bar code scanners at Phoenix Pharma in the Czech Republic Safe punching machines 09Applications

insightLINKYou can obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.mypin.cz and www.phoenix-ag.de

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NEW

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Safer punching machines with greater productivityCustomers of punching machine pro-ducer Busch in Seevetal, Germany,profit doubly from the use of C 4000Standard safety light curtains on themachines: operators are reliably pro-tected against the risk of accidents,and PSDI mode increases machineperformance by up to 30%.>> Labels, brochures, credit cards,children’s books and saving books aretypical examples of punched products.“Naturally, with sharp blades andpunching pressures of 5.7 tonnes,safety is our top priority”, says ownerBurkhardt Busch. “Non-contact moni-toring with C 4000 light curtainsmeans that we can also offer our cus-tomers production advantages.”

Standard safety with additionaladvantagesBusch punching machines areequipped with the C 4000 Standardthat has a protective field height of 300 mm and a resolution of 14 mm.The light curtain’s signals are evaluat-ed in the UE 402 switching unit. Theadvantage: in this way the machine canbe operated in either single- or double-break mode. Thus there is neither amechanical barrier to be opened andclosed on insertion or removal of thegoods to be punched, nor does thepunching process require manual initia-tion. This simplest possible handlingsaves a lot of time and therefore short-ens the machine cycle. “Compared to

using mechanical protection, machineproductivity has been increased by upto 30% thanks to the C 4000 Standardand the possibility of employing PSDImode”, confirms Burkhardt Busch.www.buschgraph.de

SICK scanners at the Czech Republic’s largest pharmaceutical distributor

Phoenix: commissioning rises from the ashes

>> More than two dozen CLV 420 bar-code scanners have started work at arecently equipped first depot. With thehelp of CDB 420 connection boxes, a SICK-CAN scanner network was cre-ated without any major installationproblems and connected to the hostcomputer via Profibus. A CMC 400 Con-nection Module Cloning was also inte-grated in each connection box.

Pharma commissioning withoutside effectsThe new commissioning processes atPhoenix prevent the “side effects” ofmanual data handling such as delays,lack of transparency or spurious com-missioning. Each order is stored oncomputer and printed out on a cardplaced inside the commissioning boxes,which are also externally labelled witha permanent bar code. CLV 420 scan-ners along the conveyor system readthe bar code on the box and guide it tothe first storage location for the goods.These are placed in the box. After ac-knowledgement, the box travels to thestorage location for the next article.When the order has been completelyprocessed, the box is transported tothe despatch area. Online transmis-sion of scanner data within the networkensures optimum synchronisation ofmaterial and information flow.

New commissioning processes at Phoenix Pharma controlled by SICK scanner networks

Light curtain on an automatic punch-ing machine

“Clonable” parameter sets min-imise parameterisationThese plug-in memory modules storeall the “inheritance” information of the connected bar code scanner. Thus new scanners can be “cloned” by back-transfer as often as required. This allows individual devices to be ex-changed very rapidly and without extra parameterisation costs.

Phoenix, the Czech Republic’s top pharmaceutical distributor, has completely revamped commissioning at its nationwide distribution centres – with SICK scanner networks. The old documentation lies inashes (so to speak) and, in its place, bar codes and Profibus have givenPhoenix flight.

Substantial time-savings and fewer rejects with the DRS 60 incremental encoder

Simple electronic zero-impulse alloca-tion at the touch of a button

SICK insight 2/2004

British printing system with CoreTech series incremental encoders10 Applications

>> An increasing number of cigarettemanufacturers have relocated their ad-vertising messages to the inside of thepack since the introduction of legisla-tion stipulating that warnings about therisks of smoking must be prominentlydisplayed on the outside. The text mustbe accurately positioned as the areaavailable for printing is relatively small.As a result, printing and cutting sys-tems for the inner frames of packsmust be synchronised with extremeprecision.

ACCU-PAC has it down to a turnACCU-PAC, produced by Britain’s Indus-trial Automation Systems, is a registra-tion system which can be retrofitted toany make of cigarette packaging ma-chine. ACCU-PAC registration systemshave been designed as a retro-fit kit to

Those who use DRS 60 incremental encoders, from the CoreTech® se-ries, in their printing and packaging systems can reduce the time re-quired for zero-pulse adjustment by 90%. Instead of an intuitiveco-ordination of devices – as is necessary with conventional encoders –pressing a button suffices with the DRS 60.

register film, tear tape, inner foil or in-ner frame, all components of the fin-ished cigarette packet. But how canone synchronise the cutting and regis-tration systems? How does the regis-tration system know the knife cut posi-tion? “The encoder zero pulse triggersat the cut position”, reports PeterEvans of Industrial Automation Sys-tems. “It used to be necessary to ad-just an estimated offset, based onwhere the cut occurred, to synchronisethe registration and cutting systems after the encoder had been fitted. Thisoffset was entered into the system andthe machine operated again. Theprocess was repeated until synchroni-sation had been achieved. This methodwas far from ideal in a modern au-tomation environment.” It can be donemore intelligently – with the DRS 60.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 204or on the Internet at:www.sick.de/insight/enMore about the customer:www.accupac.co.uk

Pressing a button in the device is suffi-cient to electronically assign a me-chanical reference point to the zeropulse.

Incredible savings potentialachieved“What used to take up to 20 minutescan now be completed in two minutesat most”, reports Peter Evans. “Re-move the cover, press the button andoff you go – it’s as easy as that. Andone doesn’t have to reject up to 50packs like before; at most just one ortwo.“

So it’s no wonder that the DRS 60is not only now standard equipment forIndustrial Automation Systems, buthas also been retrofitted to many ma-chines that have already been deliv-ered worldwide.

Zero-pulse adjustment (teach-in) by button

The DRS 60 encoder: printing and packaging in tandem

SICK insight 2/2004

SICK sensors in automatic pallet warehouse at Egemin in Belgium 11Applications

Single-source automation of three pallet warehouses

SICK sensors dominate atHansen Transmissions

>> Hansen Transmissions producescomponents and drives for wind-drivenpower stations, among other things, at the new factory in Lommel. Of deci-sive importance in choosing SICK wasthat Egemin, as system integrator forthe most varied of tasks, can always offer the most suitable, technologicallyhigh-quality sensor solutions from a single source.

Detection and measurement WL 27 series photoelectric reflexswitches detect pallets and transport

Egemin, one of Belgium’s leading system integrators of automation andsafety technology, has equipped three new warehouses in Lommel formachine and drive constructor Hansen Transmissions – entirely withSICK sensors.

containers at a wide variety of points inthe material flow. Long range, simplecommissioning and reliable operationcharacterise these devices. Elsewherein the warehouses and production areait is important to reliably detect per-sons, not pallets, to prevent the risk ofaccidents. M 2000 multi-beam photo-electric safety switch here meet all thedemands. Their particular advantage:the machines to be protected are di-rectly accessible for maintenance workor equipping purposes, for example.The MLG automation light grid handles

measurement functions at HansenTransmissions. Checking for projec-tions and overheights, as well as in-specting pallets for damage, are theprincipal areas of use. As these taskswere already known about when thesystems were ordered, the MLG unitscould be pre-parameterised in advanceat SICK’s works and were therefore im-mediately ready for use.

Identification and communicationWhich pallet is where on the conveyorsystem, and its intended destination, isdetermined by CLV 410 and CLV 420 se-ries stationary bar code scanners. Com-pact and easy to install, with a readingdistance of up to 400 mm and a rapidfrequency of 1.2 kHz, these are the rightdevices in the right place. Finally, ISD da-ta-transmission photoelectric switcheshandles online communication betweenthe storage and retrieval devices andthe appropriate aisle or plant controlsystems at the three pallet warehouses.Rapid installation of the ISD, with me-chanical, optical and electronic adjust-ment aids, soon got storage and re-trieval devices ready for operation.

The all-round sensor package thatEgemin has assembled with SICK products has proved to be an all-roundtrouble-free package at Hansen Trans-missions.

insightLINKYou can obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.egemin.com andwww.hansentransmissions.com

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Left: Equipped with SICK sensors byEgemin: the new automated palletwarehouseTop: Safe maintenance work with M 2000 multi-beam photoelectric safetyswitch

“Losing weight” with the TPM: The weight of this robot from SIG PackSystems could be reduced from 130 kgto 46 kg by using innovative TPM servo actuators.

SICK insight 2/2004

Motor feedback systems in geared motors at WITTENSTEIN AG12 Applications

For compact, light and highly dynamic TPM servo actuators

Perfect positioning with the SRM 50 motor feedback systemUnique dynamism, extremely compact housings and high rigidity char-acterise the new TPM series of geared motors, so-called servo actua-tors, from WITTENSTEIN Motion Control GmbH. Further advantages, in-cluding automatic parameterisation of the control system, precise posi-tioning and a high level of user-friendliness are provided by theintegrated SRM 50 motor feedback system from SICK-STEGMANN.

>> “High-tech machine constructor”,“top employer” and “a trend-setter indrive technology” are phrases oftenused by the specialist and businesspress to describe WITTENSTEIN AG. Soit is no surprise that the Igersheimer-

based group of companies, with its800 employees, achieves double-digitannual growth rates, reinvests 10% ofits profits in research and develop-ment, has a training ratio of 11% andpersonnel with an average age of 34.“85% of WITTENSTEIN products soldare less than five years old”, SiegfriedWallauer, Product Manager responsiblefor the TPM series, underlines the in-novative strength of all Group mem-bers. The best example of this is thehighly developed series of servo actua-tors developed by WITTENSTEIN MotionControl. The compact SRM 50 motorfeedback system has made a consider-able contribution towards motor sizesthat offer substantial space savings.

TPM – compact combination of gears and motorThe TPM is a rotary actuator consistingof an AC servomotor and a low clear-ance, precision planetary gear. “One of the special features of the TPM is its short length”, explains Siegfried Wallauer. “Thanks to its integrated design, the smallest TPM is just 113 mm long – that’s 50% smallerthan conventional motor/gear combi-nations. And it weighs considerablyless too.” Further features are its ac-celeration of up to 100,000 1/s2,achieved with state-of-the-art motortechnology, and its high gear rigiditythat permits optimum control.

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SICK insight 2/2004

The driverless metro in Denmark 13Applications

Easy riding in Copenhagen thanks to LMS

Staying on the go with the driverless metro

>> The LMS units are an importantcomponent of the obstacle detectionsystem (ODS). All objects larger than450 x 450 x 450 mm3 are detected byone of the six scanners at each stationand evaluated by the ODS, then a sig-nal is transmitted to the automatic traf-fic alarm control system (ATC).

Great safety reservesThe project’s safety planning was ex-cellent. The entire system structure (in-cluding the sensors) is designed withredundancy. Each metro station has itsown warning and visualisation system.The scanners themselves are designedfor outdoor use and programmed insuch a way that spurious signals are re-liably prevented. All in all, the entiresystem has a mean time between fail-ure (MTBF) of 115 years according tothe system integrator.

So it’s easy riding in Copenhagen: sta-tistically speaking, the first systembreakdown can be expected in 2119.

Not only is the metro new for Copenhagen, but also its driverless con-cept. The central control system and the metro’s complete automationcould not be completed until laser measurement systems were in placeat each station to provide warnings about objects on the tracks.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 205or on the Internet at:www.sick.de/insight/enMore about the customer: www.wittenstein.de andwww.sigpacksystems.com

New metro system in Copenhagen withthe obstacle detection system

The SRM 50: communication, precision and ease of use in allTPM applicationsThe TPM is ideally suited for use, forexample, as a drive for compressing hy-giene articles in packaging; in automat-ic feed systems for wood processingmachines and machine tools; as adrive for dosing pumps; as an axledrive on spraying robots (there’s an Ex-protected TPM version for use here); oras a part-turn valve actuator in plantsfor producing optical media and semi-conductors. Whatever the application,the SRM 50 Multiturn motor feedbacksystem integrated in every TPM unitensures bi-directional communicationbetween the drive and the plant controlsystem via its standardised Hiperfaceinterface. Information on commutationand rotor position is transmitted as ab-solute values when the TPM isswitched on, thereafter counting con-tinues incrementally via sine/cosinesignals. “In this regard, the EEPROMoffers important advantages as a so-called electronic type label in the SRM 50”, Siegfried Wallauer mentionsthe device’s integrated control systemparameterisation. “Gear and motorcharacteristics, and commissioning data, can be stored here and used forautonomous setting of TPM parame-ters. Programming data for the motorfeedback system, such as resolution ora shift in zero position, can be stored ina different EEPROM memory area andcalled up from there.”

This feature of the integrated motorfeedback system (which has been test-ed and approved by WITTENSTEIN forconnection to more than 20 differentcontrol systems) provides easy and reliable commissioning of the TPM. TheTPM can also fully exploit the SRM 50’s resolution of more than 134 m. increments and its high preci-sion of less than 1 minute of angle.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 206or on the Internet at: www.sick.de/insight/enMore about the customer: www.m.dk

The measurement system (above), installed at a height of 2.7 m, moves over potsand pans stacked up to 1.6 m (below)

SICK insight 2/2004

Three-dimensional object detection at WMF with the LMS 400 laser measurement system14 Applications

For high-precision pick & place

LMS 400 – top pot-picking

Precise object detection in three dimensions is the great strength of theLMS 400 laser measurement system. Automatic pick & place robots, inparticular, profit from this because parts of different sizes can now begripped in mixed operation, e.g. pots and pans of differing diameters atWMF AG.

>> Cutlery, tableware, cutting devices,coffee machines, as well as pots andpans from WMF AG, based in Geis-linger, are greatly appreciated byhousewives, amateur cooks and pro-fessional chefs. The high quality requirements are reflected in the mod-ern production sites. Thus WMF has re-cently started using the LMS 400 forthree-dimensional visual guidance

of robots during the production of potsand pans. The robot must reliably movepots and pans with varying heights, differing diameters and optically dissimilar appearance, on and off pallets. The LMS 400 allows this without the need to adapt robot programs, mechanical components orcontrol system software.

The new view of the robot’s visualguidance systemThe LMS 400 offers visible advantagesin pick & place applications. Only iden-tical goods could be transported in thepast – to ensure the precise position-ing required by the robot. The third object dimension and gripping point of each object was known. This is nowno longer necessary because the LMS 400 provides data with which allthe necessary robot information is pro-vided rapidly and accurately. This notonly convinced end-user WMF, but alsothose responsible at robot integratorKomatec. At WMF the measurementsystem, installed 2.7 m above theground, moves over the stack of pots(that can reach heights of up to 1.6 m)measuring each pot with 0.1° resolu-tion and a scanning rate of 500 scansper second. A major advantage over solutions based on camera systems is that ambient light and reflections donot interfere with the measurementprocess. All the positional and distance information required for targeted and reliable robot activity isprovided within milliseconds thanks torapid evaluation.

Rapid, precise and flexible, the LMS 400 sets new standards in 3-Dobject detection.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 207or on the Internet at:www.sick.de/insight/enMore about the customer:www.wmf.com and www.komatec.de

SICK insight 2/2004

Safe sensors on high-speed packaging machines in the Netherlands 15Applications

>> Langenpac mainly produces pack-aging machines for cakes and biscuits(e.g. cheese sticks), dry food, tissues,and industrial non-food products suchas film spools, batteries and lamps.“These are all mass-produced articlesthat require high throughput capacitiesduring packaging and cartoning”, saysPieter van Summeren, Manager of Elec-trical Engineering at Langepac. “Andwe are particularly strong here.”

SICK sensors ensure rapid and in-telligent system solutions The tasks that Langenpac machineshandle differ in complexity. The vertical

cartoning machine for cheese sticksfills sales trays at high speed. Type WT 12-2 photoelectric proximity switch-es, mechanically robust sensors with arapid switching frequency of 1.5 KHz,monitor the continuous flow of salespackaging. A special high-speed pack-aging machine for 200 boxes perminute was constructed for a producerof tissues. The requirements of a con-tact lens producer were complex: apartfrom the pure packing function, this al-so involved coding and sorting accord-ing to lens strength, sell-by date andbatch number. “SICK scanners arefirst-class here”, confirms Pieter van

Summeren. Finally, a really futuristiccartoning machine for food productswas developed with the Canadian com-pany Langen. The machine is charac-terised by a high speed and a widerange of formats. In addition to a vari-ety of detection functions, safety tech-nology here reliably protects machineoperators.

insightLINKYou can obtain further product informa-tion on the Internet at:www.sick.de/insight/enMore about the customer:www.langenpac.com

Monitoring gap-free feed of sales packaging with the WT 12-2 photoelectric proximity switch

High-speed packaging machines and cartoning equipment are staplesfor Dutch producer Langenpac. Capacities of 450 and more boxes perminute require reliably functioning sensors. Thus safety systems, bar-code readers and photoelectric switches from SICK (e.g. the W 12-2)have become standards at Langenpac.

SICK is standard

Whether cheese sticks or contact lenses– into the box with them

ATEX package offers reasonablypriced retrofittingCertification of the C 4000 for cate-gories 3G (G = gas) and 3D (D = dust)has been obtained in compliance withthe demands of the ATEX directive forprotection by mechanical safety meas-ures. This applies for a variety of protective field heights, as well as allpossible resolutions or single-beamseparation distances. Even the “nor-mal” C 4000 fulfils many of the ATEXrequirements – among other things,the front screens of the transmitter and receiver are made of shockproof polycarbonate. The ATEX package nec-essary to provide the remaining supplementary safety measures basi-cally consists of end caps for the housing (which protect the connectionareas from dust in a non-connectedstate), and the ATEX plate to be at-tached to the device. This ATEX up-grade offers plant planners high levelsof flexibility and safety. They can locate individual C 4000 units accord-ing to the demands to be met in situ,and the systems can then be rapidly and extremely cost-effectively supple-mented with the ATEX package whennecessary.

SICK sensors also for 2G and 2DIn addition to the C 4000 in its variousversions for 3G and 3D applications,safety light curtains are also availableas electro-sensitive protective devicesfor Category 2G. Their certification for2D is also in preparation, as is ap-proval of a multi-beam photoelectricsafety switch for 2G and 2D. Moreoverthe W 24 Exi series of 2G-certified pho-toelectric switches is available for gen-eral object detection tasks in automa-tion technology.

ATEX light curtains – safe and cost-ef-fective solutions for the Ex-Zone.

SICK insight 2/2004

Safety light curtains on spraying plants at BMW’s Regensburg works16 Applications

Machine safety with ATEX light curtains

EXcellent solutions

>> This electro-sensitive protectiveequipment (ESPE) can be used inZones 2 and 22 according to directive94/9/EG (ATEX). Application examplesinclude filter presses in sewage plants;printing machines; filling plants in thechemical and food industries – andspraying lines in the automobile indus-try. This is where BMW’s Regensburgworks has installed numerous ATEX-conforming C 4000 light curtains in aco-operation with spraying plant pro-ducer Dürr Systems.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 208or on the Internet at:www.sick.de/insight/enMore about the customerwww.bmw.com and www.durr.com

Standard and Advanced:

C 4000 ATEX with graduated functionalitiesThe safety light curtains of the C 4000 series are used for protecting hazardouspoints of operation on machines and plants. They all comply with EN 61496,Type 4 as well as IEC 61508, SIL 3. The Standard and Advanced device ver-sions are designed to meet different levels of automation and functional re-quirements. The Standard version is available with, among other features,ranges of up to 19 m, resolutions of 14 mm, 20 mm, 30 mm or 40 mm, andprotective field heights of between 300 mm and 1,800 mm. Compared to theStandard version, the C 4000 Advanced offers a variety of additional functionsthat can, for example, reliably differentiate between workpieces that temporari-ly jut into the protective field (for process-related reasons) and a finger or arm.

With the new C 4000 ATEX series of safety light curtains it is now alsopossible to prevent persons from reaching into the hazardous areas ofmachines during operation in which sporadic or temporary potentiallyexplosive mixtures of gases or non-conducting dust can occur.

The C 4000 safety light curtain forATEX applications in Zone 2 for gas,and in Zone 22 with a connector endcap for dust.

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SICK insight 2/2004

Counting bottles with capacitive sensors Distance measurement system 17Applications

Bottle present, cap on?

Coca Cola Beverages Polska checks with the CM 30

>> After filling, the bottles are com-bined into multi-packs with the help of shrink foil. Then it’s straight onto the pallets and off to the shops. It is, of course, annoying if packs arriving there are missing a bottle or have overflowed. So Coca Cola Beverages Polska wanted to ensurethat every pack was complete and that every bottle was in perfect condition.

Four in a row per lineFor this purpose, Coca Cola BeveragesPolska engineers installed four CM 30 capacitive sensors next to one another above every transport line.

Are all the bottles behind the shrink foil, and does each bottle have acap? CM 30 capacitive sensors at two Coca Cola Beverages Polskaworks put the “in order” ticks on the checklist.

The plastic housing of the CM 30 is ev-idence of their IP 67 enclosure rating,so repeated cleaning work on the machines cannot affect them. Sensitiv-ity and the switching distance are seton the sensors themselves. As soonas the multi-pack, held together by thefoil, passes through the sensor gate, aCM 30 detects the absence of a bottleor a cap by means of the constant ca-pacity of its condenser. Such packs areimmediately diverted out of the flow. If, however, the capacity of the CM 30 changes in accordance with thedefined value,the pack is in order andcan be palleted.Make it clear – with the CM 30.

insightLINKYou can obtain further information aboutthe product on page 29.More about the customer:www.cocacola.com

Always active in the right direction

Protective field “zapping” with the DME 5000

>> Protective field switching was origi-nally triggered by initiators – at leastthat was what was supposed to hap-pen. But other operations in the area,and above all stacker traffic, kept de-

Paper rolls, weighing up to five tonnes, are transported on a rail-mount-ed transport vehicle at Nordland Papier in Dörpen. PLS laser scannersmonitor both directions of movement. Two DME distance measuring de-vices activate the PLS protective fields according to their position.

stroying the initiator’s switching flagsglued to the floor of the hall. The result:switching proved impossible.

Robust and precise – the DME 5000Two DME 5000 laser distance measur-ing devices recently installed on thetransport vehicle manage far better.During transport, the two sensors (re-dundant for the particular direction oftransport) continuously measure thetime-of-flight of their transmitted lightpulses to the end of the drive path andback. The electronics determine theposition of the transport vehicle fromthese measurements and transmit thisinformation to the vehicle PLC viaProfibus. The data is processed hereand the appropriate binary signals aregenerated. These are passed on to theLSI, that activates switching of the PLS

protective field. This solution hasproved very robust and reliable duringoperation – this is hardly surprisingwhen one considers that the DME 5000 was specially developed fordistance measurement and positiondetermination in conveyor systems andwarehouses. And it has an extraordi-narily high measurement accuracy of+/–2 mm with a reproducibility of 0.5 mm, whereby an up-to-date meas-urement value is transmitted every mil-lisecond – more precise distancemeasurement is hardly possible insuch applications.

Precision in any position – the DME 5000 is the right choice for dis-tance measurement in automaticsmall-parts stores, for vehicle position-ing, and for crane distancing.

insightLINKYou can obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.nordlandpapier.de

Transport line with four capacitive sensors

Distance measurement devices on trans-port vehicles

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 209or on the Internet at:www.sick.de/insight/en

SICK insight 2/2004

The solution: the LUT luminescence scanner for detecting guidance paths18 Applications

Flexible when destinations change

On the right path with illuminated guidance

>> Unlike expensive inductive guid-ance, or complicated optical naviga-tion systems, this is a reasonablypriced flexible solution for free-movingand self-positioning industrial trucks.

Follow that lightWhether adhesive tape or paint – lu-minophores are available in a wide va-

Whether in production plants for large-scale machines and systems, orduring storage and logistical transport movements within works – thereare individual cases where the destinations of free-moving industrialtrucks are only temporary or used during a specific project, and aretherefore often subject to change. In such cases, following removablefluorescent guidance paths with LUT luminescence scanners has provedhighly effective.

riety of media. They are invisible to thehuman eye but light up as soon asthey are excited by high-wavelengthlight. LUT luminescence scanners bothstimulate luminophores and detectthem. The vehicle reliably follows thedetected light on the basis of digitalsignals transmitted to the control sys-tem.

Sensor solution for transport systems with heavy loadsThe leading manufacturer of transform-ers uses so-called air-cushion trans-port systems in its production, inspec-tion and dispatch areas, with loadsthat at times exceed 500 tonnes. De-pending on the size and type of trans-formers, different transport destina-tions must occasionally be reached viadiffering routes. Shorter journeysacross the works grounds are also aneveryday occurrence. The use of fluo-rescent guidance paths together withluminescence scanners provides trans-port systems with the maximum possi-ble degree of freedom, and thus maxi-mum applicability. Thus guidance pathscan be individually set up in the inspec-tion area, for example. If narrow areasmust be approached, or the vehicle re-quires exact positioning, this isachieved with millimetre accuracythanks to the device’s precise detec-tion of the guidance path.

Other sectors also face situationssimilar to those found during internalworks transportation in transformerconstruction. These include furnaceand tank construction; the productionof modules for commissioning shelves;rolling stock construction and the pro-duction of diesel and ships’ engines;the production and assembly of air-craft; or the transport of large-scaletools and machines for metal process-ing.

The LUT for detecting guidance paths –the flexible and cost-effective solution.

Suitable for free-moving industrial trucks with changing destinations: the LUT lu-minescence scanner

SICK insight 2/2004

Identification with hand-held and bar code scanners at Swedish recycling works 19Applications

A “clean” solution for a clean environment

Stationary and mobile bar code readerscontrol recycling process

>> The works – a joint venture betweenDanish and Swedish companies – wentinto operation in March 2004. It is de-signed for enormous recycling volumes– an estimated annual volume of 6,500trucks loaded with cans and bottles.“Whereby cartons with countedamounts of cans and PET bottles, andsacks with uncounted contents fromgastronomic sources must be identi-fied”, explains Claes Johansson, Man-aging Director of the company Styrlog-ic, which solved the control and identi-fication tasks in the project. “Ultima- tely, every customer wants to get theirdeposits back.”

Stationary scanners for specialcontainersA special disposable carton, suitablefor Europallets, has been developed inorder to permit consistent automatichandling inside and outside the factory.A counted number of aluminium cansand PET bottles are delivered withinthem from the trade. Each carton is

Every year, 250 million PET bottles and 850 million aluminium cans areprepared for recycling at Returpack’s new recycling works in Norr-köping, Sweden. CLV 450 stationary bar code readers and IT 3870 data-radio scanners identify the incoming consolidated packages in or-der to ensure smooth processing of the financial deposit on the goods.

identified by stationary CLV 450 scan-ners, with inductive encoders, checkedfor its content (aluminium or plastic)and then pushed onto the appropriateconveyor belt to the next process step.“The great strength of the CLV 450”,says Claes Johansson, “is that the de-vices can also reliably read poor-qualitybar codes, because not every carton isin a good condition when it arrives atthe works from the dealers.”

Mobile solution for the uncountedmaterial for recycling Returpack receives cans and PET bot-tles from gastronomy and othersources in plastic sacks, for which noindividual automated counting can takeplace. These sacks are distributed to15 manned stations at the factory.Each sack is identified online with thehelp of IT 3870 hand-held scanners be-fore its contents are emptied into largebins for counting and further transport.“What’s practical about the mobilescanners” argues Claes Johansson,

“is that they offer great freedom ofmovement – after all, the area coveredby data radio is about 730 m2. Thenthere is the reading distance of about0.5 m, which makes it possible to iden-tify the sacks ergonomically.”

By the wayIn addition to the scanners mentionedabove, a large number of WL 250 pho-toelectric switches are installed alongthe edges of the conveyor system.

insightLINKYou can find obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.returpack.se

Recycling countless PET bottles and aluminium cans at the new recycling works inSweden

The CLV 450 bar-code scanner

The IT 3870 hand-held scanner

SICK insight 2/2004

Egg labelling with a variety of SICK sensors20 Applications

Cracking the egg positioning problem

SICK sensors control automatic egg labelling

EU law stipulates that all class A* eggs must be labelled with a specialidentification code: a twelve-character producer code. So this is now required in Poland, a new EU member state, as the company Intrex has recognised. Those at Intrex have also recognised that SICK sensors crack the problem of detecting the position of eggs in the labelling system.

>> The code on the premium goodsshould look like an extension of theegg shell. This places two demands onthe automatic coding system: the eggmust be detected before printing, andmust be transported at the right speedduring printing.

R-egg-ular informationEgg detection by light – or more pre-cisely with the help of WLL 170 photo-electric fibre-optic switches or VTE 18cylindrical photoelectric switches. Thelabelling system is thus reliably in-formed that there is again somethingthere for labelling.

L-egg-ibility assuredThe DRS 60 encoder co-ordinates thespeed of egg rotation with the printingspeed of the labelling system, thusachieving a cleanly applied and clearlylegible print result.

Simple adaptation to new b-egg-innings Both the photoelectric switches andthe encoders are fit for any southwardenlargement of the EU. The ranges ofthe WLL 170 and the VTE 18 can beadapted; the DRS 60 can be orderedEx-Works with a variety of pulse num-bers for differing rotation speeds. Thusif Australia should ever join the EU, thelabelling of premium ostrich eggs, inline with their new l-egg-islation, wouldactually not be any problem at all ...

insightLINKYou can find obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.intrex.pl

* Eggs are divided into quality classes Aand B. Retailers, however, only offer classA eggs. Class B eggs are “second-qualityeggs”. They can only be delivered to spe-cially approved food companies or the non-food industry.

New labelling obligation in the EU

An important code for maintaining food quality: where is my breakfast egg from?From January 2004 no one egg is the same as another. Each egg must showwhere it originated and how the laying hen lives. A uniform code composed ofnumbers and letters informs consumers about the egg’s country of origin,whether it was laid by a hen living outdoors, only on the ground, or in cages,and in which hen-house it was laid.

Decoding the codeThe first two numbers show the type of living con-ditions under which the egg was laid. 0 is organ-ic production, 1 is for living outdoors, 2 is for liv-ing on the ground, 3 means that the hen lives ina cage. The letters are abbreviations for the coun-try of origin.

Each egg receives a special ID code in line with EU legislation

SICK insight 2/2004

2-D reading devices check medical products 21Applications

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 210or on the Internet at:www.sick.de/insight/enMore about the customer:www.ethicon.com

Checking 2-D batch numbers with the ICR 850 data matrix reader

Seamless identification of sutures

>> Ethicon, a 100% subsidiary of theUS Johnson & Johnson Group, employsabout 2,100 personnel. Every year, inaddition to 150 million surgical nee-dles, they also produce 130 m. metresof surgical sutures on the modern pro-duction plant – that’s three times thelength of the Equator. Safety aspects,quality requirements, and the trackingof every production batch necessitate100% checking of the sutures duringthe packaging process on the foil lines.

Batch numbers in data matrix codeDuring packing, the suture material is laid in a cavity – a type of shell. Before the wrapper with the product in-formation is attached, ICR 850 unitsread the data matrix code on the prod-

uct. The coding contains part of thebatch number that is now comparedwith the current order code. If the twocodes match, the wrapper with theproduct information is attached. Thischeck ensures that any product mix-upon the packing line is detected in goodtime and reliably prevents use of thewrong wrapper.

Matchcode, Profibus, visualisationThe ICR 850 is not just a reliable solu-tion here, but also a particularly user-friendly one. For example, at the startof a packing order the appropriate or-der matchcode is automatically taught-in at the code reader – the ICR 850 is thus promptly ready for operationwith maximum flexibility. The devices

are connected to the machine PLC via CDM 420 fieldbus gateways withProfibus. The use of this proven func-tional module ensures smooth data ex-change right from the start. During operation, a wide variety of ICR 850read and process information is dis-played on an industrial PC. Teach-in,matchcodes, read codes, no reads, error messages and numerous evalua-tions can be read by the machine operator in situ.

The ICR 850 – the “seamless” identifi-cation solution that is not just for sur-gical suture material.

ICR 850 data matrix readers at medical product manufacturer Ethicon,in Norderstedt, ensure that the wrappers match the products and thatthere are no product mix-ups.

The ICR 850 2-D reader checks whether the product and wrappers match

Use of numerous “magnetic” encoders in the pipe-straightening machine

Pipes pass through roller segments

SICK insight 2/2004

Pipe-straightening machines with absolute encoders in England22 Applications

Magnetic pick-up technology guarantees maximum reliability

The ATM 60 absolute encoder: the robustsolution for a harsh environment

Bronx Taylor/Wilson, English producers of pipe straightening machines,insist on the ATM 60. Several hundred devices have been installed in re-cent years, and none of them have been harmed by the harsh operatingconditions.

straight it is necessary to processthem further – typical requirements area straightness of just 1 mm deviationper 1,500 mm or even 3,000 mm – toachieve these tolerances the pipestraightening machines from Bronx Tay-lor/Wilson are used. Pipe diameters ofbetween 15 mm and 600 mm can beprocessed on them with insertionspeeds of up to 3.3 m/s. The pipespass through several roller segmentswhose pressure straightens the pipe.The task of the ATM 60 is to regulatethe height of the rollers and their anglerelative to the pipe. The encoder’s mul-titurn property is achieved by usingseveral reducing gears with magnetsmounted upon them. This enables theabsolute position of the rollers to be detected as the drive mechanism

moving the rollers turns through multi-ple rotations.

“Global” encoderThe highly robust nature of the ATM 60is ideal for machines that are installedworldwide – they prevent unnecessarycomplaints and service work. “They re-liably withstand the impacts and vibra-tions, that go hand-in-hand with thisprocess, for years – 24 hours a day,seven days a week, year in and yearout”, says John Dunn. Moreover, thedevice also “speaks a variety of lan-guages”: the communication protocolsfor Interbus, Profibus DP, CanOpen, De-viceNet and SSI allow the standardisedtransfer of digital data to the world’smost important fieldbus systems forfactory automation.

The ATM 60 is the robust rotary meas-urement system for linear travels, an-gles, positions – and pipes.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 211or on the Internet at:www.sick.de/insight/enMore about the customer:www.btwcorp.com

>> “Optical” encoders have many posi-tive features, but are relatively sensi-tive to vibrations, shocks and impactsas a result of their glass code discs.“Magnetic” encoders, such as the ATM 60, are sensors whose permanentmagnetic elements scan a magneticscale, and are considerably more robust due to their principle of opera-tion. “This was decisive for us, because each machine we manufac-ture is equipped with numerous encoders”, says John Dunn, MD ofBronx Taylor/Wilson, a company activeworldwide.

Regulating heights and anglesIt is not possible to manufacture weld-ed or seamless pipes to tight toler-ances. If pipes need to be particularly

SICK insight 2/2004

Automatic parking system with laser scanners at the Mövenpick Hotel in Berlin 23Applications

The facade of Berlin’s Mövenpick Hotel

Laser scanners prevent damage during parking and retrieval

insightLINKYou can find obtain further product infor-mation on the Internet at:www.sick.de/insight/enMore about the customer:www.woehr.de andwww.moevenpick-hotels.com

Automatic car park at Berlin’s Mövenpick Hotel

LMS 200 laser measurement systems de-tect projecting car parts

>> Berlin’s Mövenpick Hotel is locatedin the completely built-up area of a for-mer administration building. Technicalreasons made it impossible to build aconventional underground car park. Onthe other hand, however, the hotelwanted to be able to offer the maxi-mum number of beds while allowing ho-tel guests easy access to their vehi-cles. Wöhr found the solution in the in-ner courtyard – or rather below it.

No loss of space through road access or pathsAccording to calculations, the spacebelow the inner courtyard was suffi-cient for the necessary 22 parkingspaces – but only if there were no road

Car park system producer Wöhr has constructed an automatic car parkfor hotel guests below the inner courtyard of Berlin’s Mövenpick Hotel.LMS 200 laser measurement systems ensure that projecting vehicleparts are detected during automatic parking and retrieval to preventdamage.

access or paths. For this reason theproject was implemented with Wöhr’sautomatic Flurparker 570 (“corridorparker”) parking system. It offersspace-saving parking with vehicles be-ing put on pallets and pushed into theparking level lengthways or laterally, de-pending on demand. A vertical convey-or joins the parking level to the sur-face.

Safety for vehicles, ease-of-usefor hotel guestsHotel guests see nothing of the work-ing behind the Flurparker 570. Theyuse a parking chip to request an emptypallet, park the vehicle on it – and off itgoes into the depths of the car park. When the vehicle is removed there is

no damage resulting from projectingparts because LMS 200 laser scan-ners checked the vehicle contour be-fore it was accepted by the vertical con-veyor.

Hotel guests are provided with amessage in clear text if the vehicle isincorrectly positioned on the pallet, oran aerial, a wing mirror or a bulky loadexceeds the pallet dimensions. But it isnot just the dialogue with the parkingsystem that is user-friendly, but thesystem itself: on collection, integratedrotary equipment automatically makesthe vehicle available in the correct di-rection for driving off!

Berlin is also worth a visit for its parking technology – thanks to theFlurparker 570 and the LMS units it employs.

SICK insight 2/2004

Mattress production Swedish shelving system with miniature photoelectric switches24 Applications

Mini-sensor feeds the “feeders”

WL 2S handles auto-filling shelves

>> Whether milk, yoghurt, curd cheeseor fruit juices – it’s just plain annoyingwhen the shelf is almost empty andone gets cold fingers from having toreach right into the back of the fridge toget an article out. Then some cus-tomers would prefer to take a better po-sitioned product from further forward.But now an “economy of scarcity” atthe refrigerators is a thing of the past –with the new generation of self-fillingshelves.

Small, light and easy to installThe Swedish conveyor company Easy-Link AB has developed the newshelves. Particular emphasis wasplaced on a space-saving design, a lowweight, and simple installation in therefrigerated shelves. The WL 2S mini-photoelectric switches exhibit thesame preferences. This through-beamphotoelectric switch offers a range of1,000 mm – sufficient for the width ofthe shelves. The housings, producedusing extrusion technology, are ultra-light (only 20 g) as well as ultra-small,though they detect objects of almostany size. And they have an enclosurerating of IP 67 – so the sensor has noproblems when the shelves arecleaned. The WL 2S has its hands fullin the shelves during opening times.The light beam of the WL 2S is inter-rupted as soon as a hand reaches outto remove a package from the shelf. Aroller shelf floor, powered by com-pressed air, then moves the next pack-age to the front row after waiting about5 seconds.

Better presentation of goods,less time neededThe shelves not only autonomously re-fill spaces with goods, they also “full-fill” the expectations placed upon themregarding product presentation andtime-savings. Cautious estimates by re-tailers reckon that about 15 minutes of

Off the shelf, onto the shelf – with the auto-filling shelf system fromEasy-Link AB, WL 2S mini-photoelectric switches detect each removalof goods and immediately initiate the filling process.

Self-filling shelf system

refilling time is saved per day andshelf. When adjusted for one month,and with an average total of 16 auto-fill-ing shelves per store, this adds up toalmost 100 hours.

WL 2S – the sturdy solution for activat-ing the feed process for the “feeders”.

insightLINKYou can find obtain further product information on the Internet at:www.sick.de/insight/enMore about the customer:www.easylink.se

Dream machine solves nightmare

DT 500 – laying it on the line for mattresses

>> Small or large pores in foam, mattress cores in all colours, scan-ning distances of between 500 mmand 1,600 mm, and reproducible accu-racy of just a few millimetres – theDT 500 achieves, with dreamlike relia-bility, what is a nightmare for other po-sition sensors.

Eurofoam, in Kremsmünster in Aus-tria, uses the DT 500 on a machine forgluing and then stacking foam mat-tresses. The foam itself has the mostvaried of properties, depending on howa customer wants to “make” their bedslater. Sensors used in the past causedconsiderable problems with inaccuratemattress positioning in the machine.The DT 500 does better.

Comfortable positioning easily achievedThe DT 500 is a distance scanner witha particularly long range and high accu-racy. It generates a measurement value every 250 ms, and transmits itvia a 4–20 mA analogue output or a se-rial RS-422 measurement data inter-face. For mattress positioning thismeans: comfortable positioning easilyachieved. First, a mattress surface isglued onto the mattress core on oneside. Then the machine turns the core.The DT 500 now ensures that the ro-tated mattress is correctly positionedand centred so that the mattress sur-face can be attached to the other side.The finished mattresses are then put inthe mattress warehouse – tidilystacked with the help of more positiondetection with the DT 500.www.eurofoam.at and www.euro-foam.comFurther product information on page 39

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SICK insight 2/2004

GPSG – Germany’s new device and product safety legislation 25Standards

In force since 1 May 2004

Device and product safety legislation(GPSG) clears up uncertainties

insightLINKFurther details on the GPSG are available at:www.gpsg.infoor on the home page of the FederalMinistry for Economics and Employment:www.bmwa.bund.de orwww.bmwi.de.

Information on the GPSG (device and product safety legislation)

What is the GPSG?Germany’s new Geräte- und Produktsicherheitsgesetz (GPSG) device andproduct safety legislation combines the Gerätesicherheitsgesetz (device safe-ty legislation) and the Produktsicherheitsgesetz (product safety legislation),discards oft-criticised multiple regulation, and implements the EU ProductSafety Directive of 2001 in national law. Business, authorities and, above all,consumers should profit from the new arrangement. The justification for thelegal text states that: “In the context of deregulation and de-bureaucratisa-tion, the new GPSG is intended to create comprehensive legislation guaran-teeing health and safety regarding the marketing of technical products.”Much has been included from the old laws, some central aspects are new.

EU legislation: EU Product Safety Directive 2001/95/EG

National law until 30 April 2004:

National law since 1 May 2004:

Device and product safety legislation (GPSG)

Requirement: implementation in national law

Device safety legislation (GSG) Product safety legislation (PSG)

In force since 1 May 2004: Germany’s device and product safety legislation

Germany’s new Geräte- und Pro-duktsicherheitsgesetz (GPSG) de-vice and product safety legislationcame into force on 1 May 2004. Itcombines the safety legislation forproducts, that was previously con-tained in the Gerätesicherheitsge-setz (device safety legislation) andthe Produktsicherheitsgesetz(product safety legislation), and si-multaneously incorporates theEU’s Product Safety Directive2001/95/EG in national law.

>> The new GPSG is “umbrella” legis-lation incorporating the EU Low VoltageDirective, the EU Machine Directive andthe EU ATEX Directive, among others; itis also a catch-all regulation in casespecial regulations, such as buildinglegislation or laws on electromagneticcompatibility, fail to cover individualpoints.

Important changesThe most obvious change affects the term “device” that has been re-placed by the generic term “product”which distinguishes between “techni-cal equipment” and “consumer prod-ucts”. Further modifications affect,among other things, its range of appli-cability (which now also includes useddevices or exhibits); the introduction oftraceability for all consumer products;self-accusation; and CE-designation.Regarding “technical equipment”, thenew approach in §4 Clause 1 of theGPSG has created an evidentiary privi-lege for manufacturers over the author-ities increasing security for productsthat have been manufactured in com-pliance with a harmonised standard.

Dr. Werner Jansen (left) spoke to Dirk S. Heyden from SICK insight

SICK insight 2/2004

In conversation with Dr. Werner Jansen, Manager of the BGFE’s Prevention Department (Training)26 Interview

A visit to the Trade Association for Precision Mechanics and Electrical Engineering

“Safety at work involves technology, knowledge and the right attitude”

SICK insight: What are the tasks of theBGFE?Dr. Jansen: The Trade Associationshave been around since 1885, whenBismarck’s social legislation was intro-duced. Trade Associations have beenpart of the social network since then,though with some special aspects thatstill apply today. Thus companies thatare considered to be in the precisionmechanics and electronics sectors au-tomatically become members of theBGFE when they are founded. And theypay 100% of the contribution, not 50%as is the case for national pension orunemployment insurance, for example.The BGFE uses this money to carry outits tasks: compensation payments incases of industrial illnesses and acci-dents at work; medical, professionaland social rehabilitation; accident pre-vention in companies in the form of in-spections by technical supervisory

staff; providing safety advice on plantsin operation and new product develop-ments; as well as the implementationof comprehensive preventive meas-ures. The BGFE is now responsible foralmost 100,000 member firms withabout 2.2 million insured personnel.SICK insight: Training is a fundamentalpart of your preventative work. Who areyour courses intended for?Dr. Jansen: A short historical excursionwould help answer this question. Peo-ple were already thinking about preven-tion in the 20s. But they were given adecisive boost in the late 50s and ear-ly 60s when strong economic growthunfortunately led to a sharp increase inaccidents at work. And the safety atwork legislation introduced in 1974created an enormous need for training.The BGFE soon recognised that safetywas more than just technology. Sen-sors and barriers alone do not make

machines safe – what’s needed is alively belief in safety in the form of atti-tude, behaviour, organisation and lead-ership. This is why the Safety at WorkCentre here at the “Berghof” in BadMünstereifel, which was opened in1962, was deliberately set up as atraining centre – at that time the first ofits type in Germany. The express aim ofthis organisation was not merely topass on technical knowledge, but tohighlight and propagate safety-orientedbehaviour and safer organisation.These ideas are best put over in thefactories, by training multipliersthroughout the hierarchy to create safe-ty specialists who are also prepared tomake use of this material and take re-sponsibility. And it is precisely thesepeople for whom the courses are in-tended: persons on a variety of levelswith a range of different functions whoare capable of raising safety levels inthe factory.SICK insight: With about 100,000member firms you must have quite a lot to do …Dr. Jansen: Without doubt. BGFE train-ing centres – in other words, theBerghof and the other meeting placesand academies in Linowsee, Dresdenand Oberaichen near Stuttgart – organ-ise about 1,000 seminars, workshopsand such like every year, attended byapproximately 16,000 participants.Last year we welcomed our 250,000thparticipant to the Berghof. Though itmust be noted that it is mainly the larg-er companies that send employees tothe BGFE, while participants from the85,000 small and medium-sized com-panies are clearly under-represented.This may have something to do with theamount of work that potential partici-pants face, though it is certainly notbecause of the costs involved: theseminars are free-of-charge and in-

Whether switches or safety fencing, light curtains or laser scanners –components alone do not make machines safer. Specialist knowledgeand the right attitude towards safety are just as important. Getting thisinterrelationship across is one of the tasks of the Berufsgenossenschaftder Feinmechanik und Elektrotechnik (BGFE), the German Trade Asso-ciation for Precision Mechanics and Electrical Engineering. SICK insightspoke with Dr. Werner Jansen, Manager of the BGFE’s Prevention Department (Training).

SICK insight 2/2004

27Interview

clude board and lodging, i.e. the costsare covered by the membership fees.And the BGFE also pays for the travel-ling costs. SICK insight: 1,000 seminars, morethan 16,000 participants – this all re-quires a lot of organisation. But how doyou “organise” the trainers and spe-cialists necessary for the wide range oftopics studied – they don’t grow on thetrees in front of the Berghof, do they?Dr. Jansen: You’re right there – evenwith a lot of shaking we’ve never har-vested any. To be serious – our pool ofabout 350 trainers comes from manysources. First of all, the BGFE has a to-tal of 20 full-time teachers distributedamong the various training sites. Thenthere are also about 80 technical su-pervisory staff who make regular visitsto the works and are very well aware ofthe real situation in practice. Lawyersfrom the main administration inCologne and some of the BGFE’s localadministrations explain topics that in-volve the legal situation and the conse-quences of safety at work regulations.But most of our work is achieved withexternal experts from other Trade As-sociations, from universities, from offi-cial factory inspection authorities andparticularly from companies. SICK alsooffers a seminar that has been suc-cessfully run by your Mr Görnemann formany years now.SICK insight: How significant for theBGFE is co-operation with the industry?Dr. Jansen: Co-operation with the in-dustry not only ensures that our teach-ing content is heavily practice-related,but is also important for the BGFE be-cause our specialists are kept up-to-date in technological terms by the earlyconsideration of new product develop-ments. This is particularly importantbecause safety technology is increas-

ingly becoming more software-oriented.Electronics is increasingly taking oversafety functions whose examinationand assessment requires correspon-ding specialist knowledge. One can seeat a glance whether a protective door isopen or not – but whether a particularsoftware activates measure X in case Yrequires a more intensive inspection.Only well-founded specialist knowledgeis of any assistance when there are al-so safety-relevant, complex communi-cation structures in machines andplants.SICK insight: What status do the newmedia have for the BGFE’s work?Dr. Jansen: When I look back over mymore than twenty years with the BGFE Ican see that we have developed from aregulatory body to a modern service-provider – not least as a result of thenew media which we actively exploit.This starts with the intensive use ofour Seminar Database on the Internet.Well over half our participants registerfor courses online. Information of al-most any type can be downloaded atthe click of a mouse. A newsletter forsubscribers is in development and willhopefully be available soon. Twelvetimes a year we offer the “Topic of themonth” on our home page and thusachieve greater topicality. And, ofcourse, new media have created ad-vances in the seminars themselves.The latest computer and presentationtechnologies ensure that our trainersreally do get their knowledge across.SICK insight: One last question: Is theco-operative approach of the BGFE stillin keeping with the times and fit for thefuture?Dr. Jansen: One only has to lookaround at the economic landscape tosee that not every change is beneficial.In my opinion, this would also be thecase if, as is often brought up in con-versation, the Trade Associations wereprivatised. The solidarity principlewould be replaced by a kind of efficien-cy principle. I don’t have anything at allagainst efficiency, quite the opposite infact. But safety cannot be reduced to amoney matter, i.e. seminars must stillbe offered even if they do not seem toadd up commercially at first glance. Orwhat would happen to the small TradeAssociations or those that are in finan-cial difficulties as a result of the eco-nomic situation in their sector, e.g. inbuilding or mining? How would the soli-darity adjustment currently in use be

handled then? I think that the consider-ations that have so far taken place arehalf-baked because ultimately they failto ensure the safety of those we insureat the workplace – precisely becausesafe machines cannot be achieved withtechnology alone, and the passing onof safety competence in a variety offorms is still vital.SICK insight: At least one thing is cer-tain, Dr. Jansen: the idyllic location ofyour “Berghof” training centre. Thankyou very much for this conversation.

insightLINKFurther Information on the Internet at:www.bgfe.deThe 2003 Annual Report is available. Itoffers detailed information on the workof the Berufsgenossenschaft der Fein-mechanik und Elektrotechnik (the Ger-man Trade Association for Precision Me-chanics and Electrical Engineering). Thereport provides up-to-date statistics onaccidents, companies and insured mem-bers. It shows how contributions are de-veloping and provides information oncompensation, prevention, treatment andprofessional assistance. The Annual Re-port is automatically sent in printed formto companies with more than 21 insuredmembers. The Annual Report can bedownloaded from the Internet as a .PDFversion in the “Statistics” section.

The “Berghof”, the Bad Münstereifelhouse for safety at work

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Co-operation with the industry [...]is also important for the BGFE be-cause our specialists are kept up-to-date in technological terms by theearly consideration of new productdevelopments.

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SICK insight 2/2004

28 Products

Fewer cables, lower costs: with sensor connection boxes

Ready-made simplification of field wiring The costs of wiring sensors and actuators in machineand plant construction represent a not inconsider-able component in terms of time and money. SICK of-fers sensor connection boxes for direct field use toprovide customers with simple installation in com-pact, robust and proven module technology.

>> These connection boxes allow optimum adaptation ofyour wiring to the particular machine and plant periphery.

Robust and versatileThe sensor connection boxes are characterised, among oth-er things, by their high enclosure rating of IP 67, compact de-signs with cast plastic housings, and high levels of immunityto impacts and vibrations, as well as withstanding chemicaland electrical loads. Interference-free operation is ensuredby high-quality, gilt-edged contacts; threaded metal connec-tions; and halogen-free PUR connection cables. SICK offers awide variety of these sensor connection boxes to adapt to themachine and plant periphery. According to the application,SICK offers 4-plug or 8-plug M12 boxes with 2 signals perslot. The connection of these boxes can be carried out via di-rectly connected halogen-free PUR cables in 5 m and 10 mlengths, or can be achieved using an M23 central plug. Thesensors and actuators can be connected with tried-and-test-ed M12/M8 connection cables from SICK’s range of connec-tion systems, available with lengths of 0.6 m and 2 m.

Use in wet areas in the food industrySICK also offers all the advantages of proven connectiontechnology for wet areas in the food industry. Connectionboxes specially designed for this environment are availablein high-quality V4A stainless steel with an enclosure rating ofIP 69K. The cables between the connection box and the sen-sors have been adapted appropriately.

SICK sensor connection boxes – practical connection sol-utions for installation and maintenance.

With its own GSD file

The MLG light grid – the new Profibus bus stopSICK is presenting the new MLG Profibus light gridfor the first time at SPS/IPC/DRIVES. Its special fea-ture? The bus node is entirely accommodated withinthe sensor housing.

>> Doing without the otherwise usual external gatewaymakes the cost of “driving” the Profibus particularly reason-able, as the integrated bus connection saves about € 200.

Rapidly ready for actionUsers need not wait long for “departure” on the MLGProfibus. The universal GSD file ensures speedy system settings. The MLG Profibus has its own PNO number for logging-in the newbus traffic at the machine control system. The corresponding GSD file,that allows the PLC to interpret the sensor’s signals, can be downloaded at www.profibus.com. All in all, the MLG Profibus is thus ready for actionwith just a few mouse-clicks. When required, all configuration parameterscan be transmitted to a new light gridvia Profibus.

Object detection by means of parallel beamsThe MLG light grid is the right automation solution wheneversingle-beam sensors do not offer the desired reliability. Thenumber of beams and their separation from one another, i.e.the resolution of the MLG, can be assigned task-specifically– as can the range of the system. Typical areas of use areheight measurement, the detection of lying parts or objectsthat fall through the light grid, monitoring web slack, or thedetection of holes and cracks.

Those seeking a professional detection and data transmis-sion solution would do well to choose the MLG Profibus.

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SICK insight 2/2004

29Products

Magnetic cylinder sensor with ATEX approval

“T-slot talent” MZT 6defies explosion potentialIgnitable gases or non-conductive dusts in the oper-ating environment are just the right environment forthe new MZT 6 with ATEX approval.

>> Right from the start, the MZT 6 proved itself as the mag-netic cylinder sensor for detecting the position of pistons inpneumatic cylinders. The reasons: very user-friendly, im-mune to vibrations, and with high switching accuracy. Andfrom now on “secure fixing and reliable function” (to sum-marise the experience of many users of the “T-slot talent”) isalso possible in the Ex-Zone.

Give ground …… is what many standard devices have had to do, as they donot conform to the ATEX directive. In almost all cylinder T-slots their place is increasingly being taken by the MZT 6ATEX. It is approved for Ex-Zone 22, Category 3D/3G, amongothers. The sensor is not just gaining ground, but often of-fers users better and more reliable switching behaviour thanbefore. This has been made possible by a specially adaptedmounting technology, whereby the sensor is first insertedfrom above – saving time. Then the MZT 6 is pressed onto

the bottom of the pneumatic cylinder slot over its entirelength during fixing. Standard tools are sufficient to carryout rapid and firm screwing of the slotted head or Allenscrew into the metal cylinder liner – and the sensor cannotbe ripped out.

Excellent against potential explosions – the new MZT 6 ATEX.INFO 212

Growth capacity for capacitive sensors

CM family has no succession worriesSICK has extended its family of capacitive sensorswith further sensor variants. The CM 30 is now avail-able in a 2-wire design for an operating voltage of250 V AC.

>> Increased switching distances of up to 25 mm and op-tions for flush or non-flush installation characterise capaci-tive sensors from SICK – the new CM 30 AC too. Moreover,all capacitive sensors share a special highlight: their highlevel of electromagnetic compatibility. This reliably preventsspurious switching caused by, for example, electrostaticallycharged granulate in bulk material silos, mobile telephonesand radio devices, or from interfering voltages brought aboutby magnetic valves, relays or frequency converters.

CM 18 PTFE: a tough guy with fine discriminationCapacitive sensors are mainly used in applications for whichoptoelectronic sensors are unsuitable because of the highrisk of contamination, for example. Now the CM 18 PTFEgoes one step further: the use of PTFE (Polytetrafluoroethyl-ene, also known as Teflon) for the housing and the M18threaded connections allows the sensor to check the fillinglevels of aggressive media, e.g. hydrochloric acid, sulphuricacid, phosphoric acid, a variety of alkalis, and numerous solvents. The same applies for object detection in environments in which these materials can be present as gases, steams or vapours. It is also suitable wherever

plants require frequent cleaning with chemicals or at hightemperatures. INFO 213See page 17 for an application report.

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SICK insight 2/2004

The UE 440 and UE 470 safety controllers30 Products

UE 440/470 safety controllers

Flexible, compact and reliable

>> While safety PLC and open fieldbussystems are becoming increasinglydominant in larger, complex productionsites, simple applications are still bestsolved with safety relays. The UE 440safety controller – the device for com-plex protective applications, and theUE 470 – the variant specifically de-signed for presses and rotary attach-ments, with integrated single-break,double-break and protective functions –are positioned precisely between thetwo. Among other features, they offer15 single-channel inputs, of which sixcan be connected as two-channel in-puts. There are also two safe connec-tions (Cat. 4, SIL 3) for electro-sensi-

Freely programmable Intelliface UE 440/470 safety controllers are theright choice for smaller to medium-sized machines with significant safe-ty requirements. They fill the technological gap between safety relaysthat require complicated wiring and the safety PLC, whose cost-benefitratio is unfavourable in this machine segment.

tive protective equipment from SICKwith internal device interfaces. Eightoutput pairs, of which two are safe out-put pairs, allow individual control ofdownstream plant components.

The compact alternativeUE 440/470 interfaces are charac-terised by low engineering and initialcosts per input and output, lower wiringcosts, and optimum user-friendlinessduring operation, troubleshooting orwhen making modifications. The con-trol systems, accommodated in com-pact housings, also convince with theircustomer-specific parameterisationand Category 4 compliance with

EN 954-1 and SIL 3 according to EN 61508. In combination with electro-sensitive protective equipment fromSICK, UE 440/470 interfaces not onlycover a wide range of safety functionssuch as Emergency Stop, Restart, orthe monitoring of protective doors –there are also interesting expandedfunctions for users.

Intelligent configuration memoryPre-configured ready-to-use C 4000light curtains often contain a lot of ex-pertise in the form of parameterisationor operating-mode-specific settingssuch as blanked protective field areas. UE 440/470 interfaces also ensurethat these are not lost if a sensor is re-placed. Of course, they autonomouslydetect the new light curtains and auto-matically configure it with the data ofthe original device retained in the con-figuration memory.

Thus UE 440/470 interfaces arethe safe choice whenever flexibility andrelay technology wiring costs are limit-ing factors, and use of a safety PLCwould be unwarranted.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 214or on the Internet at:www.sick.de/insight/en

Protecting hazardous areas and access with the UE 440

When greater safety is required: the UE 440 safety controller

SICK insight 2/2004

The W 190L series of laser photoelectric switches 31Products

New W 190L series of laser photoelectric switches

Specialists for standardand special applicationsExternally uniform, but internally with differing laser technology adaptedfor meeting application requirements – this is the new W 190L. TheStandard series of this sensor family is designed for “uncritical” appli-cations. The W 190L High Grade series is intended for demanding appli-cations and provides maximum accuracy and resolution.

Numerous features in common

As distinctive as the interiors of the individual W 190L sensors can be, theyare all similar on the outside. All sensors have a red-light laser in ProtectionClass 2. As a result, the sensors can be rapidly and accurately aligned on tar-get objects. The rotatable M8 plug or the 2 m cable are just as much devicestandards as the yellow and green LED display, providing practical assistanceduring commissioning and operation. The uniform compact plastic housingmade of ABS allows use of the devices even under difficult conditions.

>> All the sensors have a red-lightlaser in Protection Class 2, so they canbe rapidly and accurately aligned onthe target object.

For standard useThe W 190L Standard series is a com-plete family of photoelectric switchesconsisting of through-beam and reflexphotoelectric switches as well as prox-imity switches with adjustable back-ground suppression. They are reliable,user-friendly and economical sensors,whose basic features and functions aredesigned for solving conventional appli-cations.

High Grade: individually optimisedfor demanding applicationsSpecialisation is trumps with the W 190 Laser High Grade series. Thus,the CMOS technology of the WTB 190TLscanner offers a very high resolution.This permits reliable detection of ob-jects with highly reflective surfaces,such as foils. With appropriate pro-gramming, the scanner can operatewith a choice of background or fore-ground suppression. The WLG 190Tglass photoelectric switch is designedfor the reliable detection of transparentobjects. Whether glass bottles or flatobjects, such as discs; whether thin-walled PET plastics or transparent foils– the WLG 190T makes even the al-most invisible visible. Both sensors of-fer teach-in programming at the touchof a button or externally via the controlcable. This allows simple definition ofscanning distances and ranges. Menunavigation takes place on an easily vis-ible numerical display via which, for ex-ample, the type of switching can beprogrammed and, if necessary, a timedelay activated.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 215or on the Internet at:www.sick.de/insight/en

The W 190L series consists of Standard and High-grade laser sensors for demand-ing applications

SICK insight 2/2004

The programmable IVC-2D smart camera32 Products

>> “Vision” solutions for factory au-tomation: the introduction of the IVC-2D marks a breakthrough in high-tech image-processing technology forfactory automation. This camera com-bines the latest technology with a high-ly flexible and powerful library of imageevaluation programs. Quality inspec-tions on assembly lines, robot guid-ance, or checking labels on packagingare just a few of the examples of thewide variety of application possibilitiesof the IVC-2D in industrial environ-ments.

A tool for expertsThe IVC-2D offers image-processingusers a wide range of possibilities.These include approximately 100 soft-ware tools from the program library,with which the most varied of two-di-

With its integration of the Swedish image-processing experts IVP lastyear, SICK has taken a further step in expanding its leading techno-logical position in the area of factory automation. The first result ofthis combination of competence in sensor technology and specialistknow-how in image processing is the new 2-D IVC-2D Industrial VisionCamera, which was presented to interested users at the internationalVISION trade fair in Stuttgart in October.

mensional tasks can be solved.Shapes, geometries, sizes or designs –users can make very detailed adjust-ments of the camera via the graphicprogramming interface to meet the re-quirements of their object detection.The solution is exclusively oriented onthe function of the machine – withoutany compromises and thus without im-pairing its performance potential. Dif-

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 216or on the Internet at:www.sick.de/insight/en

Excellent co-operation – the latest jointdevelopment with the new SICK IVP logo: the programmable IVC-2D smart camera

The smart-camera IVC-2D

Setting its sights on the future

SICK IVP – the new brand in image processing

fering pixel resolutions, a shutter for re-ducing the effect of ambient light, in-dustrial housing and connectiontechnology, and immunity to impactsand vibrations guarantee the smartcamera a high level of availability in in-dustrial environments.

Fieldbus-enabled with Fast EthernetIn addition to three freely programma-ble switching outputs, the IVC-2D offersa Fast Ethernet connection for rapidand uncomplicated construction of acommunication network for transferringdata and parameters to the machinecontrol system. This also removes anycommunication restrictions on its use.

SICK IVP: from vision sensors forstandard applications and optimallyprogrammable solutions to complexcamera systems – it is needs-orientedimage processing that counts.

SICK insight 2/2004

The IN 4000 inductive safety system 33Products

Sensor can be connected directly to safe PLC

The IN 4000 safety systemswitches on metal Friction-free, immune to vibrations, easy to install and unaffected by dirt– the new inductive IN 4000 safety system fulfils all the requirementsfor the reliable monitoring of position or protective gates in harsh indus-trial environments. A further highlight: the sensor of the IN 4000 can al-

so be connected directly to a safe PLC.

>> The basic version of the IN 4000consists of an inductive sensor in a cu-bic housing for switching distances of10 to 15 mm, and a relay evaluationunit. The entire system, as well aseach of the two individual components,is certified for Category 4 in compli-ance with EN 954-1, making individualsafety solutions possible.

The direct solutionIf the control system of the machine orplant to be protected is based on asafe PLC, the IN 4000 sensor can beoperated directly. This is possible be-cause the sensor’s input and outputsignals are designed to correspond toEN 61131-2 and are thus compatiblewith the I/O signals of a safe PLC. Con-trol Category 4 according to EN 954-1is maintained even if the maximumnumber of 10 sensors is connected inseries.

The relay solutionIf there is no safe PLC available, thesensor can be connected to the IN 4000 evaluation unit with relay out-puts. Here, too, connection of up to tensensors is possible – leading to con-siderable cost savings, particularly inthe case of complex machines orplants. Three safety-relevant N.O. con-tacts, two N.C. contacts, and integrat-ed external device monitoring alsoallow flexible integration in the particu-lar machine controller.

Monitoring the switching areaprevents tamperingThe sensor’s inductive operating princi-ple means that no separately coded ac-tuator is required, i.e. the sensordetects the presence or absence ofmetal directly. In order to meet the re-quirement to prevent simple tamper-ing, the switching area of the sensor ismonitored in terms of both time andspace. Unauthorised alterations aredetected and lead to the machine be-ing safely switched off.

The design of the IN 4000 inductivesafety system thus offers completelynew approaches to the safe monitoringof position and protective gates on ma-chines and plants.

The basis version of the IN 4000: relayevaluation unit and inductive sensor

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 217or on the Internet at:www.sick.de/insight/en

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SICK insight 2/2004

New contrast scanners The IT 3810 hand-held scanner34 Products

Good and reasonably priced

The IT 3810 hand-held scanner: bar codes in focus The IT 3810 hand-held scanner has been designed as a good, reasonablypriced solution for reading bar codes on documents and low-volumegoods. Its reading performance and simple operation is good, its high re-liability and low cost make it reasonably priced, too.

>> As a basic model lacking no techno-logical necessities, the IT 3810 roundsout the successful IT 3800 series, ofwhich more than 1,000,000 have beensold. The linear image-capture modulegenerates a clear scanning line on thebar code and reads it at the usualcounter distance of between about 100 mm and 150 mm. Thanks to menuoptions and quick-start instructions,the IT 3810 is easily and quickly pre-pared for operation. A variety of inter-faces, including a keyboard wedge,RS-232 or USB permit connection tomobile terminals as well as stationarycomputer systems.

Robust and user-friendlyTypical areas of use for the IT 3810 arefixed and mobile workplaces, at whichthe bar codes on documents, packag-ing or storage spaces (as in invento-ries) require detection. The robust andshockproof device design ensures ex-traordinary availability; the ergonomichandle, low weight and simple target-ing of the bar codes provide a high lev-el of user-friendliness.

Deal yourself a good hand with the bar-code reading advantages of the IT 3810.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 219or on the Internet at:www.sick.de/insight/en

Poster for hand-held scanners provides overview

Have you got a good grasp of scanning?With or without cable? Radio: yes or no? Bar code or 2-D? Range? Wall-mount-ed receptacle or belt attachment? USB, RS-232 or both? Who can keep agrasp on the scanning possibilities? Become a “scanner-grasper” – withSICK’s new hand-held scanner poster.Theoretically, SICK’s hand-held scanner family and accessories offer well over200 potential configurations. Request the scanner poster and any confusionwill be brought to an end – with a practised grasp of scanners you will imme-diately be able to identify your mobile bar-code or 2-D reader. To receive your poster use the attached card under: INFO 220Know the devices – scan with the right one!

The IT 3810 hand-held scanner

The KT 3 Laser compact contrast scanner

Highly reliable detection of smallobjects >> The new KT 3 Laser is intended to be a “contrast” to other scanners.Maximum scanning distances and minimum light spot – both features ofthe new KT 3 Laser – allow no con-trasts to escape detection, whethercracks in glass, grooves in metal, or printed marks.

Moreover the sensor, in its minia-ture housing, is easily installed even ifspace is limited.

A real giant in performanceIn terms of device properties, thedwarf in SICK’s family of contrast scan-ners is actually a giant. 20 to 60 mmrange with a light spot of only 2 mm2 ata scanning distance of 40 mm, largedetection reserves with changing ob-ject distances, switching frequenciesof 1.5 kHz, and an enclosure rating ofIP 67 are features that ensure high de-tection reliability in a wide variety of ap-plications. Then there is the rapid com-missioning of the KT 3L resulting fromstatic teach-in on the mark and thebackground – a process that can becarried out either on the control panelof the device or via the control cable. Ifthe target object is highly reflective, au-tomatic adaptation of the switchingthreshold guarantees reliable detec-tion.

Thus the KT 3L is dazzlingly pre-pared for e.g. the detection of cracks in glass and narrow grooves on metal-lic surfaces, as well as the detectionand precise positioning of small marksand labels. INFO 218

SICK insight 2/2004

NEW: The DKS 40 incremental encoder Ultrasonic sensors 35Products

Predestined for monitoring the rotation ofrollers, cylinders and axles

The DKS 40 incrementalencoder – the compact androbust cost-cutter

>> Given its application and price seg-ment, the DKS 40 offers unaccus-tomed quality. Its housing consists ofsolid die-cast zinc and is also extreme-ly compact – with a diameter of 50 mmand a height of 42 mm. The user thussaves on valuable installation space.The DKS 40 is extremely robustagainst impacts and vibrations as a re-sult of using the highly successful mini-disc technology. Whether in a tooling,textile, packaging or timber processingmachine – conditions can be tough andspace limited.

The DKS 40 is available with a face-mount flange and 8 mm solidshaft. The device offers all commonline numbers up to 1,024 per revolu-tion. There is a choice of electricalinterface between Open Collector,TTL/RS-422 and HTL/push-pull. Theconnection cable is positioned in sucha way that it is possible to lay the cabledownin a radial or axial direction with-out any excessive bending. With thisflexibility, the DKS 40 sets a new stan-dard in its class.

Robust, compact, reasonably priced,flexible and rapidly available for use –the new star from SICK-STEGMANN canbe seen at SPS/IPC/DRIVES.

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 221or on the Internet at:www.sick.de/insight/en

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Users are increasingly demanding encoders for standard applications,such as monitoring the rotation of rollers, cylinders and other axles, in arobust but nevertheless reasonably priced design. The new DKS 40 wasspecially developed for these applications. It is not only the compact de-sign and robustness that attracts attention, but also the fact thatits extremely attractive price makes it a genuine cost-cutter.

New ultrasonic sensors

UM 18 – whenspace is limited>> SICK presents the new UM 18 ul-trasonic sensor, specially designed forapplications with limited space. The device, in robust M18 fine-thread housings, is available in two variants –Standard and High End.

The detection of transparent ob-jects (e.g. PET bottles) or checkingliquid levels in test tubes are just twoof the many applications for the new UM 18. Both device variants offer anoperating scanning distance of be-tween 30 mm and 250 mm, as well asteach-in and switching threshold pro-gramming via the control cable. The Standard UM 18 is best suited for those for whom a single switchingoutput is sufficient. The High End version is available for those who require more.

More functions and additionalswitching reliabilityExternally, the UM 18 High End is dis-tinguished by the two function LEDsand the two switching outputs. Inter-nally, an integrated temperature com-pensation system ensures that thesensor’s detection accuracy and relia-bility remain constant despite changesin ambient temperature during opera-tion. The possibility of backgroundteach-in is a real highlight. Critical ob-jects can thus be detected with partic-ular reliability, as it is not their often un-defined sonic reflectivity but the inter-ruption of the taught-in backgroundsound reflections that leads to a response from the UM 18.

The UM 18 ultrasonic sensor – reliable switching made easy. INFO 222

SICK insight 2/2004

The new V 4000 Press Brake Category 4 camera sensor36 Products

Reliable image processing on press brakes

The V 4000 Press Brake optimises safety and processes

>> Conventional systems for safe-guarding the hazardous closing move-ment on sinking brake presses consistof simple optoelectronic sensors andreceivers and are mounted on the topclamping bar and thus move with it.While they detect any hazardous reach-ing into the protective field, they haveserious disadvantages for machine productivity.

The V 4000 Press Brake offers“visionary” useThe new V 4000 Press Brake corre-sponds to Category 4 in compliancewith EN 954-1 and SIL 3 according toEN 61508 – and thus offers maximumsafety. Machine vision, i.e. image pro-

The new V 4000 Press Brake Category 4 camera sensor offers bothmaximum safety at work and maximum optimisation of folding process-es. This has been made possible by programming a safety field whoseevaluation can do more than just monitor a light path.

cessing, is the technological approachupon which this electro-sensitive pro-tective equipment is based. A two-di-mensional safety field, co-ordinatedwith the particular bending process, isactive during the downward motion ofthe die. The height of this field de-creases continuously as the bendingdie, on which the V 4000 Press Brakeis installed, approaches the die plate.This offers a variety of advantages:thick sheet metal, bent metal shapes,and thin plate with side walls are sub-ject to differing protection modes – ac-cording to the various bending tasks:“Standard” for simple one-dimensional bending, “Box” for bending multi-di-mensional objects such as boxes, and

“Limit stop” to take into account limitstops tight on the object to be bent.The system is exceptionally easy to in-tegrate into the press constructor’smachine control system. In this waythe safety equipment can be switchedto the optimum protective mode via se-lection of the bending program. Themachine can thus activate the differentprotection modes appropriate for thebending techniques, one after anotherand as often as required, for the sameobject, e.g. first “Standard”, then“Box” for a high box side, and finally“Limit stop” for the low part of a side.

Now possible: folding without anintermediate breakThe features and opportunities of the V 4000 Press Brake provide a very im-portant advantage for the actual bend-ing process. Unlike with conventionalsystems, the downward movement ofthe press bar must no longer be

SICK insight 2/2004

The KT 5 contrast scanner (with) display 37Products

Bar display for easier use

The KT 5 contrast scanner dis-play: a “straight back” for com-fortable use

>> Teach-in and tuning – a maximum oftwo steps to get the contrast scannerready for use. First, the bar display ofthe KT 5 Display supports the user dur-ing teach-in, when the sensor is taughtthe mark and its background, wherebythe sensor activates the optimumtransmission colour of the three-colourLED according to the contrast. If, in in-dividual cases, even more accuratefine adjustment is necessary, the dis-play permits pixel-precise fine adjust-ment of the current signal level via atuning button.

It’s all a question of adjustmentSo users can now check the currentsignal level in combination with the cur-rent switching threshold, as well as as-sessing detection accuracy and, ifnecessary, carry out a manual adapta-tion of the switching threshold. Thus if,for example, the appearance of a label

Those who desire maximum ease of use from their contrast scannersshould select the new KT 5 Display. Why? The new bar display on theback of the sensor housing now makes teach-in and fine adjustment par-ticularly easy.

changes (leading to altered grey valuesof marks, and the background or reflec-tivity), the KT 5 Display can now be eas-ily re-adjusted during operation.

Performance features that re-define the device standardThe new KT 5 Display has several per-formance features upon which usersplace particular value. In addition tothe three-colour LED technology andthe proven 2-point teach-in, these in-clude a switching frequency of 10 kHzand automatic adaptation of switchingthresholds with highly reflective materi-als. Individual alignment and attach-ment possibilities cover a wide varietyof mounting situations and ensure boththe electrical and mechanical compati-bility of the KT 5 Standard.A winner without drawbacks – the KT 5Display with the new informative back.

INFO 224

Bildtext

insightLINKWeitere Infos erhalten Sie mit der Karte am Ende des Magazins unter:INFO 200oder im Internet unter:www.sick.de/insight

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 223or on the Internet at:www.sick.de/insight/en

NEW

Sstopped just before folding, with a newapproach then being made using a footswitch. The savings in cycle time thatthis brings about increase machine ca-pacity – and thus economic efficiency.

Setting new standards in practiceThe intelligent image processing of theV 4000 Press Brake also sets newstandards regarding commissioningand availability. Vibrations – typical forpresses – do not trigger any system re-sponse because the entire camerafield, within which the safety-monitoredarea is programmed, is intelligentlyevaluated. The monitored area of thesafe camera sensor tracks even smallchanges in alignment. This immunity toany misalignment also makes adjust-ment during first commissioning, and

after a change of tools, simpler andquicker than with other “passenger”systems.

The very simple integration in exist-ing control systems is also remarkable,as the V 4000 Press Brake operateswith the signals that are anyway usedon press brakes.

The V 4000 Press Brake – press pro-tection that offer users and integratorsa real technological lead.

Maximum optimisation of bendingprocesses and maximum operatingsafety – with the V 4000 Press Brakecamera sensor

The bar display informs the user about the detection reliability of the taught-in contrast

NEW

S Automatic counting of persons at airports, shopping malls or stadiums

LD PeCo enables more efficient safety strategies

With 11 or 16 beams in a com-pact housing

The ELG 1 shortrange – the rea-sonably priced au-tomation light grid>> Simple installation and robustnessduring operation characterise SICK’sautomation light grid. With a range ofup to 3 m, the ELG 1 is the ideal solu-tion, e.g. for regulating throughput,checking and positioning pallets, de-tecting objects on overhead conveyors,or counting parts.

Those who know how difficult it isto create one’s own light grid fromlarge numbers of individual sensorsappreciate the advantages of the newELG short range. No more misalign-ment and there is no longer a mess ofcables between the sensors and thecontrol system – the ELG 1 eliminatesmany disadvantages that are almostimpossible to avoid with multi-beamdetection solutions involving individualsensors.

Optical synchronisation, optimumobject detectionELG 1 options are avail-able with a monitoringheight of 150 mm with16 light beams, or amonitoring height of100 mm with 11 lightbeams. Senders andreceivers are opticallysynchronised – thusthere is no need for theotherwise necessarycable. A detection fieldwith beam separationsof 10 mm is generatedbetween the senderand the receiver hous-ings. This fine resolu-tion allows even smallparts to be detected.Furthermore, it is evenpossible to detect flatobjects with the help ofcross-beam evaluation.

The ELG 1 – it’sbetter to install a singledevice than improvisewith lots of sensors.

INFO 225

LD PeCo is a new type of long-range system for counting persons and de-termining the direction in which they are moving. Whether children oradults, individuals or entire groups – the non-contact measurement sys-tem reliably detects how many people there are, where they are, and inwhat direction they are moving.

>> The system is particularly suitablefor counting people in large buildings,e.g. at airports, shopping centres orstadiums, as it detects the direction ofmovement and can monitor pathwidths of up to 26 m. In this way theLD PeCo can, among other things, de-termine the best place for advertising,control air conditioning, or provide im-portant information for security andrescue measures in an emergency.

Detection by means of invisiblelight curtainsThe LD PeCo is an actively scanning,highly precise laser measurement sys-tem, whose scanner emits two invisi-ble, fan-shaped, parallel light pulsesand measures the time until receptionof their reflections. Regardless of the

size and geometry of a space, room orpassage, LD PeCo can be adapted totake any spatial structure into account,e.g. supporting pillars or electronicgoods security portals. The time-of-flight of the transmitted light pulseschanges as soon as someone walksthrough the light curtains, and the per-son is counted. When several people,even of different sizes, cross the moni-tored area, they are also reliably de-tected and counted. Simultaneously,the LD PeCo detects which of the twolight curtains is interrupted first andcalculates the direction the personsare moving in. This quantity and direc-tional information can be transmittedto, for example, the central buildingcontrol system via RS-232, RS-422 ortwo digital switching outputs.

SICK insight 2/2004

The ELG 1 light grid The LD People Counter laser measurement system 38 Products

The LD PeCo provides reliable results even in dense crowds

insightLINKYou can obtain further product information on the Internet at:www.sick.de/insight/en

Can be installed almost anywhereThe maintenance-free LD PeCo offersalmost no restrictions regarding instal-lation. The system can be installed out-side the aisles or beyond any possibleaccess, thus protecting it against dam-age or tampering. People can be reli-ably counted, even in high arcades inshopping malls, or in arrival and depar-ture halls at airports, thanks to amounting height of up to 15 m. Unlikecameras, the LD PeCo operates inde-pendently of the light conditions and iseffectively protected against stronglight or targeted dazzling.

The LD PeCo – the detection solutionthat meets numerous requirements inbuilding management.

NEW

S

SICK insight 2/2004

DT 500/DS 500 distance sensors 39Products

>> Numerous users are not distancingthemselves from the DT 500 and DS 500 distance scanners – on thecontrary. Since it was initially intro-duced at the Hanover Industrial TradeFair 2004 the devices have enjoyedever-increasing popularity.

This is particularly the case in ap-plications such as collision preventionfor cranes, distancing for transportedobjects, or measuring the heights ofstacks. The sensors have proved them-selves everywhere as a result of theirhigh accuracy – even with pitch-blacksurfaces.

Analogue or digital – a choice butno dilemmaWhile the DS 500 has two switchingoutputs that can be displayed, the DT 500 offers a choice between a 4–20 mA analogue output and a serialRS-422 measurement data interface.The start and end of the measurementrange is freely programmable via thecontrol and display field – thus the DT 500 can be ideally adapted to theparticular task involved.

3 mm – greater “inaccuracy” is not possibleThe range of 18 m on a black back-ground with an accuracy of 3 mm – pos-

sible as a result of the minimised tem-perature drift of just 0.05 mm/K –leaves nothing to be desired in terms ofdetection accuracy. At the same time(the devices provide a measurementvalue every 250 ms), they also exhibitextremely precise background suppres-sion – even if the background materialhas a light surface. During develop-ment, however, care was not only takento ensure precision but also user-friend-liness: an integrated display allows sim-ple setting of measurement ranges andswitching thresholds, as well as dis-playing the current system function.

“Better by a long chalk” – this is theview of users convinced by the perform-ance of the new DT 500 and DS 500distance sensors.

Even suitable for black surfaces – DT 500 and DS 500 distance scanners

The LD PeCo

Black is beautiful!

DT 500/DS 500 distancescanners offer long rangeand great accuracyTastweite und Genauigkeit

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 226or on the Internet at:www.sick.de/insight/en

For further reading …

… see page 24

Dream machine solves nightmareDT 500 – laying it on the line for mattresses.

SICK insight 2/2004

The LD PDS building security laser measurement system40 Products

Recommended by da Vinci, Tizian and Dürer

LD PDS – protects valuablesand prevents vandalism

>> In many cases laser measurementtechnology, such as the LD PDS, hasproved an economical and technical al-ternative for monitoring buildings, aswell as a sensible supplement to CCTV.

Reliable detection and precisecamera guidanceIndependent of the lighting conditionsin an area, and effectively protectedagainst strong light impingement or de-liberate dazzling, the LD PDS lasermeasurement system offers maximumdetection reliability. The active scanner

The LD PDS is a new, non-contact building security laser measurementsystem for horizontal and vertical 360° all-round monitoring. The Pro-tection and Detection System (PDS) offers versatility and detection re-liability. It is thus ideally suited for security functions in buildingmanagement. Famous paintings are already protected by the LD PDS.

of the measurement system transmitsan invisible fan-shaped light pulse andmeasures the time until reception of itsreflection. The time-of-flight of thetransmitted light pulse changes assoon as someone reaches into or en-ters the protective field – and triggersan alarm signal. As the system not on-ly detects persons as such, but can al-so determine their position in an area,observation cameras can also be ex-tremely accurately aimed and focusedon the basis of the information sup-plied by the LD PDS.

Maximum flexibility thanks to dual DSPIn addition to a first digital signalprocessor (DSP) for controlling themeasurement system, every LD PDShas a second DSP that carries out aprogrammable application-specific con-version of the measurement values ob-tained, and transmits them via RS-232,RS-422 or two digital switching out-puts. As a result, any security techni-cian, system integrator or user of themeasurement system can adapt themonitored area appropriately. If thischanges, e.g. as a result of putting upnew walls or buildings, or exchangingguarded objects of different sizes, thisis also easily taken into account viasoftware in the device. Thus the lasermeasurement systems allow continuedflexible use of spaces or wall areas.

Light “veils” protect Louvre worksAbout 30 LD PDS are in use at theLouvre in Paris, one of Europe’s oldestand most prestigious museums. As aresult of their designs, the devicescould be integrated into the walls of the exhibition rooms and protectedagainst sabotage and interference.The “veil” of light generated by the de-vice does not impair visitors’ views ofworks by Leonardo da Vinci, Raphael,Rembrandt, Tizian, Dürer and othergreat masters.

The LD PDS

insightLINKYou can obtain further product information on the Internet at:www.sick.de/insight/en

SICK insight 2/2004

The CVS 1 Color Vision Sensor 41Products

>> The CVS 1 Color Vision Sensorchecks whether the amount, or numberof pixels, of the colour tone in its fieldof view matches at least the minimumtaught-in – in principle it therefore functions like a colour scanner with avery large light spot and very long op-erating distance.

Industrial design in “photoelectricswitch” formatThe CVS 1 is used for colour detectionin industrial environments. For this rea-son, during development emphasiswas placed upon: simple teach-in pro-gramming, direct display of the imagecaptured by the CVS 1 Color Vision

Sensor, typical cycle times of just 10 ms, and the storage and immediateretrieval of up to 16 different colourtone inspections.

What is special about all these fea-tures is that they have been achievedwithin the CVS 1 camera sensor itself(only about the size of a photoelectricswitch) – without any supplementaryexternal control and evaluation unit.There is a separate monitor and controlpanel that can be connected to thecamera sensor for use in mounting lo-cations where its own display cannotbe seen.

Great performance – low priceThe CVS 1 offers highly versatile use –from monitoring the browning of meat-balls, and checking the presence ofbottle tops and lids, to detecting logosand checking labels in packaging ma-chines. Here, for example, labels withdefective designs can be detected – al-most impossible with point-based sen-sor detection. The CVS 1 also detectscolour in applications such as checkingthe completeness of crates or carriersystems, checking the presence of en-closed instructions, differentiating be-tween objects on the basis of colour,and checking the filling levels of trans-parent containers. Given all these ad-vantages, one can hardly believe theprice of the CVS 1 – the device is theonly one in its performance class avail-able for less than € 1,000!

Whether price or performance – theCVS is a fantastic solution from anypoint of view.

The intelligent small-scale CVS 1 Color Vision Sensor: a photoelectric switch for detecting colour in industrial environements

insightLINKYou can obtain further product informa-tion with the attached card under:INFO 227or on the Internet at:www.sick.de/insight/en

Large-format colour detection with the CVS 1 Color Vision Sensor

Suitable for meatballs, bottle tops and packagingA large detection field, integrated illumination, long operating distances,a colour monitor for simple operation, a teach-in button and extremelyshort evaluation times. A single device, the CVS 1, offers all these fea-tures – normally requiring expensive camera and computer equipment.

SICK insight 2/2004

Standardised sensor teach-in Bluetooth42 Know- how

Maximum simplicity for users

SICK supports standardised teach-in

>> Intuitive operation without a manu-al, simple and rapid commissioning,prevention of unintentional triggering,and clear visual indication of devicestates on the sensor or in response toremote querying – this is how userswant to commission and operate theiroptoelectronic and ultrasonic sensors.So the leading suppliers of standardsensors are working towards the goalof formulating uniform teach-in philoso-phies for customers and producers,and deriving shared features fromthem.

Uniform featuresParticipants in the workgroup have dis-cussed uniform sensor features basedon the requirements of customers andthe solutions already implemented indi-vidually by producers. Among otherthings, this affects the use of buttons;operating modes and their visualisa-tion by means of LEDs; automatic ac-ceptance of teach-in values; indication

In partnership with other producers, SICK is working on the rapid imple-mentation of a producer-independent standard teach-in process in the“Standardisation of sensor teach-in processes” workgroup in the Ger-man Trade Association for Electronic Components and Systems (ZVEI).

of error states; and time locks in theteach-in process intended to preventunintentional operation. Icons have al-so been defined for uniformly labellingteach-in buttons for:p single-value teach-in: only set on one

object, and p two-value teach-in: setting takes

place on one object and one back-ground.

Draft standard handed in to CENELEC*A draft for standardising the teach-inprocess of standard sensors has beenpresented to CENELEC for Europeanstandardisation as an appendix to EN 60947-5-2: the IEC 60947-5-2 Annex G Draft. Parallel to this, SICKhas integrated the latest generation ofoptoelectronic switching circuits (so-called opto-ASICs), that are in com-plete conformity with the agreed draftstandard, in its latest optical sensorsfor automation, including the WT 9-2,

WT 14-2 and WT 18-3, among others.All producers – a single goal:

straight forward teach-in without com-plicated operating instructions.www.zvei.org and www.stafuco.org

* CENELEC is the European ElectrotechnicalStandardisation Committee

The DME 5000 distance measuring device: teach-in by mobile phone

Parameterisation and diagnosis via Bluetooth

>> Replacement of the serial in-terfaces of sensors such as the DME 5000 laser distance measuringdevice is particularly attractive. Withthe help of a Bluetooth-enabled laptop,service technicians can communicatewith the sensor on the high bay stackerfrom a distance, without having to en-ter a blocked aisle of shelving. This isconsiderably simpler and more com-fortable than via cable. And it is alsosecure, as Bluetooth not only encodesthe radio signal, but also changes itstransmission frequency up to 1,600times per second.

Greater mobility and comfortdrive the standardCable-free connections, mobility of end-devices, and online communicationover short and medium ranges are thereasons why Bluetooth is well on theway towards becoming the standard inthe cable-free IT environment. Numer-ous end-devices are already equippedwith this radio interface.So it’s hardly surprising that the DME 5000 with the Bluetooth interfaceattracts great interest whenever it ispresented.

insightLINKComprehensive information on “Blue-tooth” is available in six languages atwww.bluetooth.com the official Bluetooth web site.

Away with the cables – this trend is becoming increasingly commonamong modern automation components. Whether parameterisation ordiagnosis – cable-free data transmission via Bluetooth simplifies work insitu, e.g. in high-bay warehouses.

Teach-in button labels

Single-value teach-inwithout background/target differentiation

Two-value teach-in

Optional

Target Background

SICK insight 2/2004

Autoworld in Brussels, Belgium 43Museum

>> Several hundred cars can be seen –lovingly restored and looked after.Horse-drawn vehicles are just as mucha part of the museum as are the first“real” cars and their successors: statecarriages, luxury limousines, convert-ibles, coupés – as well as buses andtrucks. Motorcycles are a further areaof interest.

A variety of collections embeddedin their timeSeveral private contributors have lenttheir collections to the museum overthe decades. The Mahy Collectionshows extraordinary and prestigiousvehicles, the Thiry Marcel Collectionconcentrates on two-wheeled vehicles,while buses and transport vehicles of

One of Europe’s most interesting automobile museums is accommodat-ed in the Palais du Cinquantenaire: the Brussels Autoworld. It tells oftimes long past, while also stimulating a critical consideration of the carin today’s social environment.

all types are to be seen in the GalleryPierre d‘Ieteren. There is also a replicaof the 1902 Motor Show, and a depart-ment for the history of car design.Looking at the exhibits conjures up inone’s mind’s eye the history of the lastcentury. The Belle Époque of the 20s,two world wars, the limousine era andthe revolutions of the 50s and 60s, aswell as the last three decades – duringwhich the car finally developed into acommodity for the masses.

Goods for the masses = good forthe masses?In addition to its purely expositionalaims, the Brussels Autoworld also fol-lows technical and social educationaims. Children and young adults are of-

fered a variety of visitor programmesthat, in addition to the automobile astechnology, also consider how the carhas influenced the appearance of theworld, the development of societies,and the attitudes and ways of life ofmankind and families.

Whether the car, as a good for themasses was, and is, always good forthe masses – the visitor must come totheir own conclusion. Whatever thecase, the Brussels Autoworld providesa richness of stimuli here.

100 years of automotive history at the Autoworld Museum in Brussels

insightLINKYou can obtain further information about the Brussels Autoworld on the Internet at:www.autoworld.be

A vehicularjourneythrough time

Turkish subsidiary for south-east Europe

SICK founds S.I.C.K.

>> As of now, S.I.C.K. (Sensörler veIleri Cihazler Kontrol Sanayi Ticaret)A.S. has exclusive rights to sell the en-tire range of products in Turkey, and willlater also distribute them in a variety ofneighbouring countries.

10-year history of successOnur Mühendislik was founded in1994. While just six staff were em-ployed during the first two years, meet-ing all the needs of sensor sales in

As part of its strategy of expanding its market position in south-east Eu-rope, SICK has integrated its former Turkish sales representative in Istanbul, Onur Mühendislik, into its worldwide sales network as a new subsidiary.

Turkey, Onur achieved continuousgrowth during the following years de-spite the difficult economic conditions.A total of 22 personnel are now em-ployed by the new SICK subsidiary, up-on whose specialist knowledgenumerous customers and users rely –including major press producers, auto-motive suppliers and logistical compa-nies that use sensors, safety systemsand bar-code readers.

SICK insight 2/2004

Company founded in Turkey Results of the safety co-operation44 SICK Tour

Safety co-operation: Omron + Rockwell + SICK

DeviceNet Safety on the march

>> SICK sees DeviceNet Safety as atechnology on a par with Profisafe andAS-Interface Safety at Work, and hasdeliberately integrated a lot of expert-ise in the development of products.The UE 4470 is one of the first exam-ples of this.

For consistent machine safe-guarding conceptsAny combination of safety sensors andactuators can be integrated locally anddecentrally in DeviceNet Safety net-works with the UE 4470 Safety Con-troller. Status, diagnostic and errormessages can be detected andprocessed in situ or via the network. In-tegrated and certified basic and appli-cation function blocks (such asautomatic reset, enabling switches ortwo-hand control units) permit the solu-tion of simple and more complex safetytasks, allowing the realisation of con-sistent machine protection concepts,

In October 2002 the companies Rockwell Automation, Omron and SICKpresented the Open DeviceNet Vendor Association (ODVA), the safety co-operation they had founded. The aim of this collaboration was and remainsthe development of hardware and software components that use De-viceNet Safety, the safety extension of DeviceNet, as their protocol. TheUE 4470 Safety Controller is one of the first results.

such as those relevant for packagingmachines or machine tools, robot cellsand conveyor systems.

Equal partners with differingemphasesWith Rockwell Automation, Omron and

SICK, three partners that are leadersin their market segments with leadingmarket positions in the USA, Asia andEurope, have united in a safety co-op-eration. Each company contributesspecific expertise: Rockwell Automa-tion and Omron provide control system,programming and network technolo-gies, while SICK provides expertise insafety applications and technology.

Flexible safety automation with De-viceNet Safety – SICK actively supportsthe dialogue on “distributed logic” innetworks. INFO 228 www.odva.org – key words: CIP Safety

The UE 4450 safe bus nodeand the UE 4470 safety con-troller (right)

10 years’ SICK Hong Kong>> Danny Chan, the current ManagingDirector, and three other employees,were the original team at SICK HongKong in 1994. The company developedas dynamically as the market: after afirst office in Guangzhou, a branch wasopened in the metropolis itself oneyear later. With further offices in Bei-jing and Shanghai, SICK China now hasa presence in the most important ar-eas of the nation. The company pro-vides support to all the key industriesin China: automobile construction andthe electronics industry, steel works,machine tool manufacturers, the print-ing and packaging industries, food anddrinks producers, as well as compa-nies involved in material handling.

Congratulations for the last tenyears and all the best for the newdecade.

SICK insight 2/2004

Finding products in the eCatalog Hong Kong celebrates tenth anniversary 45SICK Tour

In September 2004, almost 60 staff celebrated the founding of SICKHong Kong ten years ago. The company formed the core of the SICK Op-tic-Electronic Co. Ltd., Guangzhou China which came into being in 2003.

Hong Kong at a glance:

Official name: Hong Kong Special Administrative Region of the Peo-ple’s Republic of China, since 01.07.1997

Area: 1,092 km2 – about the size of Martinique – c.f. China with 9,597,995 km2 = almost as large as the USA or approx. 27 times the size of Germany

Population: approx. 7.3 m. – about as many people as in allSwitzerland – estimated total population of China isalmost 1.3 bn.

Population density: 6,771 persons per km2 – c.f. 387 on Martinique

Exchange rate: 1 Hong Kong dollar (HKD) = ca. 0.10 EUR; 1 EUR =9.66 HKD (in October 2004)

Sources: Homepage Spiegel / LänderlexikonThe Team of SICK Hong Kong

The Product Finder offers you theopportunity to enter parameters to se-lect the products that potentially meetyour needs. You can narrow down thesearch results as desired and thereforeinfluence the number of products se-lected. You can thus rapidly and com-prehensibly obtain information on ourproducts.

You can obtain detailed product da-ta such as the data sheet, connectiondiagrams, accessories, etc. by clickingwithin your search results.

To the product via the Application FinderThe Application Finder guides you from

the application to the product. By se-lecting the task, sector and productsused one rapidly reaches an appropri-ate application description and linksthat take you to the products used inthe application. Thus your search al-ways results in a solution. And you canfind mounting sets, plugs, lenses, etc.in the Accessory Finder.

Please note: As a result of the enor-mous range of products not all productsare available in the Finder pages duringthe transition period.

SICK Product Finder eCatalog on the Internet

ecatalog.sick.com Find sensors online

>> Find – don’tseek. Click –and stay up-to-date. It’s neverbeen easier –

with SICK’s Prod-uct Finder eCatalog.A complete range of automation sen-sors; industrial safety systems; andtrail-blazing material flow, identificationand handling systems – the ProductFinder eCatalog invites online researchfor SICK products (currently in three lan-guages).

SICK insight 2/2004

P6 SICK Rundschau “Eat that frog” by Brian Tracy46 Book Corner

>> When I picked up this book Ithought: Well, it looks funny enough,the frog on the cover, looking at me inthat way with its big froggy eyes – butI’m supposed to eat that? No thanks!!!

OK, even I quickly grasped that itwas just a bit of imagery for somethinguncomfortable, something that I reallydon’t want to do, which I may even finddisgusting. And there are a few thingsthat spring to mind which I would takethe trouble to think of 1,000 excusesto keep putting off. But what effectsdoes that have on my life? Either pri-vate or professional.

So let’s see what tips and tricksBrian Tracy can offer me to conquer myweaker self.

Right at the start he impresses up-on us the importance of not startingthe day with the easier tasks, as we hu-mans are wont to do. So the first job isto clearly define what the biggest “frog”is. It’s helpful to plan the day properly.A range of rules and various lists arevery helpful here.

It is also very important to considerthe repercussions of doing or not doingsomething. This can become a key fac-tor in the long-term perspective of life.Whereby one also determines the next“frog” – what more could one want?

“Eat that Frog”21 great ways to stop procrastinatingand get more done in less time

The 21 steps to success build uponone another logically and are compre-hensibly structured with key words andsub-headings. Many of the steps alsooffer exercises that help me put thetheory into practice.

Summary: A very stimulating bookthat I would recommend. It made methink about my long-term aims in lifeand about how I can achieve themmost effectively, if I really want to.

Book Corner by Ingrid Rathfelder, EditorSICK insight e-mail newsletter

“Eat that frog” is available from BerrettPublishers, Inc., ISBN 1-57675-198-8

Another significant tip: set prioritiesand never start a B, C, or D task beforethe A task has been completed.

Concentration on key areas, suchas planning, organisation, job place-ments, delegation, inspection, meas-urement and reporting, is the next ma-jor factor, particularly in management.In this context it is important to contin-uously improve oneself. Here Tracy rec-ommends, among other things, keep-ing the working environment clean andtidy. Oh dear, looking at my desk is soawfully depressing!

How well I succeed in taking myspecial talents into account, what canprove to be important impediments,how I can motivate myself to take ac-tion, how I can put pressure on myself,when matters are critical, what the“Salami Tactic” or “Swiss CheeseMethod” are, and much else besides,are covered in the remaining third ofthe book.A well organised summary at the endprovides assistance in again clarifyingthat eating the biggest frog in the morn-ing is both satisfying and motivating,and that I will then find the other tasksmuch easier to deal with.

The rule is that you should

never do a “B” task

when there is an “A” task

left undone

Rule: Long-term thinking

improves short-term

decision making

The key to the success of this

method of working in specific

time segments is for you to plan

your day in advance and specifi-

cally schedule a fixed time period

for a particular activity or task

insightLINK

Weitere Infos erhalten Sie mit der Karte am Ende des Magazins unter:INFO 121

insightSERVICE

Trade fair dates Imprint Contacts 47Info

Central Sales, GermanySICK AGSchiess-Straße 5640549 DüsseldorfGermanyPhone +49 211 53 01-0Fax +49 211 53 01-100e-mail vzdinfo@sick.de

Company HeadquartersSICK AGSebastian-Kneipp-Str. 179183 WaldkirchGermanyPhone +49 7681 202-0Fax +49 7681 202-38 63e-mail info@sick.de

Trade fair dates GermanyTrade fair Location Date 2004/2005

SPS/IPC/DRIVES Nuremberg 23.11.–25.11.2004

i+e Freiburg 27.01.–29.01.2005

LogiMAT Stuttgart 01.02.–03.02.2005

HANNOVER MESSE Hanover 11.04.–15.04.2005

SEMICON Europa Munich 12.04.–14.04.2005

interpack Düsseldorf 21.04.–27.04.2005

Trade fair dates EuropeTrade fair Location Date 2004/2005

Elektro Vakbeurs Hardenberg, NL 07.12.–09.12.2004

elec Paris, F 09.12.–13.12.2004

DRIVES AND CONTROL Danzig, PL 09.02.–11.02.2005

AIDC Papendal, NL 08.03.–09.03.2005

CFIA Rennes, F 08.03.–10.03.2005

MOCON ’s-Hertogenbosch, NL 30.03.–31.03.2005

AUTOMATICON Warsaw, PL 05.04.–08.04 2005

Swiss Sensor Market Zurich, CH 07.06.–09.06.2005

VISION SOLUTIONS Nijmegen, NL 15.06.–16.06.2005

SAWO Posen, PL 20.06.–23.06.2005

ELEKTROTECHNIEK Utrecht, NL 26.09.–30.09.2005

Trade fair dates worldwideTrade fair Location Date 2004/2005

PRO MAT Chicago, Illinois, USA 10.01.–13.01.2005

METALFORM Rosemont, Illinois, USA 20.03.–23.03.2005

FIE Anhembi, São Paulo, BR 25.04.–29.04.2005

SubsidiariesAustraliaPhone +61 3 9497 4100+1800 3 3480 2 – toll freesales@sick.com.auAustriaPhone +43 22 36 62 28 8-0office@sick.atBelgium/LuxembourgPhone +32 2 466 55 66info@sick.beBrazilPhone +55 11 5091 4900sac@sick.com.brChinaPhone +85 2 2763 6966ghk@sick.com.hkCzech RepublicPhone +420 2 57 91 18 50sick@sick.czDenmarkPhone +45 45 82 64 00sick@sick.dkFinlandPhone +358 9-25 15 800sick@sick.fiFrancePhone +33 1 64 62 35 00info@sick.frGreat BritainPhone +44 17 27-83 11 21info@sick.co.ukItalyPhone +39 02 27 40 93 19ced@sick.itJapanPhone +81 3 3358 1341info@sick.jpKoreaPhone +82 2 786 6321/4kang@sickkorea.netNetherlandsPhone +31 30 229 25 44info@sick.nlNorwayPhone +47 67 81 50 00austefjord@sick.noPolandPhone +48 22 837 40 50info@sick.plSingaporePhone +65 6744 3732admin@sicksgp.com.sgSpainPhone +34 93 4 80 31 00info@sick.esSwedenPhone +46 8-680 64 50info@sick.seSwitzerlandPhone +41 41 619 29 39contact@sick.chTaiwanPhone +886 2 2365 6292sickgrc@ms6.hinet.netTurkeyPhone +90 216 388 95 90 pbxinfo@sick.com.trUSAPhone +1 (952) 941 6780info@sickusa.comMore representatives and sales offices in all major industrial nations at www.sick.com

ImprintPublisher: SICK AG · Postfach 310 · 79177 Waldkirch · Germany · www.sick.com

Phone +49 7681 202-0 · Fax +49 7681 202-38 63 · info@sick.de

Co-ordination: Anette Hippach · Customer Magazine Project Manager, SICK AGAnette.Hippach@sick.de

Specialist editors: TOP MEDIA · Dirk S. Heyden · 69469 Weinheiminfo@topmedia-weinheim.de

Conception/layout: johnson][braun Direktwerbung · 76133 Karlsruhejb@johnsonbraun.de

Translator: Richard Dennis · 79194 Grundelfingen · richarddennis@t-online.de

Printing: Druckerei Furtwängler · 79211 Denzlingen · info@druckerei-furtwaengler.de

Pictures: SICK AG, Getty Images, Autoworld Brussels, BGFE, Roland Krieg Fotodesign

Individual contributions may be reproduced after prior consent. Please contact us at: Phone +49 211 5301 0 · Errors excepted · Subject to technical change