Identifying Solutions: 1 - 2 0 1 1 Sick'S Customer Magazine

> Identifying
solutions
Your industry in our focus
www.sick.com
1 _ 2 0 1 1 S I C K S C u S t o m e r m a g a z I n e
Handling, storing, sorting
New sensor and system solutions in
the industry focus logistics

Page 4 to 13
Packaging as a challenge
Industry focus packaging
highlights new trends

Page 14 to 23
Trends in logistics
Interview with Prof. ten Hompel
of Fraunhofer IML

Page 24
: anwendungen
2
01 2011
Learning from each other
Dear Readers,
In the course of the swift economic recovery, we were able at the
end of the 2010 fiscal year to exceed even our record sales in 2008.
We are delighted about this steep upturn, for among our customers,
too, things are improving noticeably. By adapting capacities, we man-
aged to respond to their large number of orders with prompt deliveries.
In order to be able to continue providing our clients with a high level of
service, we have not only hired many new employees but also aligned
our organization, our product range, and our spectrum of services
accordingly, in an even more customer-oriented way. This approach
also entails continuously qualifying our staff further, especially in Ser-
vices and Sales. In this way, they get to know even better the tasks
and secondary conditions of many different industrial sectors, devel-
oping together with our customers and product specialists proposals
for solutions that are both technically and economically efficient.
Moreover, it is not only we who learn from our customers but they also
learn from us. On page 53, you can find out more about accredited
safety services from SICK, such as plant walk-through. This strategy
involves our safety experts cooperating with operators to determine
the major safety aspects on machines and plants on location and to
formulate recommendations for effective safety strategies.
Based on the 2010 reader survey, you have shown us that you
appreciate SICKinsight very much and that you would enjoy reading
even more about our products and solutions. Therefore, we would like
to thank you for your active participation and present you in this issue
with major-interest topics such as the industry focus on logistics and
on packaging. Both at the CeMAT in Hanover and at the interpack in
Dsseldorf you will have an opportunity to exchange ideas with our
industry specialists on the latest trends in your industry. We are confi-
dent that we will manage to find a solution for your task as well, a so-
lution that provides great added value to your machines and facilities.
Already we are looking forward very much to being able to welcome
you there at our exhibition stands and we would like to wish you an
inspiring read!
Yours sincerely,
Markus Vatter
Member of the Executive Board Finance/Human Resources
: editorial
.........................04
Swiss Postal Services trusts in auto ID system ...06
Compartment clear clear sailing for the pallet ...07
Safe handling of containers and pallets...............08
High-end camera systems at TNT Air Hub ............09
Oslo: Traffic invoicing via laser measurement .....10
Sensor for mobile robots .......................................11
Automatic returns detection of printed products ....12
Collision prevention at the quay ...........................13
......................14
Piracy protection for pharmaceutical industries ....16
Battle against product pirates ...............................17
Sensor designs for the packaging industry ..........18
Simply well packaged with VISTAL
: W9-3 ...........19
Sensors from SICK with IO-Link interface ............20
3D quality check for lids and caps ........................21
Perfect detection of preforms and PETs...............22
Automation of washing facility ..............................23
: Views & Voices
Autonomous control and swarm intelligence .......24
SICK as partner in teaching...................................26
: applications
Workflow-oriented CE marking ..............................27
Book return without moment of shock .................28
Luminescence vision sensor on glue patrol .........29
Empties return station at Migros ..........................30
Greenhouse fertilization with gas analyzers ........31
Safety technology in-company training at SEW....32
Sensors for wafer and biscuit baking plants ........33
Control with SICK 3D color camera ......................34
: technology
Integrating intelligently using IDpro ......................35
: Know-how
Muting and pattern recognition ............................36
: Products
Universal solutions for rotary path measurement ...38
Code reader for pharmaceutical,
logistics and automotive industries ......................39
Laser scanner featuring multi-echo technology ...40
Motion Control: monitoring zero-speed safely .....41
Upgrade of the MLG automation light grid ...........42
Cylindrical construction with a future ...................42
Inox portfolio complemented ................................43
New versions of the Inspector vision sensor .......44
Flexi Link: networking safety controllers ..............45
Level detection, plug & play ..................................46
IMA inductive plus analog ..................................46
Inductive sensors for any machine design ...........47
Motor feedback purely digital ...............................48
Safety laser scanner in miniature design .............49
New fork sensor: lithe and lissome and more .....50
Photoelectric sensor for transparent materials ...51
Gas analyzer system GMS800 one for all .........52
: Service & Support
With accreditation and a trained eye....................53
: SICK tour .......................................................54
: SICKinsight
[plus]
Automobile development
under bamboos and palms ...................................56
: Service .............................................................57
: news
03
Federal President Christian Wulff visits SICK
Id have liked to become an engineer
As part of his inaugural visit to the German federal state of Baden-Wrttemberg,
Federal President Christan Wulff, together with his wife Bettina Wulff, former
Baden-Wrttemberg Minister President Stefan Mappus and his wife Susanne
Verweyen-Mappus, paid a visit to SICK AG in Waldkirch on 16 December 2010.
Federal President Christian Wulff in conversation with Dr. Robert Bauer and Gisela
Sick. In the background, on the left, Bettina Wulff and, on the right, Stefan Mappus,
former Minister President of the German federal state of Baden-Wrttemberg
>> Federal President Christian Wulff was
captured by the fascination of sensor intel-
ligence. During the tour of the production
and final assembly facilities, he wanted to
know in detail which steps were necessary
to manufacture high-tech and high-quality
photoelectric sensors. He expressed his
interest and enthusiasm for sensors by
saying: I would have liked to become an
engineer. At his express wish, the tour
ended with a visit to the electronics train-
ing workshop facility, where he discussed
with trainees. In the course of the conver-
sations with the press that occurred dur-
ing the tour, the Federal President was vis-
ibly enthusiastic about the company SICK,
its innovative strength and the sense of to-
getherness among the staff, which helped
the company to successfully survive the
economic crisis. He considers SICK to be
among the important factors driving the
upturn in the German economy.
The visit of the Federal President
was not only a great honor and recogni-
tion for our company; it also allowed an
exchange of views and knowledge in a
very pleasant atmosphere, Dr. Robert
Bauer, Chairman of the Executive Board
of SICK AG, summed up afterwards.
>> The study of Best Places to Work in
Germany for assessing the attractive-
ness of employers is carried out by the
Great Place to Work Institute Germany
and Handelsblatt. The participants in-
cluded 290 enterprises overall, divided
into four size categories.
top placements confirm SICK
as an attractive employer
Last fall, once again, the great variety of
opportunities SICK offers to its employees
and their families found expression in a
convincing, positive vote. Among all com-
panies entered, SICK once more reached
a secure place in the top 100, securing
fifth place among the 19 enterprises in
>> In the last issue of SICKinsight, we
questioned our readers about the struc-
ture, content, design of our customer
magazine. The results look quite respect-
able: SICKinsight goes down so well that
the majority of those surveyed would like
to read more than two issues a year.
In connection with the 2010 reader
survey, we raffled off a stylish MP3 play-
er as well as additional Solutions Tour
prizes. Gnther Odenthal (on the left in
the photo) from SIVAplan in Troisdorf
was the happy winner of the main prize,
which Christoph Brinkmann (on the right)
from SICK Vertriebs-GmbH presented to
him in person.
SICK is a top-ranking employer once again, this is the outcome of an annu-
ally conducted, independent, and nation-wide evaluation of companies job at-
tractiveness. For the fact that SICK has not only reached the top 100 in 2011
but has done so every year since 2003, the company was awarded the special
distinction of Trust Champion in Gold.
eighty-seven percent of employees
find their workplace great
Distinction in gold for
SICK as an employer
SICKinsight reader Survey 2010
And the winner is
its size category. A particularly positive
note: Nearly 87 % of employees found
their workplace at SICK to be very good.
SICK a great place to work!
www.sickinsight.com
01 2011
04
>> In many companies, logistics is the
area with the greatest potential for in-
creasing efficiency and reducing costs.
As an intralogistics insider and techno-
logical leader, SICK is innovative accord-
ingly when it comes to pursuing new
paths in terms of warehousing, materials
handling, or distribution.
Solutions for conveyor systems,
sorters, industrial trucks, and cranes
In carton conveyor technology, sensors
from SICK detect and classify objects of
the most diverse sizes and shapes and
recognize undesired outward bulges in
cartons. This permits trouble-free stor-
age processes, continuous tracking of
cartons, as well as maximum through-
put rates of such facilities. Reliable pal-
let and load detection, for which SICK
supplies different approaches to a so-
lution, guarantees the highest level of
plant availability and process reliability.
By means of SICKs sensor systems
for volume measurement and object
identification, sorter systems become
highly accurate in their sorting, also
providing a database for exact invoic-
ing. In overhead conveyor systems,
sensors from SICK ensure collision-free
and space-optimized plant operations
with high sorting quality and continu-
ous tracing of goods. With respect to,
among others, AGVs, mobile assembly
or transport platforms, as well as ser-
vice robots, solutions from SICK pro-
vide safety in curves and narrow and
top industry competence combined with broad all-in-one portfolio
SICK the intralogistics insider
For all logistical and intralogistical industries and areas, SICK offers exten-
sive logistics competence and a complete portfolio from a single source that
is probably unique.
winding courses, optimum speeds for
the highest possible transport perfor-
mance, as well as positioning and navi-
gation support.
In the intralogistics trend: sensor
highlights from SICK at the Cemat
At the CeMAT, SICK presents a series of in-
novative sensor solutions for intralogisti-
cal fields of application. It is hard to imag-
ine intralogistics without todays variety of
automatical identification technologies.
With IDpro, SICK is the first manufacturer
to introduce a cross-technology platform
and portfolio strategy for bar code, 2D
code, and RFID. On this basis, the presen-
tation also features consistent connection
concepts for PROFIBUS and EtherCAT.
New possibilities for distance measure-
ment and positioning, respectively, are
offered by the linear measuring sensors
of the OLM200 product family with PRO-
FIBUS and the Inspector P30 vision sen-
sors. By using these sensors, one meets
the most exacting requirements on preci-
sion and performance when positioning
aisle stackers highly accurately to rack
compartments. The W27 photoelectric
sensor permits reliable object detection
even with respect to irregular shapes. The
S300 Mini safety laser scanner provides
safety and economic efficiency for pro-
tection of mobile compact vehicles. The
legal-for-trade VMS520 Sorter for volume
detection and further innovations com-
plete this years trade fair spectrum from
SICK at the CeMAT.
>LOGISTICS
05
>> As an international key trade fair
for logistics, the CeMAT is the suit-
able platform for demonstrating how
efficient, reliable, and sustainable
automation solutions from SICK are
for logistics. At the same time, SICK
presents itself as a competent partner
covering the entire life cycle of a facility
from finding a solution at the project
stage to maintenance and repair of fa-
cilities during ongoing operations. And
worldwide at that!
Well prepared for logistical challenges
Whether the objective is selecting indi-
vidual sensors or integration of complex
sensor systems or technologies the
logistics solutions from SICK have been
known in the industry for years for their
scalability and migration capability. This
goes both for sensor applications on the
object, e.g. detecting, identifying, and
measuring, and for plant-related tasks,
e.g. detecting speeds, distances, orien-
tations, and operating conditions, as well
as safety-capable monitoring. With con-
tinuous innovations, SICK has a decisive
influence on new logistical concepts, e.g.
>> Trade fairs, symposiums, seminars,
customer and theme days offer an oppor-
tunity to get talking to users and trend-
setters. To this end, SICK used, among
others, the airport trade fair in China, to
organize a well-attended customer day in
China on the topic of warehousing and
materials handling technology. The high-
light in the Far East was eventually the
conferment of the AGVS Award 2010 dur-
ing the CeMAT Asia trade fair. The prize,
awarded by an independent selection
committee, honors SICKs contribution
to innovative products and solutions in
the area of autonomous guided vehicles.
Additional events organized by SICK
in the field of logistics were, among oth-
ers, the Innovations Day Logistics Auto-
mation in Garching, held at the buildings
of the Technical University of Munich, a
seminar dealing with CEP and logistics
at TNT in Lige, and a series of further
events at customers and users prem-
ises.
Internationality in intralogistics is a
big topic for SICK in 2011 as well. This
is documented not only by participation
at the CeMAT in Hanover, but also by the
companys presence at trade fairs in im-
portant global regions including CeMAT
Russia and CeMAT Brazil.
Sensor and system solutions for logistics
Efficient, reliable, and sustainable
Logistics happens worldwide
On location interna-
tionally with expertise
At the CeMAT 2011, SICK shows innovative ways for top-rate productivity,
safety, availability, and quality of logistical facilities and processes. The fo-
cus is on the kind of scalable sensor and system solutions that are pos-
sible only with what probably constitutes the broadest sensor portfolio for
logistics.
Around the globe, SICK is on the
road as a competence provider and
partner for sensor and system solu-
tions in logistics.
with respect to autonomous and flexible
shuttle systems, cellular or modular ma-
terials handling and modern transport
systems, or miniature vehicles and ser-
vice robots. Moreover, innovations from
SICK are also in demand when it comes
to stationary or mobile assistance sys-
tems for collision prevention.
oriented toward sustainability
One important yardstick for an innova-
tion is in intralogistics as well its
sustainability. SICK takes this idea into
account from development to produc-
tion, to distribution and operation of its
products right to the end of their ser-
vice life. Manufactured with methods
that conserve resources and minimize
emissions, smaller, lighter, more energy-
efficient in their system behavior, easier
to recycle and dispose these features
ensure efficiency and an assured future
beyond tomorrow. Solutions from SICK
also help our customers, for example,
to control complex sorting facilities or
volume-optimized freight handling, thus
contributing their share to environmen-
tally friendly logistics.
Visit us at the fair:
CeMAT in Hanover
from 2 to 6 May 2011
Hall 27 Stand C43
01 2011
06
Further product information:
www.mysick.com/applications
More about the customer:
www.post.ch
Parcel logistics
>> The increase in reading rates es-
pecially in the case of damaged, dirty, or
incomplete bar codes and optimization
of sorting processes were the most impor-
tant goals behind the modernization. For
this purpose, automatical identification
systems from SICK are now used in various
areas of the facility: ICR890 camera sys-
tems, CLV490 bar code scanners, OPS590
omniportal code reading system, and
VMS410 volume measurement systems.
They ensure reliable detection of bar codes
and Data Matrix codes and permit imaging
for automated video coding as well as vol-
ume measurement of all transported and
sorted parcels.
automatical identification in the
network from a single source
SICKs MSC800 modular system con-
troller helped implement optimum and
reliable networking of all individual com-
ponents to form complete automatical
identification solutions. Moreover, for
transferring the process data, the special-
ists from SICK worked together with the
Postal Services team in developing an
Ethernet Powerlink interface, which met
the system requirements for real-time
communication between sorter control
and the automatical identification system.
In ongoing operations, SICK also provides
for remote monitoring and diagnosis of
the camera systems using the RDT400
software tool, which made it possible to
further optimize system availability.
SICK recognized as a CeP expert
When it came to awarding the project,
SICK convinced those in charge at Swiss
Postal Services with technical expertise
in the field of identification and volume
measurement for CEP (courier, express
and parcel services) sorting facilities as
well as with its extensive range of ser-
vices furnished by contact persons di-
rectly on location. Due to the complete
product portfolio with laser scanners,
volume measurement systems, and cam-
era technology, it was possible to match
the systems individually with the require-
ments of Swiss Postal Services. This was
crowned by success: We managed to
achieve a reduction of no reads by ap-
prox. two percent, which in light of manual
follow-up coding entails a 30-percent sav-
ings in required working time, says Josef
Meierhans, Manager Technology Services
at Swiss Postal Services and jointly re-
sponsible for the Hrkingen, Frauenfeld,
and Daillens sites. Evaluation quality,
positioning, and monitoring of the parcels
on the tipping trays was optimized as well
by means of the camera systems. With re-
spect to data integration and the problem
of interfaces, we also worked together
very well and in a goal-oriented way with
the team from SICK, Josef Meierhans of-
fers a very positive assessment not only
of the sensor and system technology but
also of the services provided by SICK.
Swiss Postal Services has modernized the conveyor and sort-
ing facilities at its three parcel centers in Hrkingen, Frauenfeld,
and Daillens with efficient optical reading systems for 1D and
2D codes from SICK.
Swiss Postal Services trusts in automatical identification system from SICK
For parcel logistics with Swiss precision
+
More information
on page 09
07
The S100 Professional compact laser scanner from SICK is per-
fect for checking occupancy of storage bays in multiple-depth
storage models and different storage aids. Viastore, an intralo-
gistics systems house, views things precisely that way as well.
>> This assessment is based on the
positive experiences gathered using the
laser scanner in various high-bay storage
projects. Featuring a scanning angle of
270, switchable monitoring fields, and
a high level of integration ease, the de-
vice minimizes equipment, installation,
and commissioning expenses decisively.
thinking outside the box
In one of the Viastore projects, the spe-
cific issue was storing and retrieving dif-
ferent storage aids at multiple depths
using aisle stackers. In order to imple-
ment this task with the known possible
solutions, i.e. with photoelectric sensors,
we would have required at least 17 sen-
sors, reports Ralf Link, Team Leader
viasprint/Conversion at Viastore Sys-
tems GmbH. On top of that, installation,
adjustment, and commissioning would
have taken several days.
By using the S100 Professional la-
ser scanners, Viastore opted for a sig-
nificantly more efficient and economical
solution. With its up to 16 field sets, the
sensor can detect the entire compart-
ment depths to be occupied plus adja-
cent storage bays, explains Ralf Link.
Thus, through the simple field defini-
tion, one can not only ascertain whether
the target storage location is occupied
but also whether the adjacent storage
location is properly filled or whether a
collision might occur.
accurate with every scan
The Viastore project leader has identi-
fied an additional benefit for the ongoing
plant operations: Especially in the case
of double-depth storage and use of sen-
sor technology with simple check points,
a few isolated detection problems
emerge, since due to the flexion and tor-
sion of the load handling device, photo-
electric sensors may miss the target, as
it were. This problem does not emerge
when using the laser scanner and its
two-dimensional field monitoring. Here,
every scan hits the mark, says Ralf Link.
Compartment clear clear sailing for the pallet
Multiple-depth check for
compartment occupancy
www.viastore.de
Using the S100 laser scanner
from SICK, one can detect the
entire compartment depth,
even of adjacent storage bays
Checking for occupancy of storage bays
01 2011
08
Safe travel path monitoring
At King Shaka International Airport in Durban, South Africa,
S3000 safety laser scanners monitor the travel paths of rail-
mounted heavy-duty transport vehicles for airfreight.
>> The project was realized by ICM Air-
port Technics GmbH, Viernheim, which
belongs to the Unitechnik Group. The en-
terprise deals with the implementation
of semi- and fully automated transport
solutions in the airport sphere.
Collision protection for fast 7-tonners
The rail-mounted vehicles are so-called
ETVs (elevator transfer vehicles). Inte-
grated into an overall materials handling
solution, these hoisting vehicles take on
the transport of airfreight containers and
pallets. Speeds of up to 2.5 m/s and a
gross vehicle weight of nearly seven tons
demanded a protection solution that
would not impair the availability and per-
formance of the transport vehicles at the
same time.
S3000: protective requirement
fulfilled, availability ensured
In choosing the S3000 safety laser
scanners, Unitechnik has opted for the
optimum protective solution optimum
because it is non-contact and flexibly
programmable. One scanner each is
installed for every vehicle and direction
of travel. Use of the parameterized four
warning and four protective fields and
their switching depending on the cur-
rent speed guarantees the highest pos-
travel path monitoring for
airfreight transport vehicles
Safe handling of
containers and pallets
www.icm-airtec.com
The S3000 safety laser scanner from
SICK (top right) offers the highest
possible safety when monitoring
the travel paths (bottom right)
of rail-mounted airfreight transport
vehicles (image on the left)
sible level of protection in every travel
situation. When detecting an obstacle,
the scanner signals slow down the ve-
hicle to creep speed, stopping it at a
defined distance if necessary. As soon
as the obstacle no longer occupies the
travel path, the transport vehicle starts
moving again.
In this way, the S3000 safety laser scan-
ners provide not only personal and col-
lision protection in accordance with
guidelines and standards but also the
desired availability and performance of
the transport vehicles.
Image-based bar code identification
09
TNT Express has modernized the high-performance distribution cen-
ter at the international airport hub of Lige, and in doing so, equipped
the conveying and sorting facility of the air hub with 25 new bar code
reading stations that are endowed with image-based ICR890 from
SICK without interruption of ongoing operations.
>> The air hub operated by TNT in the
Belgian city of Lige is one of the ma-
jor hubs for airfreight on the European
mainland. Every night, about 450 met-
ric tons of parcels, courier and express
consignments are delivered and trans-
shipped, which equals close to 15,000
parcel or goods consignments.
Ident tunnel engineered by SICK
The new high-end camera systems were
integrated into bar code tunnels indi-
vidually constructed by SICK and they
detect 1D and 2D codes on five sides of
packaged goods. The scanner tunnels
consist of robust aluminum structures
equipped with three image-based ICR
890 high-end reading systems. Each of
them features real-time focus control, a
high-performance decoder, as well as a
digital zoom function.
reading performance
improved significantly
Since the old system caused reading
failures of more than six percent, it was
particularly important to TNT to increase
the reading rate with damaged, contami-
nated, or incomplete bar codes. It was
possible to achieve this already when
implementing the comparative system.
Smooth conversion during
ongoing operations
Actually, the team from SICK had a maxi-
mum of three days available to install one
complete reading unit. Through stringent
planning and implementation on the
part of SICK, it was possible to reduce
installation time of a complete system to
two days successful implementation of
the 25 entirely new bar code reading sta-
tions at the Lige air hub was finished
within a mere three weeks.
top grades from tnt
Alain Lamarche, System Manager Logis-
tics at TNT Lige, believes that his deci-
sion on the new technology partner SICK
has been confirmed. The complete solu-
tion from a single source includes simple
integration and expandability to OCR and
High-end camera systems from SICK at tnt air Hub in Lige
Nonstop identification integration
during nonstop operation
www.tnt.com
The bar code reading stations from
SICK are equipped with image-based
ICR890 code readers
video-coding applications, as well as the
option of also measuring volumes, low
maintenance requirements and mini-
mum operating costs. We were particu-
larly impressed by the high reliability of
the data detection of 1D and 2D codes
by the ICR890 camera scanner dur-
ing running operation, Alain Lamarche
sums up. In addition, SICK offers us a
really high level of security and depend-
ability by means of their 24/7 hotline.
+
More information
on page 06
01 2011
10
The Norwegian capital of Oslo has one of the worlds most in-
novative toll systems. The central component of the 29 munici-
pal toll stations overall are LMS211 laser measurement sensors
from SICK. They detect the vehicles on all lanes, at different
speeds and no matter what the weather.
>> The features making this possible
are the LMS211s proven detecting la-
ser measurement technology with its
scanning angle of 90, intelligent eval-
uation processes that produce reliable
measuring values even in snowfall, rain,
and fog, as well as the weatherproof
and heated outdoor housing with IP 67
enclosure rating.
Non-contact toll detection
lets traffic and
The Oslo Toll Ring System is an entirely
electronic toll detection system for
any type of vehicle and for single-lane
and multiple-lane operation. Another
special feature is that in many respects
among other things, on bridges, traffic
light systems, extra wide lanes, or spe-
cial aspects of residential development
it can be adapted to city planning and
road construction characteristics as
well as to traffic-related conditions.
In Oslo, entry into the municipal
area is monitored at 29 toll stations
overall. The system configuration used
in each of these stations consists of
one front and one rear camera system
each with infrared light for photograph-
ing vehicles, as well as an LMS unit in
between connected to an antenna for
vehicle identification. The LMS unit
consists of two parallel systems aligned
across the road, which detect the ge-
ometry and speed of the vehicles. If the
antenna detects a toll transponder in a
Traffic invoicing via laser measurement
Oslo: Municipal toll system,
state of the art
passenger car or an on-board unit (OBU)
in the case of trucks, the toll is charged
automatically for these vehicles. If the
antenna does not receive a signal dur-
ing passage, the respective vehicle is
photographed from the front and back,
the vehicle owner determined via the
license plate, and the toll invoice deliv-
ered via mail.
toll revenues flow
Since commissioning, the Oslo Toll Ring
System has distinguished itself due to
high availability and accuracy. By means
of this system, an average of 350,000
vehicles a day can be detected. There-
fore, in Oslo two things are flowing: both
traffic and toll revenues.
The vehicles entering Oslos city zone are detected by LMS211s
Vehicle detection in electronic toll systems
+
More information
on page 13
11
www.kokeisl.net
S300 CMS safety laser scanners from SICK with integrated
navigation support provide not only safety on the travel paths of
KOKEISLs mobile picking robot but also assist with navigation
and positioning.
>> Personal protection and navigation
support the objective of the safety laser
scanners with CMS function from SICK
is the concurrent handling of protective
and navigation-supporting functions by
a single sensor. In this connection, the
devices, such as the S300 CMS used
on a KOKEISL picking robot automated
guided vehicle, utilize the measurement
data accumulating during safety-capable
detection of space contours.
navigation without artificial
landmarks
In order to carry out autonomous trans-
port tasks in complex environments,
the picking robot must move quickly
and flexibly through the modern produc-
tion facility, i.e. navigating freely and
adapting to rapidly changing processes
and conditions. Based on the contour
measuring S300 CMS safety laser
scanners from SICK, BlueBotics devel-
oped the ANT (autonomous navigation
technology) navigation system used in
the KOKEISL picking robot. To navigate
autonomously, the vehicle requires nei-
ther pre-defined routes nor special land-
marks such as inductive or, respective-
ly, magnetic strips, points, reflectors, or
the like in the building.
Safely on the move in any
situation and position
Assisted by the measured value tele-
grams of the S300 CMS, the naviga-
tion processor on the vehicle constantly
checks the environment, measures the
distances to potential obstacles, and
knows at any time where the vehicle is
located. In doing so, it recognizes, with
the help of contour measurement by the
Personal protection and navigation
assistance for mobile robots
One sensor
two functions
Illustration: The S300 CMS safety laser
scanners detect natural and artificial
landmarks in the environment
S300 CMS and the corresponding evalu-
ation in the navigation system, any ob-
jects or working persons, either stopping
or avoiding them reliably.
The bottom line: AGVs such as the
KOKEISL picking robot do not require
any additional sensor technology to sup-
port their navigation system if they have
safety laser scanners from SICK with
CMS functionality on board. Use of the
2 in 1 design minimizes the cost for
components and wiring, and in addition,
often valuable because scarce installa-
tion space is saved. As a result, one can
reach a maximum amount of economic
and cost efficiency.
Automatic guided systems
01 2011
12
www.isi-automation.com
www.gwbi.de
Image-based bar code identification
>> Here, the image-based ICR850 code
reader literally plays the deciding role.
The line camera identifies randomly ori-
ented and positioned 1D and 2D codes
on greeting cards, calendars, and gift
books in different sizes. Sorting the
printed products requires high process-
ing speeds that could be achieved by
means of integrating the ICR850 directly
into the machines LAN.
Sorting challenge: quantities, compo-
sition, and product formats indefinite
One of Germanys leading producers of
greeting cards, Grafik Werkstatt Biele-
feld, manufactures high-quality graph-
ics and printed text products. They
stand out due to their atmospheric
imagery, philosophical and expressive
texts, much care for detail in design,
and great appreciation of quality in
manufacturing. Products not sold, e.g.
after Christmas or at the end of the
season, are taken back by Grafik Werk-
statt Bielefeld. In the returns process,
High-speed identification with direct ethernet integration
Automatic returns detection
of printed products
For Grafik Werkstatt Bielefeld, ISI Automation has developed a
high-performance returns sorting system featuring ISIPlus
that
was equipped completely with code readers, distance sensors,
and photoelectric sensors from SICK.
the challenge is to take in quickly large
quantities of products varying widely in
size, color, and material.
Versatile identification improves
returns detection
In order to increase returns perfor-
mance, the people at Grafik Werkstatt
opted for a special machine with inte-
grated conveyor, control, and operating
technology from ISI Automation. The
image-based ICR850 code reader is
used in the machine to sort the prod-
ucts by means of their 1D and 2D
codes. A DT20 distance sensor, and a
photoelectric sensor from SICK trigger
the code reader, which then reliably
identifies the articles passing through
despite different product heights and
the random positions of the codes. The
machines ISIPlus
measuring system
synchronizes the processing steps
and due to direct integration of the
ICR850 into the Ethernet LAN is ca-
pable of checking the detected prod-
ucts for plausibility in real time within
the ISIPlus
measuring system, thus

comparing the returns. Products whose
codes are covered are detected manu-
ally afterwards using cordless hand-
held scanners from SICK.
evidence of performance and overall
package were decisive
Prior to using the products from SICK
in the special machine, ISI Automation
conducted extensive performance tests.
These were passed successfully. This re-
sult, the availability from a single source,
as well as the commitment of SICKs
staff in planning the project eventually
made up the overall package that was re-
ceived very positively at ISI Automation.
Reinhard Becker, Grafik Werkstatt;
Frank Marek, ISI Automation; Michael
Gulsch, PxC Phoenix; Helmut Wieneke,
SVD, and Wolfgang Strmer, Grafik
Werkstatt (from left to right)
13
www.libraterminais.com.br
Collision prevention
>> LMS laser measurement sensors
from SICK do an excellent job, among
other things, preventing collisions on
hundreds of installations at all of the
major container ports worldwide. In-
creasingly, the focus of terminal opera-
tors such as Libra Terminais, but also
of terminal suppliers, shipping com-
panies, and insurance companies, is
on preventing accidental collisions of
crane booms and the superstructures
of ships via sensors. The reason: Insur-
ance statistics confirm that damage
costs as well as follow-up expenses in
the so-called ship-to-shore (STS) area
can be eliminated almost entirely by
suitable electronic sensor solutions.
Libra Terminais relies on efficient and
safe terminal facilities
Together with two other terminals in Bra-
zil, Libra Terminais belongs to Grupo Li-
bra, one of largest port operators and lo-
gistics enterprises active in the nations
Collision prevention at the quay
No chance for crane crashes
When cranes collide with ship superstructures, the consequence
may be damages in the millions of dollars. In order to prevent
these, the people at Libra Terminais in Brazil rely on laser mea-
surement technology from SICK as anti-collision sensors.
foreign trade. Libra moves approx. 16 %
of all containers in Brazilian ports, for in-
stance, at the Libra Terminais Terminal
in Santos. Few months ago, two new STS
cranes from ZPMC, a Chinese manu-
facturer, were put into operation here
equipped with LMS laser measure-
ment sensors for collision prevention.
In 2011, we will just in time for the
15
th
company anniversary also retrofit
the existing STS cranes from wire cable
systems to LMS, because they provide
the required safety and thus represent
a lasting investment with a guaranteed
future, says Roberto Lopes, General Di-
rector from Libra Terminais in Santos. In
addition, Libra Terminais is planning to
use intelligent laser measurement sen-
sors to modernize the other lifting vehi-
cles and cranes, such as reach stackers,
and RTGs, safely and reliably for con-
tainer handling in the container stack
area whose functionality is assured in
the future.
Laser measurement technology for
ports and terminals: precise, reliable,
and extremely weather-resistant.
Currently, SICK offers various laser mea-
surement sensors for STS collision pre-
vention. The LMS211 has been tried and
tested for many years in several thou-
sands of installations around the globe.
The application experience gathered us-
ing this product family and further tech-
nological refinement have resulted in the
development of a new laser measurement
sensor, the LMS511. For port and termi-
nal applications, e.g. positioning, profiling,
distance measurement, and collision pre-
vention on cranes, crane booms, straddle
and van carriers, gantries and AGVs, the
enhanced range and optimized detection
performance under extreme weather con-
ditions are the most important improve-
ments of the new LMS500 family.
LMS laser measurement sensors from
SICK the reliable anti-collision solution
for ports and terminals.
+
More information
on page 10
01 2011
>PACKAGING
14
>> Increasingly, consumers wish to
select more target group oriented
products from a steadily increasing as-
sortment. In this context, in addition
to attractive price, individual design
or environmentally suitable packaging
determine their choices. Other buying
strata concentrate their attention on
package size, simple preparation or
handling, as well as the recyclability of
the packaging. Retailers, on the other
hand, wish to be able to transport the
products safely, stow them away or re-
arrange them quickly, as well as posi-
tion them in appealing ways. Therefore,
producers very rarely manage with only
few packaging sizes or final packaging
formats. The most common scenario
is plants that package even smaller
batch sizes in increasingly more pro-
ductive and flexible ways without ex-
tensive change-over times and doing
so in light of packages designed for the
Sensor technology in packaging machines flexible and fast
New packaging needed
The demographic transition in industrial societies, smaller households, and
ever-accelerating product life cycles are changing the demand for food, con-
sumer goods, beverages, and cosmetics. This confronts producers and plant
engineers with new challenges.
most diverse product shapes, such as
bags, cups, boxes, trays, tubes, glass-
es, wraparound packs or blisters, all
the way to folding cartons or thermo-
formed packs.
meeting new requirements
This so-called shelf ready packaging
(SRP) is currently changing both pro-
duction and plant design as well as
automation technology. In this context,
flexibility and productivity are the most
important features that distinguish
modern packaging machines and
plants. Playing an important role in
this, sensor technology is charged with
supporting automation technology.
SICK offers sensors in modular design
that can be adapted quickly to produc-
ers new requirements. They are easy
to access during malfunctions, avail-
able worldwide, and thus keep down-
times as short as possible.
15
>> Following the motto of Packaging
discusses trends, last October more
than 60 customers, researchers from
Deutsches Verpackungsinstitut dvi (Ger-
man Packaging Institute), and product
managers from SICK talked about new
challenges and technological trends in
the field of packaging. For the first time,
machine builders from the packaging in-
dustry and brand name producers met
at SICKs Customer Center in Waldkirch
to exchange ideas. The event will be con-
tinued this year.
SICK at the interpack
Additional information on this topic will
be available at the interpack trade fair
in Dsseldorf in Hall 06, Stand C 01. In
a trade fair model of a standard pack-
aging machine by Somic, one can view
machine modules, controllers and visu-
alization from Schneider Electric/ELAU
installed together with sensor technol-
ogy from SICK. The modular mecha-
tronic system, comprised of software,
electronics, and mechanics, provides
recognizing trends in time
Packaging hidden champion
in marketing
For manufacturers of machines, top flexibility in the packaging field means
structuring their packaging machines as much as possible in cost-effective
and modular ways, enabling the equipment to cope with any challenge on
location. SICK supports them in this endeavor with new sensors.
New packages require greater accu-
racy and faster detection by sensors
in soft, smooth, reflective, or matt
surfaces just the same as in trans-
parent packages.
nearly unlimited technical possibilities to
react quickly and reliably to customers
wishes.
What SICK sensors stand for
In this connection, sensors from SICK
stand for robust detection (WTB4), for
preventive maintenance (WL4G), for re-
duced downtimes (WTB12), and for pro-
cess reliability (LUT9). The measured val-
ues are indicated on an IPC of Schneider
Electric/ELAU, the company that also
supplied the decentralized plug-in drive
and control technology.
>> Moreover, these packages must be
sorted carefully, filled accurately, and
guided without scratching. This requires
a measuring technology that in addi-
tion to high measuring accuracy is also
capable of quickly detecting and further
processing the measured values. Repeat
accuracy in the measuring process is
crucial for the accurate cutting of pack-
aging material the more precisely, the
less waste accumulates. This saves en-
ergy and time.
The great variety of packaging men-
tioned above also results in smaller batch
sizes and more frequent changes of con-
tainers. This costs changeover time and
means additional tooling procedures pre-
ponderating in terms of the availability of
filling and packaging plants. Intelligent
sensors can be adjusted to the respective
production conditions using preset and
taught-in parameters. At SICK, a special
ASIC building block networks the intelli-
gent sensors with all of the major fieldbus
systems without any interface problems.
When changing formats, all it takes to ad-
just the sensors to new container shapes,
sizes, or colors from the master control
system is pushing a button.
Challenges for
sensor producers
The calculation
is working out
Visit us at the fair:
interpack in Dsseldorf
from 12 to 18 May 2011
Hall 06 Stand C01
Packaging specialists convened
in Waldkirch
01 2011
16
Anti-counterfeiting
More information about EFPIA:
www.efpia.org
>> Looking at recent developments in
anti-counterfeiting such as pilot projects
in Sweden from EFPIA and new legislation
in Turkey, France and Brazil, it is expected
that Europe will go for 2D Data Matrix code
technology for serialization. All specialists
agree that the question is not IF Europe will
choose the 2D Data Matrix code technol-
ogy but WHEN Europe will come up with a
new legislation. Looking at the pharmaceu-
tical package proposals for the European
Commission, a package of safety features
is proposed. Overt and covert features,
individual product codes (2D codes) and
seals which reveal any opening of the pack
shall protect the legal supply chain against
counterfeited medicines.
If you have a need to detect safety
features, seals or serialized 2D Data Ma-
trix codes it is important that you use
high-performing and reliable systems.
You can implement the most powerful
Track & Trace-software, but when your
reader does not read the 2D codes or
your sensors are not detecting the seals,
this will have a negative influence on the
productivity of your packaging line.
Counterfeit medicines,
a fast-growing problem worldwide
Sensors from SICK offer added value through reliable detection of 2D Data Matrix codes
Counterfeiting medicines is a globally widespread and fast-grow-
ing problem. Driven by the World Health Organisation (WHO), Eu-
ropean commission, FDA (Food and Drug Administration), EFPIA
(European Federation of Pharmaceutical Industries and Asso-
ciations) and others, anti-counterfeiting measures are being dis-
cussed, tested and implemented. All of them have one thing in
common: the serialization on the package level.
This is where the 2D code reader and
sensors from SICK have their added
value. Years of experience in R&D and
production as well as experience in
many other industries have made SICK
solutions reliable, fast, robust and easy
to use. Additionally, SICK can offer you
a service covering the lifetime of your
readers and sensors, from consulting
to service. With a worldwide network of
more then 50 subsidiaries we can sup-
port you at all your international produc-
tion locations.
With an extended expertise in
bar code reading, RFID, vision systems
and automation sensors, SICK is your in-
ternational partner concerning your anti-
counterfeiting challenges.
bar code reading
17
By now, pirated products often are so perfect that on the
outside they can hardly be distinguished from the original.
Counterfeit-proof marking of products, components, and
spare parts protects machine and plant builders from harm.
The rule is: The more complicated a marking, the safer is the
system.
>> According to the VDMA (German En-
gineering Federation), pirated products
and product theft cause annual sales
losses in German machine and plant
construction amounting to 6.4 billion
euros. Meanwhile, two thirds of compa-
nies manufacturing investment goods
are reportedly affected by the issue of
illegal copies. The problem in this: In
addition to the financial damage, the
companies reputation is also at stake.
Therefore, protection from forgers and
product piracy ought to be part of qual-
ity assurance.
By means of a multi-stage protec-
tive barrier comprised of safety marks,
companies can protect their products,
components, and spare parts. The cru-
cial goal: Keep expenses for verification
as low as possible and the effort for the
plagiarist as high as possible. At the
same time, all measures against piracy
ought to be integrated into the entire
product life cycle, with the safety guide-
lines also practiced and internalized in
the company.
At the lowest safety level, one can
use safety marks such as holograms
and safety labels. The devices serv-
ing for detection are sensors or cam-
era systems that recognize colors,
structures, and shapes. A combina-
tion of safety marks applied openly
and concealed offers a higher safety
level. Here, the products can also be
marked with UV color pigments that
sensors specifically developed for this
purpose identify reliably. With SICKs
luminescence scale, for instance, one
can define and apply the desired pig-
ment proportion even as a package is
designed. Subsequently, in the packag-
ing line, luminescence sensors check
for presence of the markers.
The top safety level combines tech-
nical and organizational features. With
a randomly generated data matrix
code and an archived serial number,
one can mark products, packages, and
spare parts unmistakably. Every code
is unambiguous worldwide. If required,
customs or service staff can read out
the secret manufacturers information
Battle against product pirates
Quality assurance does
not stop at factory gate
More information about VDMA:
www.vdma.org
using the mobile IT4820i or IT4600
2D hand-held scanners and compare it
with the database. Certainly, in terms
of packaging, this involves a change:
Instead of pallets, individual products
now require labeling and registering.
At cycle times of 300 to 400 units a
minute, this is a specialty of the image-
based LECTOR
620 code reader. How-

ever, if all safety marks are matched
perfectly to the demands, product
pirates have a difficult time imitating
originals.
A luminescence sensor from SICK checks for presence of a marking in a packaging line
01 2011
18
Hygienic design
One of the great challenges faced by the food industry is the
constantly increasing demand on the part of major retail chains
to achieve longer best-before dates for packaged foods. In or-
der to attain this goal, the microbiological contamination of the
packaged food item must be reduced, which has a direct impact
on the packaging processes, cleaning processes, and machine
design. At the same time, the permanently mounting pricing
pressure on food and beverage producers requires considerably
faster set-up times when changing over varieties or package
sizes as well as higher cycle speeds of the packaging facilities.
>> An essential key to being able to meet
both of these challenges at the same
time is fine-tuned, modern sensor tech-
nology that sets new hygiene standards
and features robust electronics as well
as more efficient communication solu-
tions. This becomes possible by fusing
the classic requirement spheres of facto-
ry automation and process automation.
In this connection, process automation
contributes the classic rugged materials
such as stainless steel, with high stan-
dards regarding toughness, the familiar
hygienic certificates for the process as-
pect such as EHEDG, as well as the need
for output signals that go beyond a mere
binary signal. From factory automation
come the typical demands for miniatur-
ized construction sizes, simple device
selection, extremely easy commissioning
and operation, very fast response times
of the sensor, remote parameterization
plus standards of leak tightness in ac-
cordance with IP 69K and cleanability
of the housing according to ECOLAB and
Diversey standards.
Thus, with respect to the new fam-
ily of W4S-3 Inox photoelectric sen-
sors, SICK relies not only on a stainless
steel housing made of 316L steel that
features a continuous and extremely
smooth surface due to production us-
ing the MIM method (metal injection
molding). The company also applies
several innovations to comply with an
IP 69K enclosure rating and guarantees
optimum cleanability throughout even
with aggressive cleaning agents. For ex-
ample, the control panel is not made of
plastic as is common; instead, the sen-
sor has a laser-welded stainless-steel
membrane and is thus literally fused
with the stainless-steel housing. Due
to the snap-action effect of the sen-
sor, a tactile feedback of the operating
procedure is provided in an ideal way.
The front screen of the sensor features
special quartz coating and is fitted
into the housing with high precision.
The coating and the special gluing of
the front screen result in stability even
against 30-percent hydrogen peroxide.
By means of the efficient teach-in op-
tion and automatic switching threshold
adjustment, the sensor also sets new
standards in detecting transparent ob-
jects, which increases the availability
of filling machines and packaging facili-
ties. The sensor has the common clean-
ing certificates such as EHEDG, ECO-
LAB, and Diversey.
Thus, the reduction of microbiologi-
cal contamination can be achieved us-
ing sensors constructed accordingly,
such as the W4S-3 Inox or the LFP level
sensor. However, one can improve the
shortening of commissioning processes,
cycle and set-up times even further: by
realizing the sensory functions in a co-
ordinated way from a single source with
continuous operating, connecting, and
communication designs.
For this reason, SICK has been ex-
tending its range of sensors for measur-
ing quantities such as level, pressure, and
temperature for years in order to be able
to offer manufacturers of filling machines
and packaging facilities in particular a
comprehensive range that allows using
synergy potentials in construction, com-
missioning, and everyday operations.
Food neatly packaged
New sensor designs for the packaging industry
Sensor technology from SICK sets new hygiene standards
Small photoelectric sensors
19
Food neatly packaged
New sensor designs for the packaging industry
Performance in the extremely robust VISTAL
housing as
well as a unique mounting variability make the new family of
W9-3 photoelectric sensors the perfect solution for the high
demands on ruggedness, and application variety in the pack-
aging machine.
>> Not made of metal and yet nearly
as robust as steel VISTAL
, the highly
rugged housing of the W9-3 shows what
is possible in plastic housings when it
comes to stability and leak tightness.
With this housing, the sensors achieve
a ruggedness that assures users of first-
rate availability even in a harsh operating
environment.
Unlimited mounting options
Just as unprecedented as the rugged-
ness is the great variety of mounting
options. The devices are available as de-
sired with M3 or M4 hole pattern. In ad-
dition, the complementary slotted hole
design provides even more flexibility con-
cerning sensor integration.
Performance and variability
The refined chip technology in connec-
tion with the powerful PinPoint LED,
the photoelectric proximity sensor with
a second emitter LED for the best pos-
sible background suppression, the auto-
collimation-based photoelectric sensor,
as well as the glass photoelectric sen-
sor with automatic switching threshold
adjustment are other features worth
Top grades for ruggedness, performance, and variability
Simply well packaged
with VISTAL
: W9-3
www.mysick.com/products
The hygienic LFP level sensor combines,
in an exemplary way, the spheres of fac-
tory and process automation. The sen-
sor, measuring only 54 mm in diameter,
works according to the principle of guid-
ed radar (time domain reflectometry),
which makes it nearly independent of
the properties of the fluid to be mea-
sured and thus obviates the need for
re-parameterization when the composi-
tion of the fluid to be measured changes.
Moreover, it features at the same time
an analog output signal and two switch-
ing points, which permits the realization
of efficient control concepts using a re-
duced number of sensors and therefore
less cleaning effort. In addition, the LFP
as well as SICKs photoelectric sensors
have IO-Link, a simple communication
protocol independent of the manufac-
turer, which renders remote parameter-
ization and error diagnosis far more ef-
ficient, without displaying the complexity
setbacks of existing bus systems. Similar
to the W4S-3, the LFP is made of 316L
stainless steel and features an IP 69K
enclosure rating as well as the common
hygiene certificates. The use of a mea-
suring method following state-of-the-art
technology allows standardization to one
device family, reducing restrictions con-
cerning installation requirements.
Thus, it is possible to meet the cur-
rent challenges on packaging and filling
processes using a new generation of
sensor technology that pursues a holis-
tic approach. In this connection follow-
ing the hybrid field of application in the
packaging industry the classic advan-
tages of factory automation and process
automation are merged. The essential
point in this is reduced complexity and
minimized maintenance effort, without
having to compromise on ruggedness
and hygienic suitability.
highlighting. The device is convincing in
terms of performance and variability in
order to actually solve any application in
the packaging process.
The W9-3 from SICK features
varied options for mounting
01 2011
20
IO-Link technology
>> With IO-Link, industry has created a
standard that is valid universally for sen-
sors and actuators in the field. A three-
core unshielded cable connects the
sensors to the automation systems. By
means of a downward compatible inter-
face, one can transmit all of the configu-
ration data to the sensor, making it pos-
sible to retrofit even older machines with
the latest sensors. SICK has developed
an ASIC module that evaluates differ-
ent states and measuring values of the
sensor and transfers them to the master
control system. Function blocks for the
programming tools from Siemens, Bosch
Rexroth, Schneider Electric, and Beck-
hoff support the programmer in adapting
the intelligent sensors.
Using the easy access to the measur-
ing values and parameters thus allows
teaching in optical sensors specifically
with respect to new products. In this way,
the sensor can distinguish packages
in different sizes, colors, and shapes.
During commissioning, it is possible to
teach-in and save all of the relevant data
for each product individually. In produc-
tion changeovers, all there is left to do
is loading scanning distances, switching
points, and hystereses into the sensor,
which then guarantees safe switching
that covers all of the objects processed.
This method is particularly suitable
for packaging machines and packaging
lines that require frequent changeover or
are exposed to severe strains from their
environment. By means of the transmit-
ted status signal of the IO-Link sensors,
it is possible to detect contamination or
slow changes early on and to eliminate
them specifically during the next product
changeover.
Sensors from SICK with Io-Link interface
Producing more flexibly by
using intelligent sensors
Whenever a new machine needs to be installed or a new pro-
duction line converted to new packaging formats, one must
adapt the sensor technology to new tasks as well. Intelligent
sensors based on the open IO-Link interface eliminate these
bottlenecks, opening up new possibilities for flexible machine
and plant concepts.
The possibility of conveying clustered
measuring values to the control system
allows detecting the quantity of lumi-
nescent additives even during ongoing
operation. In this way, one can monitor
oil lubrications of machines, glue ap-
plications, or check packages for piracy
protection.
With the function locking the teach
button during operation and the intel-
ligent sensor identification, SICK offers
improved protection from manipulation.
Thus, the machine builder can deter-
mine individually which sensor variants
to admit for replacement. Viewed from
this perspective, this amounts to more
functions at the same sensor price.
Intelligent sensors from SICK are
usable in versatile ways in the
packaging and food industries
Checking for presence and position
21
The IVC-3D smart camera from SICK inspects caps of plastic barrels for being placed correctly;
On the bottom right, there is a plastic barrel with a cocked cap
>> Tetra Pak in Lund, Sweden, has cho-
sen IVC-3D smart cameras when it comes
to checking lids and caps of packages for
its Tetra Top package. Tetra Pak is a world-
wide leading company in the area of food
processing and packaging solutions.
Benefit of the 3D camera
With the extremely precise 3D camera
technology from SICK, Tetra Pak found
the suitable solution for checking lids
and caps. The IVC-3D smart camera
combines image processing, lighting,
and evaluation in a single housing.
At Tetra Pak, these features were per-
fectly suited for checking caps on Tetra Top
package. The 3D camera locates the caps
of the containers at high speed, verifying
proper fit. In each image, the height and in-
clination of the cap are measured to check
the correct application. By using the 3D
3D quality check for lids and caps
3D cameras used in liquid packaging
SICKs sensors and vision systems can be used to checking lids
and caps of liquid packaging.
method, solutions are possible even when
the containers are located in a carton and
when solutions using the 2D method/back
lighting cannot be applied. Containers with
flawed lids are sorted out and the mea-
sured values are transmitted to the master
control system for analytical and statistical
purposes.
High quality ensured
The 3D camera technology from SICK
ensures high standard of quality prod-
ucts and satisfied customers. Martin
Thuresson , developer of the 3D inspec-
tion system at Tetra Pak says, A 3D
solution was chosen to enable simple
package volume changeover without me-
chanics. This way, the solution requires
no operator intervention. The 3D system
offers correct measurements even if the
package pose varies, as well as an inte-
grated unit with simple interfacing.
And Marcus Ek, responsible for the 3D
inspection system adds, The system
gives a good quality inspection of our
packages and allows a simple and stan-
dardized installation, which was impor-
tant in our application.
The easy-to-operate camera is facto-
ry-calibrated and thus simple to install.
Moreover, the camera met additional
requirements by Tetra Pak, featuring
uncomplicated data exchange with the
master control systems by means of Eth-
ernet (EtherNet/IP, OPC, TCP/IP), Digital
I/O, or RS-485, as well as stand-alone
operation without PC.
The 3D method works even in the
case of diverging positions and inclined
containers with the type of reliability not
possible when using 2D solutions.
www.tetrapak.com
01 2011
22
Detection of transparent materials
www.kosme.com
The Austrian KOSME Company, specializing in machines for the
production of PET bottles, relies on the WL11-2 photoelectric
sensor from SICK when it comes to detecting transparent preforms
and thin-walled PETs.
>> With the WL11-2 from SICK, we
are using a photoelectric sensor in our
stretch and injection blow molding ma-
chines on which we can rely anytime,
says Wilhelm Hofsttter, Technical Head
at KOSME in Sollenau, Austria. It is per-
fectly suited to detect thin-walled and
translucent objects such as preforms
and PET bottles, since it reliably detects
the minimal attenuation of the light path
by the transparent materials. In this way,
it works flawlessly in counting and sort-
ing out even when the machines are op-
erating at top speed.
KoSme: up to 12,000
Pet bottles an hour
The Austrian KOSME Company based
near Vienna is active in the area of
plastic packaging, specializing, among
other things, in the production of PET
bottles. The stretch blow molding ma-
chines of the company, a wholly owned
subsidiary of KRONES AG, can cover
a broad spectrum of bottles. This
ranges from mini PETs holding 0.05
liters all the way to large 30-l con-
tainers, confirms Wilhelm Hofstt-
ter. Depending on the requirements,
machine capacities of up to 12,000
bottles an hour are possible. The high
speeds make special demands on pro-
cess-reliable detection. The WL11-2
meets them dependably.
WL11-2: the photoelectric sensor
that sees through
Following functional tests under real
production conditions during ongoing
operations, KOSME switched from an-
other brand to the WL11-2 from SICK.
With its high-performance PinPoint
sender technology, the sensor proved
highly suitable due to its adjustable,
Detecting, counting, and sorting out transparent materials
Perfect detection of
preforms and PETs
high response sensitivity for detecting
materials that typically feature a reduc-
tion of the optical light path between
the sensor and reflector by less than
10 %. The signals used for counting or
for activating the pneumatic cylinders
or nozzles are very reliable, even though
the speeds are very high and the vari-
ety of object to be detected very great,
Wilhelm Hofsttter confirms his positive
operating experiences.
Another advantage of the WL11-2
is its ease of integration. The space-
saving and extremely robust housing
as well as the practical mounting and
connection features provide universal
integration options. An added detail is
simple operation. Fast alignment by
means of the visible red light spot and
adjustment of sensitivity using teach-in
are mastered alike by machine opera-
tors and maintenance personnel with-
out any additional training, Wilhelm
Hofsttter points to an aspect particu-
larly important for the end user.
His conclusion: The WL11-2 photoelec-
tric sensor keeps what it promises!
The WL11-2 (image on the left) is
extremely user-friendly even when in-
stalled: easy-to-access teach button
(image on the right)
Position detection in harsh environment
23
www.daloon.com
The rugged V18V cylindrical photoelec-
tric sensor from SICK does a good job in
a harsh environment
The Danish Daloon Company, the worlds largest producer of
spring rolls, relies on the highly rugged V18V cylindrical photo-
electric sensors from SICK in the harsh environment of an auto-
matic washing facility.
>> The task of the sensors is to detect
reliably the position of stainless steel
transport cars, used in production to
transport vegetables for the spring rolls,
within the washing facility.
required: maximum detection
reliability and plant availability
The empty transport cars arriving from
production are pre-washed in the auto-
matic cleaning facility, freed from resi-
dues using acidic and alkaline agents,
pressure-washed at 100 C, disin-
fected and force dried. For this fully
automatic process, they must be po-
sitioned precisely within the machine.
Though specified accordingly on paper,
sensors from other manufacturers
used previously were never capable of
withstanding the harsh conditions for
more than three weeks. Availability of
the cleaning facility was thus impaired
correspondingly. In contrast, the V18V
cylindrical photoelectric sensor from
SICK proves to be the perfect solution
in everyday use.
V18V: perfect performance
in practical application
During an intensive advance trial
phase at Daloon, the V18V proved
that it met the indicated specifica-
tions, including IP 69K, for use in this
extreme environment, ensuring per-
manent availability in detecting the
position of the transport cars. They
detect the transport car only if it is
in the correct position at the start of
the cleaning program, explains Peter
Madsen, responsible for plant mainte-
nance at Daloon. This method guar-
antees trouble-free operations without
any possible damage to the cleaning
fittings or the transport cars. As a re-
sult, availability and throughput of the
washing facility now meet Daloons re-
quirements and expectations. At the
same time, the sensor-related expendi-
tures for maintenance and repair were
reduced substantially, thus improving
the economic efficiency of the clean-
ing system considerably. At last, we
now have the photoelectric sensor that
solves our automation problem. It also
shows how the boundaries of use are
shifting or nullified when the device
layout and not merely the data sheet
is designed consistently toward the
application requirements, confirms
Peter Madsen.
Simple on paper, tough to implement in practice
Automation of washing facility
using stainless steel sensors
01 2011
24
: Views & Voices Trends in logistics
Intralogistics is about to embark on a new era. That is the im-
pression one gets from the Cellular Transport Systems project,
which involves a swarm of 50 autonomous vehicles demonstrat-
ing how materials handling as well as rack storage and retrieval
will work in the future. The project has been realized and will
be shown at the 2011 CeMAT trade fair by the Fraunhofer Ins-
titute for Material Flow and Logistics (IML). How and why ants,
autonomous control, and intelligence within a swarm are rede-
fining intralogistics is explained by Prof. Dr. Michael ten Hompel,
Professor at the Technical University of Dortmund. He holds the
Chair of Materials Handling and Warehousing Systems and is
Managing Head of the Institute at IML.
SICKinsight: Currently, the IML is attract-
ing public interest with new topics. Some
publications have referred to you per-
sonally as the 100-million-euro man,
because you have obviously managed
to use these topics to tap some major
funding pots. What are these topics that
move both the national economy and the
relevant industry?
autonomous control and swarm intelligence
Cellular transport systems will
dominate tomorrows intralogistics
In conversation: Prof. Dr. Michael ten Hompel, Professor at the Technical University of Dortmund and Head of the Institute at IML
Prof. Dr. Michael ten Hompel: Let us
rather speak of the 100-million-euro
team. A huge research cluster such as
this one always constitutes a joint effort.
In our case, more than 120 companies
and 11 research institutions share in the
project. Nevertheless, I am certainly de-
lighted very much personally about our
success! This success is based quite
essentially on the fact that we have
identified, through the EfficiencyCluster,
the great challenges for logistics. At the
heart of it, there is the question of how
we can efficiently control the individual
supply with goods, production, and mo-
bility. In my view, this constitutes at the
same time one of societys greatest chal-
lenges. Acting prudently in terms of lo-
gistics and thus efficiently must become
attractive. At present, we are proceeding,
particularly in e-commerce, based on the
motto, I dont care how the goods reach
me, as long as they are on the table
within 24 hours. We will have to modify
our view on that score. A second crucial
development is urbanization
SICKinsight: What effects will these
mega trends have on workflows and the
design of machines and plants?
Prof. Dr. Michael ten Hompel: Before or-
ganizing or controlling anything, we have
to start by measuring and identifying.
This has a lot to do with product marking
: Views & Voices
25
More about the
Fraunhofer IML:
www.iml.fraunhofer.de
and improved sensors whose data must
be available in real time. This represents
the basis without which we are unable to
control any supply chain properly. More-
over, we ought to give up the idea that to-
day logistics can be controlled with a fax
and a calculator. Using such means, one
cannot even begin to master the com-
plexity of modern logistics. Whats more,
the complexity and speed are continuing
to increase exponentially. We must learn
to rely in future on Internet technologies
and autonomous control. This does not
mean that humans are left excluded
with the development of intelligent air
freight containers all the way to cloud
computing in the logistics mall. However,
around the time of the CeMAT, I particu-
larly like telling people about our cellu-
lar transport systems. By the time the
CeMAT comes around, our large-scale
experiment involving 50 autonomous ve-
hicles, the so-called Multishuttle Move,
will be finished. In a 65-meter (approx.
71 yards) hall, built specifically for this
purpose, we will show that using such a
swarm allows realizing the entire classic
materials handling technology as well
Before organizing or controlling anything,
we have to start by measuring and identifying.
This has a lot to do with product marking
and improved sensors
quite the contrary! One of the essential
tasks of modern assistance systems will
entail hiding complexity and virtualizing
computing performance.
SICKinsight: What are specific future proj-
ects that the IML pursues and what are the
interest groups to which they appeal?
Prof. Dr. Michael ten Hompel: Well,
where shall I start? In more than 700
projects a year, we are dealing with the
entire spectrum of logistics, beginning
The Fraunhofer IML is regarded as the prime location concerning questions of
holistic logistics, working in all fields of in-house and external logistics. Currently,
at the Fraunhofer IML, founded in 1981, staff includes 190 scientists as well as
250 Ph.D. candidates and students with an intermediate diploma, all of them sup-
ported by colleagues in workshops, laboratories, and service sectors.
Teams put together according to project and customer requirements create cross-
industry and customer-specific solutions, including, among others, in the fields of
material flow technology, warehouse management, business process modeling,
simulation-supported corporate and system planning, as well as in the sectors of
traffic systems, resource logistics, and e-business. Fraunhofer IML manages the
Internet of things across the entire network of Fraunhofer institutes. If required,
the IML can fall back on 17,000 employees in 80 institutes of the Fraunhofer-
Gesellschaft.
The largest logistics research project in Europe today is the EfficiencyCluster
Logistik Ruhr, involving 120 associated companies and 11 research institutes.
In addition to Dortmund, further locations are Cottbus, Frankfurt/Main, Prien on
Lake Chiemsee, Lisbon, and Beijing.
Brief information on the Fraunhofer Institute for material Flow and Logistics (ImL)
as rack storage and retrieval. This con-
stitutes the consistent implementation
of autonomous control for the in-house
sphere. Just think of the whole thing as
an anthill
SICKinsight: What is the contribution
that manufacturers of automation com-
ponents can or must make to cope with
these future scenarios? In this context,
we from SICK are obviously interested
above all in sensor technology. Could you
give us some indication in this respect?
Prof. Dr. Michael ten Hompel: Since we
did completely without conventional ma-
terial handling systems, nothing stands
in the way any more. The cellular trans-
port systems bring the goods directly to
their destination. Since nothing stands
in the way anymore, we are no longer
required to position as accurately when
moving, but we must quickly and in three
dimensions detect the environment,
other vehicles, persons, and obstacles,
operating accordingly within the swarm.
For this purpose, we need fast, reason-
ably priced 3D sensors and methods
for sensor fusion in order to merge the
knowledge of the swarm into swarm in-
telligence.
SICKinsight: Autonomous transport
units, busy as an ant, with intelligence
that is distributed and yet coordinated by
an overriding principle considering the
possibilities that open up here, logistics
experts will not be the only ones going
into raptures. Many thanks for this infor-
mative conversation.
01 2011
26
: Views & Voices University education
More about the
Aschaffenburg College:
www.fh-aschaffenburg.de
SICKs strong commitment to supporting universities, colleges, and
institutes practically is no secret. However, the fact that SICK is
also viewed as a suitable partner for teaching is a special distinc-
tion and at the same time an incentive, Harald Schmidt, lecturer
in safety technology at the College of Aschaffenburg, makes clear
in our interview.
SICKinsight: Mr. Schmidt, how did
SICKs involvement at Aschaffenburg
College come about?
Harald Schmidt: SICK has an extensive
training program to begin with. Courses on
safety technology in particular are so well
attended by our customers that it is diffi-
cult sometimes to find suitable premises.
Colleges and universities, such as the one
in Aschaffenburg, offer such capacities.
One of these customer-training seminars
was attended by Prof. Dr. Armin Denner
from the Faculty of Industrial Engineering;
after the event, he approached us, asking
whether we were interested in familiarizing
not only existing customers but also poten-
tial future customers with the subject of
safety technology. The idea was born
SICKinsight: Safety technology is nothing
new indeed, but something must have
aroused the colleges interest in integrat-
ing such a seminar into the curriculum
university education: SICK as partner in teaching
Teaching assignment in safety
technology at Aschaffenburg College
In conversation: Harald Schmidt, SICK Safety Solution Development and Lecturer at
Aschaffenburg College, and Bernd Herkenrath, Senior Consultant at SICK
Harald Schmidt: Safety technology is
continuously changing. Just think of
the new Machinery Directive or the new
standards pertaining to the functional
safety of machines. For many, the topic
comes to life only when technical and
normative theory meets head on with
operational practice. My students now
I am beginning to talk like a professor
specialize in production and manu-
facturing engineering and will become
operators of machines and plants. In
this context, topics like the right safety
distances or, else, the consequences of
manipulations on protective equipment
become relevant really quickly. Many
are also completely unaware of the li-
ability aspects associated with lacking
safety technology. Such insights always
cause a great aha effect
SICKinsight: Why did the college decide in
favor of SICK? Simply because you were in
the right place at the right time?
Harald Schmidt: No, probably that would
have been too thin. In the customer work-
shops, we proved to be convincing as a
manufacturer offering competent con-
sulting. Our didactic materials, above all
the Guidelines Safe Machinery, are very
technical and informative. As a qualified
industrial engineer, I have been working
in safety technology for more than 10
years, and I am a TV-certified expert on
functional safety. SICK ranks among the
leaders in innovation regarding safety
technology. All of this combined guar-
antees a high quality of teaching at the
latest level of knowledge and this is
important to the college. The goal is to
sharpen awareness of the topic, to show
what needs to be mastered, and to pro-
vide an overview of individual aspects.
If this has been achieved, the benefit in
terms of safety technology is enormous.
SICKinsight: How is your course posi-
tioned within the Facultys curriculum?
Harald Schmidt: The lecture on machine
safety held in the past winter semester, is
a required course for prospective indus-
trial engineers specializing in manufac-
turing and production engineering, and
at the end of January, I scheduled a writ-
ten exam. Of course, it was nice to see
that no one failed. Although the grades
differed heavily, all in all, the materials
had been well absorbed and applied. In
the upcoming winter semester, the lec-
ture will once again cover the same top-
ics. As a key topic, machine safety con-
tinues to be relevant for teaching.
SICKinsight: In that case, we also wish
you every success in the future with
your students and for additional
teaching assignments as well
: applications Safexpert safety software
27
www.kohler-germany.com
In order to ensure risk-compatible and continuous machine and
operator safety over the entire life cycles of their machines, the
people at KOHLER Maschinenbau rely on the workflow-oriented
safety engineering using the Safexpert safety software.
>> KOHLER Maschinenbau GmbH in the
Baden town of Friesenheim is a manu-
facturer of strip feeding lines for presses
and automatic punching machines. We
offer expertise for peripherals connected
to presses. Over 5,000 facilities from
KOHLER are operating worldwide, says
Jrgen Scheuerle, Management Repre-
sentative and Associate of KOHLER Mas-
chinenbau GmbH. Customers include the
automotive and automotive supply indus-
tries, fabrication shops, manufacturers of
white goods, the fittings industry, as well
as various niche markets. Since often no
C-standards exist for our machines, we
always face the challenge of developing
a safety concept of our own and of trans-
ferring that into the risk assessment, ex-
plains Edgar Bund, BSc. Eng., Technical
Editor at KOHLER Maschinenbau GmbH.
With Safexpert, KOHLER has built up an
internal CE network via the Sales, Plan-
ning, Mechanical and Electrical Construc-
tion, Quality Assurance, Final Inspection,
and Documentation departments. All of
the areas can work on integrated safety
solutions simultaneously, coordinated
and parallel to the production progress of
the respective machine.
Workflow-oriented Ce marking
Safe construction of leveling
systems and press peripherals
Edgar Bund (BSc. Eng.), Technical Editor
at KOHLER, and Carsten Gregorius,
Portfolio Manager at SICK
In focus at KoHLer: risk assessment
Risk assessment as the core of the en-
tire conformity assessment procedure is
the focus at KOHLER as well. The prepa-
ration of the engine and component list
takes place in the framework of a sys-
tematic process. It includes all of the ac-
tuators and sensors required as well as
their respective features, outlines Edgar
Bund. In a so-called safety matrix, they
are then assigned to the respective ac-
cess points to the facility, following which
one defines the cut-off circuits for each
of the machine sectors. With respect
to examining the safety risks resulting
from a possible foreseeable misapplica-
tion, Safexpert also offers valuable sup-
port, e.g. an overview listing all possible
hazards and covering different groups of
persons.
Safety as teamwork
In Safexpert, every measure can be as-
signed a to do with responsibilities and
date. Thus, measures once defined can
be taken into consideration even during
the design phase, explains Edgar Bund.
And no matter if we envisage a safety
gate or electro-sensitive protective equip-
ment, the risk is assessed by means of
Safexpert before and after every safety
measure taken. After finishing the sys-
tem, what follows is completion of an
internal production check as well as in-
stallation of the facility at the customers
site, including its technical safety inspec-
tion. In this connection, the proper func-
tion of each safety-relevant component
is established in accordance with an in-
spection schedule derived from the safe-
ty matrix, elucidates Edgar Bund. The
test result, e.g. the mechanical function-
ality of gates or the safety-capable cut-
off of drives, are documented meticu-
lously. If everything works smoothly, the
CE label is attached at the end. The test
and inspection assistant integrated into
Safexpert provides valuable support for
this purpose.
The bottom line: Safexpert is the ideal so-
lution for safety engineering at KOHLER
Maschinenbau.
01 2011
28
: applications Hand and finger protection
The Swiss Trion AG, manufacturer of automatic return systems for
libraries, uses miniTwin2 safety light curtains in the terminals to
provide operation without a moment of shock.
>> Trion is active worldwide as a supplier
of facilities for intralogistics in librar-
ies. The systems consist of individu-
ally realizable conveyor sections, sorting
modules, as well as issue and return
terminals for indoor and outdoor areas,
explains Richard Jaworsky. When books,
CDs, or DVDs are returned, these items
are identified in the terminal. After that,
they are transported through the modu-
lar conveyor system to a sorting station,
where they are classified automatically
according to subject areas and sorted
out to roller carts standing by. Every
year, we realize in joint projects, primarily
with RFID system integrators, about 30
such facilities in the most diverse stages
of development, says Thomas Steiner,
Head of Production at Trion. In addition
to availability of the systems, everyone
involved attaches particular importance
to safe operation of the terminals by cus-
tomers. There is no risk of injury stem-
ming from the terminals gently opening
and closing sliding panels, says Richard
Jaworsky. However, we wish to avoid,
e.g. children or older customers getting a
fright if the panel closed too early when
inserting a book. In order to rule out
such moments of shock, Trion integrates
compact miniTwin2 safety light curtains
into its terminals.
minitwin2: safe, compact,
and easy to integrate
In the miniTwin2 safety light curtain, the
sender and receiver elements as well as
the evaluation unit are accommodated
in a single, always consistently built and
well-designed housing stick. What is
particularly important for our library ter-
minals, says Thomas Steiner, is that
the light curtain is built very small, has
no blind zones, and at the same time of-
fers a resolution of 14 mm compatible
with finger protection. This means not
only that even small childrens hands
are detected reliably but also that we
can mount the light curtain directly
behind the sliding panels in a way that
saves space and is ergonomic to oper-
ate. The topic of integration is also cru-
cial to Trion from another perspective.
The special housing construction with
a flat and curved side as well as the
design of the electrical connection by
Left: In the case of miniTwin2, the light curtain is formed by the installation of two miniTwin sticks tilted at 180 to each other,
placing the sender and receiver modules opposite each other; Right: Inserting a booklet, for instance, into the user terminal, inter-
rupts several beams of the light curtain, preventing premature closing
means of a standard connection cable
with a universally rotatable, 5-pin M12
connection plug rules out errors both
regarding the mechanical and electri-
cal connection. In addition, the varied
alignment, status, and diagnostic dis-
plays ensure a high level of operating
convenience for commissioning and in
case of service.
Safe sensor solution
contra moments of shock
In operation on location, the miniTwin2s
deliver convincing performance due to
their extraordinary insensitivity against
any kind of ambient light. Other sys-
tems do not offer that, thereby causing
high false alarm rates that are unaccept-
able for either libraries or their clients,
confirms Thomas Steiner. That does not
apply to the miniTwin2. Even in bright
natural light, the sensor technology is
not dazzled, preventing moments of
shock by premature closing and impair-
ing neither the return process nor the
monitoring function, comments Richard
Jaworsky.
Intelligent sensor design
supplemented by professional
all-inclusive package
The advantages of miniTwin2 are signifi-
cant but not the only aspects that were
operator safety for automatic library terminals
Book return without moment of shock
: Applications Detection of fluorescent substances
29
www.ljunghall.se
www.trionag.ch
important to Trion in opting for this light
curtain. Thus, the combined stick design
for sender and receiver as well as the
use of standard connection technology
common in industry reduce the expens
es at Trion in procurement, warehousing,
and service logistics. Added to this are
extensive customer service and prompt
reaction to any questions. Markus Bhl
mann, our contact at SICK, is very quick
to help when needed, and almost al
ways he manages to provide a very good
technical solution, confirms Richard Ja
worsky. On top of that, there is SICKs
worldwide presence. Nearly anywhere,
suitable devices are available within a
few hours, something particularly appre
ciated by our final customers.
Small wonder, therefore, that Trion
uses other sensor technology from SICK
as well: inductive sensors for monitor
ing the positions of sorter protective
hoods and for controlling the speed
of the sliding panels, WL100 compact
Offer praise for the comprehensive cus-
tomer service by SICK and prompt reac-
tion to any questions: Richard Jaworsky,
Deputy Head of Production, and Thomas
Steiner, Head of Production at the Swiss
Trion AG in Dbendorf near Zrich
photoelectric sensors to detect media
at module interfaces in conveyor sys
tems, ELG automation light grids and
in case of confined installation space
WLL190T2 fiberoptic photoelectric
sensors for detecting objects when cy
cling through the facility.
>> In Sweden, the automotive supplier
Metallfabriken Ljunghll AB was facing
precisely this problem in its production
plant. For reasons of process and qual
ity control, it was essential to guaran
tee the presence of the application of
transparent glue on components with
a metal surface. Important secondary
conditions: Added to the adhesive are
luminophores that become visible when
excited to illuminate by a light source fea
turing UV emitted light. However, the use
of classic luminescence scanners nev
ertheless had to be ruled out, since com
plete distribution of the adhesive within
an area needed to be detected.
Luminescence vision sensor
on glue patrol
The task was solved using the Inspec
tor I40LUT. The UV lighting integrated
into the vision sensor causes the glue to
glow in bright, longwave light, ensuring
in this way the necessary contrast to the
background. Focused not on a spot but
instead on an area, the I40LUT can reli
Detecting something transparent on shiny surfaces is not par
ticularly easy in the first place. When, on top of that, the location
where a glue application needs to be present is not clear, its a
case for the Inspector I40LUT.
ably detect the presence and quantity of
the glue application while simultane
ously carrying out additional inspection
tasks on the part.
Tested briefly, sold quickly, detecting
reliably in the long term
After being presented with the applica
tion, a sales representative from SICK
proposed the Inspector I40LUT and
simply brought the device along for the
customer call. The test demonstration
carried out directly on the object was
convincing and in no time, several vi
sion sensors were sold. Installed and
parameterized quickly and easily, they
have since proven an inspection solution
guaranteeing reliable detection as ex
pected.
When luminous power is decisive
On patrol with the
Luminescence Inspector
The I40-LUT detects the presence and quantity of transparent glue
01 2011
Feed station for the pallets loaded
with Euro-format stacking crates at the
Migros Aare Cooperative
30
: Applications Object detection
www.migros.ch
www.kaiser-engineering.ch
In its empties return station, the Migros Aare Cooperative ben-
efits from SICKs new WL27-3 Reflex Array photoelectric sensor
featuring a light array 50 mm in height. During peak hours, this
plant extension carried out by Kaiser Engineering in Rheinfelden
nearly doubles the throughput in the pallet feed station.
>> The Migros Aare Cooperative, with
a staff of about 80,000 and sales
amounting to 5.2 billion Swiss francs,
is Switzerlands largest chain of retail
stores. In the economic area of the
Migros Aare Cooperative, more than
120 Migros retail stores are supplied.
Every hour, dozens of trucks are pull-
ing in and out. At the empties return
station, things are really busy, as up
to 4,000 pallets are placed by forklifts
on the appropriate feed stations. This
corresponds to moving approx. 70,000
Euro-format stacking crates for subse-
quent sorting. At peak periods, Easter
and Christmas, the number of Euro
stacking crates delivered even reaches
about 130,000 a day. In that scenario,
every second counts when unloading
the trucks and loading the feed sta-
tion, stresses Anton Loosli, the Head of
Maintenance Delta at Migros Aare.
Solution with the WL27-3 Reflex Array
increases productivity
At the empties return station, the pallets
are unloaded from the trucks and set on
the feed stations by a forklift. Following
this, the pallets loaded with Euro stack-
ing crates are transported to the sorting
facility by a chain conveyor. The bottle-
neck in this transport chain was the feed
station. After a pallet had been set down
and its presence checked by a classic
Photoelectric sensor with light array
Throughput in empties return
station at Migros doubled
The WL27-3 Reflex Array
increases throughput at
the feed station in a cost-
effective way; Detection of
objects > 12 mm indepen-
dent of location within the
50-mm light array
photoelectric retro-reflective sensor us-
ing a point-shaped light spot, a waiting
period of approx. 10 seconds passed be-
fore the pallet was transported onward.
Time and again, this resulted in unnec-
essary waits for the forklift drivers, since
they were not able to unload the next
pallet yet, as the space was still occu-
pied. The Kaiser Engineering Company in
Rheinfelden had worked out a convinc-
ing solution with SICK AG, Switzerland,
using the new WL27-3 photoelectric
sensor. By combining the bright red light
PinPoint LED with special optics, the sen-
sor generates a nearly constantly 50 mm
high light array between the photoelec-
tric sensor and the reflector. Objects
> 12 mm are detected reliably within the
light array independent of location. The
Reflex Array sensor and the reflector are
integrated into the lateral guidance sys-
tems in the front area of the feed station.
As a result, the fork of the forklift truck
can be detected reliably. Now the start-
ing signal for transporting the pallets is
triggered by the detection of the trucks
fork, shortening the waiting times to ap-
prox. 3 seconds. In this way, the clear-
ance signal for transporting the pallet
further is linked directly to moving the
forklifts fork out from the pallet. This
measure heightens the drivers safety in
order to avoid collisions as well as overall
plant safety, says Anton Loosli, and On
top of that, it increases throughput at the
feed station enormously.
: applications Gas analysis
31
>> The growth of the plants can be in-
creased considerably in a natural and
ecologically healthy way, by using clean
incineration exhaust to enrich the air
with CO
2
in the tomato greenhouse. Ni-
tric oxides from the exhaust can even
be reused as fertilizers under controlled
conditions. With its gas analyzing sys-
tem, SICK monitors the nitric oxide val-
ues for optimal feeding of the plants,
combining economy with environmental
protection.
Small power stations are often used
for the generation of power and the hea-
ting of greenhouses. Their exhausts can
be reused in an environmentally friendly
way if they are cleaned of toxics. There-
fore incineration gases are directed into
flue gas purification plants so they can
be used for fertilization.
Brilliant gas measurement
The nitric oxide content has to be
measured continuously for the obser-
vation of the legally binding emission
limits and the limit monitoring of the
exhaust ducts into the greenhouse.
The GMS800 DEFOR by SICK, the UV
specialist for selective NO
x
measure-
ment, does this job. Even in the small-
est measuring ranges it measures ex-
cellently: measuring ranges from 0 to
50 mg/m NO and NO
2
can be precisely
made. The summation of NO + NO
2
to
NO
x
is carried out directly in the ana-
lyzer. The special measuring method
does not require a NO
x
converter. The
complete extractive measurement
system MAC800 consists of a heated
extraction probe, the heated measur-
ing gas line, a measuring gas cooler,
a measuring gas pump, the analyzer
GMS800 DEFOR and a device for the
test gas admission.
Controlled greenhouse fertilization
with SICK gas analyzers
Growing with CO
2
In order to grow, plants trans-
form carbon dioxide into starch
by photosynthesis. They can,
however, digest much more
than ambient air offers.
Profitable safety
The use of the suitability-tested analyz-
ing system by SICK ensures a high level
of safety for people and plants in the
greenhouse. Furthermore, the reliable
measurement supports ecological and
economic aspects. The measuring sys-
tem is easy to maintain, offers low-cost
services, and measures with high avail-
ability. The NO
x
measurement provides
reliable instantenous values. Therefore,
plant control can be optimized in an
environment-friendly way. The costs for
the exhaust purification are minimized
and tomatoes with as little CO
2
emis-
sions as possible are produced.
01 2011
32
: applications In-company training
Attractive, modern, and future-proof this is how young people
imagine their in-company training. Hands-on experience and inde-
pendent working are called for and cutting-edge technologies.
It happens just this way in technical vocational training at SEW-
EURODRIVE, where trainees integrate safety technology from
SICK into their project work.
>> In times of acute shortage of skilled
labor, nothing is more essential than com-
petent and practically oriented training
of employees. And particularly leaders in
technology like the manufacturer of drive
technology, SEW-EURODRIVE, and SICK
have ideal opportunities by way of in-com-
pany training to familiarize their future
employees with subsequent demands
and tasks. Learning directly on the
model, literally grasping the practically
oriented implementation of technical but
also economical requirements, as well as
independent work during training make
trainees interesting to many departments
in our company after the end of their train-
ing period, says Norbert Steltz, Head of
Electronics Training at SEW-EURO DRIVE.
Company contract as
practical final exam
This is brought home, for instance, by the
training program for electronic engineer
for devices and systems. Apart from the
corresponding theory, the exam adminis-
tered by the IHK (Chamber of Commerce
and Industry) also involves a practical
component. In technical vocational train-
ing, we realize this requirement through
work on so-called company contracts,
explains Gregor Wohlfart, the Training
Commissioner Technology in Sales and
University Marketing at SEW-EURODRIVE.
To this end, the young people are to
carry out a defined project contract
on their own. Like Gabriel Currle and
Sascha Oberst, who just completed their
training successfully. In connection with
their exam, they were given the task of
protecting, from three sides and without
contact, the workspace around a model
of an automatic hoisting device with three
synchronous servo lifting axles. As we
searched for the suitable sensor technol-
ogy, we decided in favor of SICK, says
Gabriel Currle. Here we were able to use
three fundamentally different technolo-
gies for protection: the V300 safe came-
ra system, an S300 safety laser scanner,
and the miniTwin safety light curtain. It
was clearly no disadvantage in this con-
nection that SEW-EURODRIVE and SICK
had already been cooperating for years
in the area of further training and qualifi-
cation of employees and customers. Mr.
Wohlfart established contact for us to the
key account manager from SICK respon-
sible for SEW, Volker Neuenhaus, with
whom we settled the technical questions
in advance, says Sascha Oberst. Subse-
quently, we visited SICK at the SPS/IPC/
Safety technology in in company training at SeW-euroDrIVe
Learning with the help of the
latest technologies
Freddy Heinzelmann, Gregor Wohlfart, Sascha Oberst, and Norbert Steltz from
SEW-EURODRIVE; Volker Neuenhaus, SICK, and Gabriel Currle from
SEW-EURODRIVE (from left to right)
: applications Quality control
33
www.haas.com
www.sew-eurodrive.de
High temperatures, harsh ambient conditions, and challenging
tasks make very high demands on optical sensors in industrial
baking machines. Here, sensors from SICK are the preferred
choice, e.g. at Franz Haas Waffel- und Keksanlagen-Industrie
GmbH in the Austrian town of Leobendorf.
>> Nearly all of Haas wafer and biscuit
baking plants are high-performance so-
lutions for fully automated baking of wa-
fer sheets in different sizes, biscuit and
cake products, wafer cones, and pan-
cakes in large-scale industrial produc-
tion processes, explains Martin Kopf
(BSc. Eng.), Head of Electric Construc-
tion at Franz Haas Waffel- und Keksanla-
gen-Industrie GmbH. In terms of sensor
technology, this means recognizing the
most diverse baked goods i.e. coping
with different shapes, sizes, degrees of
browning, and surface structures. From
the perspective of automation technol-
ogy, the objective is, despite a great
product variety and many different pro-
cessing steps and ambient conditions,
to identify rugged and low-maintenance
sensor solutions that can be used across
facilities if possible, Martin Kopf sums
up the situation.
two product families of photoelectric
sensors for diverse detection tasks
When detecting dough strands, pre-
formed dough pieces, wafer sheets,
cookies or cones, Haas has been rely-
ing primarily on two product families
of photoelectric sensors from SICK for
many years: WTB12-3 and W12L-2 La-
ser. Above all, this is due to the sensors
superb detection behavior with regard
to our different products, which assures
us of high product output, as well as the
simple operation and commissioning, for
which we do not require any specialist
personnel, explains Martin Kopf. The fa-
cility environment and the baked goods
determine which sensor is used. If, for
instance, chocolate cookies need to be
detected on a light conveyor belt, we will
use a photoelectric sensor with back-
ground suppression, elucidates Martin
Kopf. For flat wafers or lye bread with
its dark, shiny surface, sensors with fore-
ground suppression are the best choice.
With respect to the ruggedness of the
sensors, ECOLAB attests to the sensors
of the WTB12-3 and W12L-2 Laser prod-
uct family that they reliably and perma-
nently fulfill the requirements of material
stability such those entailed in cleaning
and disinfecting processes in the food
environment.
The bottom line: By using the sen-
sors from the WTB12-3 product family
in two versions as well as the W12L-2
Photoelectric sensors for wafer and biscuit baking plants
Robust sensors for fancy pastries
DRIVES trade fair in Nuremberg, receiving
explanations about the functioning of the
devices with the help of the exhibits. For
commissioning, the technical service hot-
line of SICK Vertriebs-GmbH in Dsseldorf
helped us out, adds Gabriel Currle.
In addition to selecting and integrat-
ing the technical solutions, the com-
mercial handling was also part of the
company contract. To this end, the
DriveAcademy, acting as the customer,
issued a separate project number. The
two trainees then had to calculate the
project in business terms, checking that
they were within the scope of their time
and cost structure regarding integration
as well, explains Gregor Wohlfart. They
mastered this brilliantly and gathered
valuable experience.
Perfectly prepared for practice
The example demonstrates how in-com-
pany training, especially in the technical
skilled trades, has changed away from the
school orientation toward practical learn-
ing on the model. And for this purpose,
one needs cooperation with partners who
not only have the same training philosophy
but also rank among the technological
and market leaders, says Freddy Heinzel-
mann, Product Manager Functional Safety
at SEW-EURODRIVE. On top of that, in
the automotive industry, for example, or
in warehousing and conveying facilities,
nearly everywhere we encounter SICK as
a supplier of sensor and safety technol-
ogy. Employees who have already worked
with devices or on operator interfaces from
SICK in the course of their training can im-
mediately contribute their expertise.
In this way, things have come full cir-
cle. Attractive, modern, and independent
training guarantees not only a future to
young people but also to the training com-
pany acting as a future employer. How-
ever, the use of innovative technologies
not only creates the desired win-win situ-
ation for trainees and trainers but also for
customers, as they can count on qualified
answers to their questions and tasks.
Therefore, Gabriel Currles and Sascha
Obersts safe lifting axle model, which
the DriveAcademy will use for purposes of
training and further education, will not be
the last joint training project carried out
by SEW-EURODRIVE and SICK.
Laser, the Haas Company manages to
solve reliably the most diverse tasks
associated with the detection of baked
goods in the high-performance baking
machines. The sensors enjoy a high
degree of acceptance worldwide among
end users. Moreover, because of SICKs
global presence, a replacement device is
quickly on site if worst comes to worst,
Martin Kopf summarizes the advantages
that the photoelectric sensors from SICK
offer him.
01 2011
34
: applications Quality control
www.adbro.co.uk
Adbro Controls has integrated SICKs revolutionary new 3D and
color imaging camera, the ColorRanger E, in an extremely high-
speed conveyor-based quality control and high speed reject system.
>> Designed primarily for the food indus-
try, this innovative solution can easily be
integrated with existing installations.
Adbro engineer, Nicky Brian, com-
ments: The ColorRanger E has en-
abled us to deliver a complete palette
of inspection parameters for critical QC
tasks. Size, height, shape and some
surface defects have been possible
with previous profiling scanning cam-
eras; however, the new system can
inspect for color defects as well. With
all the data combined, the system can
replace manual QC inspection, it offers
precision inspection down to 0.3 mm
diameter, at speeds up to 1 m a sec-
ond, on a 600 mm wide belt.
A typical system would involve the
integration of the ColorRanger E and
PLC which tracks the exact position
of goods on a conveyor belt. The PLC
compares scanned defects against the
pre-programmed range of ideal items
for approval, or rejection, it delivers
the information to a pneumatic nozzle
which then blows the faulty item off the
belt with compressed air. Other useful
data such as trends and defect types
are also recorded. The system could be
easily and quickly attached to existing
conveyor systems, and integrated with
process control without requiring total-
ly new installations.
Nicky Brian adds: We have com-
prehensively tested the system and its
capabilities, with trials on a range of
food items, such as bread rolls, sweets,
and biscuits. We have extensive pro-
duction and process experience, and
the ColorRanger E system from Adbro
and SICK is simple to install on existing
process lines, and to scale up in size.
It can easily replace existing sensors,
and black and white cameras, and
doesnt require new conveyor installa-
tions or extensive downtime, making
it a cost-effective method of improving
critical quality control.
Adbros working demonstration and
trial unit demonstrates a typical system
with ColorRanger E. Lights and profiling
lasers are in an enclosed unit, with the
array of pneumatic nozzles over a gap
between the belts. Defective items are
detected, tracked, and rejected by a
blast of directed air blowing the item
into the gap between the belts. The
display screen offers process control
either at the application or remotely.
adbro delivers extra quality control with
SICK 3D color camera
: Technology Integration concept for automatical identification
35
With IDpro, SICK introduces for the first time a cross-technology
platform and portfolio strategy for all automatical identification
technologies. IDpro permits an application-specific selection of suit-
able automatical identification products from a single producer.
>> Investing in the suitable automatical
identification solution in a future-proof
way is not always easy from a business
perspective. Technical requirements can
often be realized using different tech-
nologies such as bar codes, 2D codes,
and RFID. Practice shows that there is
no single correct identification technol-
ogy what matters throughout is the
application and its basic technical and
economic conditions. However, indus-
try demands standard integration and
operating platforms. Behind this lies
the desire to be able to use the mark-
ing technology appropriate in each case
without having to invest great sums for
integration and training. This is where
SICK comes in with IDpro.
IDpro three technologies,
one integration concept
With IDpro, SICK offers a portfolio strat-
egy across technologies for the CLV6xx,
LECTOR
620, and RFH620 product fam-

ilies. All of the IDpro devices stand out
due to industry-compatible design, and
they can be connected, configured, and
parameterized in the same way. Conse-
quently, one can realize solutions for cli-
ents that are cost-effective and a secure
investment.
By means of the IDpro platform, it
is possible to develop hidden potentials
for more effectiveness and economic
efficiency. Generally, machine and plant
builders have defined an in-house con-
trol and software structure. Therefore,
conversion to a different automatical
identification technology is quite often
associated with substantial adjustment
expenses. In future, using IDpro will
allow applying the most suitable auto-
matical identification technology on an
order-by-order basis. Thus, when using
2D codes or RFID transponders, one
can continue to apply the existing en-
gineering and expertise, since one has
automatically familiarized oneself also
with 2D and RFID devices during train-
ing for, e.g. bar code technology. In this
way, reduced training and documenta-
tion effort is also reflected positively in
economic terms.
To integrators, IDpro affords secu-
rity in planning and investment because
their designs are not rendered worthless
by a change in technology. They will al-
ways be able to use the basic concept of
the solution, adapting the data capture
on the object to the respective condi-
tions and orders without having to carry
out complex changes to the IT processes.
A case in point confirming this is Laetus
GmbH in the Hessian town of Alsbach-
Hhnlein. The Laetus Company special-
izes in the development, production,
and sales of advanced control systems
for checking pharmaceutical packag-
ing materials. Building on the current
network of CLV6xx bar code scanners,
the new LECTOR
620 will now be inte-

grated into the existing structure, says
Gnter Rodeck , BSc. Eng., Director Prod-
uct Management Standard Systems,
Three technologies one integration concept
Integrating intelligently using IDpro
Marketing & Business Development at
Laetus. Due to the fact that in the in-
tegration of LECTOR
620 we were able

to build on the existing IDpro platform,
expenses for integration and training de-
creased considerably thanks to the stan-
dardized parameterization software and
operator interface.
IDpro investment in the suitable
solution with an assured future
Currently, SICK is the only supplier in the
area of automatical identification that
carries all three technologies bar code,
2D, and RFID in its portfolio, developing
and manufacturing them in-house and
having created a standard platform, i.e.
continuous operator interfaces, process
interfaces, and connecting options. This
allows the planning of specific applica-
tions far in advance of having to settle
the question of identification technology.
In selecting the optimum technology for
the respective application, SICK provides
all of the information from a single source
using IDpro: across technologies, compre-
hensively, and neutrally.
www.sick-idpro.com
www.laetus.com
01 2011
36
: Know-how Muting
To allow automatic material transport in intralogistical pro-
cesses into protected hazardous areas, reliable differentiation
of humans and material, of persons and pallets, is necessary.
For this purpose, SICK offers interesting solutions with its safety
capable sensor and control technology.
Muting and pattern recognition
Safe ways through
the hole in the fence
>> Production facilities in automotive
manufacturing or at logistics centers
are typical examples of highly automat-
ed plant processes that nevertheless in-
volve numerous persons possibly stay-
ing there, e.g. plant operators, service
technicians, or maintenance workers.
All of them have to be protected from
the hazards of automatically operated
facilities. Usually, however, complete
fencing, e.g. of a robot or a vertical
transfer car, is out of the question, since
they are integrated into an automated
material flow. Therefore, the hole in the
fence necessary for transporting ma-
terial to and from the dangerous area
must be monitored in such a way that
pallets can pass while persons are de-
tected reliably, causing the machine or
facility to switch off.
Application-specific alternatives
The C4000 Palletizer or the C4000
Fusion safety light curtain, and the
M4000 multiple light beam safety de-
vice are available for this purpose. Com-
bination with the UE403 safety modules
or the Flexi Classic and Flexi Soft safety
controllers results in possible solutions
featuring top reliability and economic ef-
ficiency either through muting or pat-
tern recognition.
The well-designed combination
is what matters
Which one of countless combinations
of sensor and control technology consti-
tutes the best solution for a particular
application depends on many factors,
among others, space available in the
Muting station with M4000 Advanced
in combination with UE403 in
intralogistics
Material yes Person no
: Know-how
37
muting solutions using: ue403
safety module
Flexi Classic
(ue410-mm)
Flexi Soft Solutions with
special functions
Muting on site (IP 65) yes --- --- self-teaching
pattern recognition
Muting in control cabinet
(IP 20)
--- yes yes not required
Connectible safety light
curtains/multiple light
beam safety devices
product family
M4000 Advanced
product families
M4000 Standard,
M2000
C4000/C2000
miniTwin
product families
M4000 Standard/
Advanced,
M2000
C4000/ C2000
miniTwin
C4000 Palletizer/
C4000 Fusion
2-sensor muting
crossed arrangement
yes yes yes self-teaching
pattern recognition
2-sensor muting serial
arrangement (2 sensors
in hazardous area)
yes yes, in connection with
XU module
yes self-teaching
pattern recognition
4-sensor muting yes yes yes self-teaching
pattern recognition
Muting without
muting sensors
--- --- --- yes
Integration of further
safety applications
--- yes yes ---
Concurrence monitoring
of the muting sensors
yes yes, in connection with
MDI module
yes ---
Override/bypass
integrated
override override, in connection
with MDI module
override/bypass bypass
Added value of
the solution
simple and fast wiring simple and universal simple and universal no muting sensors
required
universally usable
muting application
expandable in
a modular way
expandable in a
modular way,
no additional safety
controllers required
self-teaching
machine, the type and feeding of objects
and automation-related additional func-
tions to be carried out by the respective
sensor or safety controller.
Muting is the mother of all solu-
tions for access protection in automat-
ed material transports. A muting station
consists, e.g., of muting sensors, an
M4000 multiple light beam safety de-
vice, the UE403 safety module, at least
one muting signal transmitter, e.g. a
muting LED, and sometimes also swing
doors. When an object passes the mut-
ing station prior to entering the hazard-
ous area, the chronological and logical
sequence of the muting signals is re-
corded and evaluated.
Alternatively, the method of pattern
recognition monitors, on the one hand,
the size and closed shape of an object,
e.g. the goods on a pallet, while it can
also, on the other hand, recognize the
size and number of several objects, e.g.
the struts of a mesh box or pallet and,
respectively, the individual goods trans-
ported at consistent intervals. Since per-
sons within the protective field always
generate a different pattern than the
object patterns, one can thus achieve
a safe differentiation between humans
and material.
The following table illustrates the
possible combinations of electro-sensi-
tive protective devices and safe control
technology.
Object pattern recognition by C4000
Palletizer on a pallet conveyor
38
: Products
Freely programmable and thus available quickly and flexible to
use these are the benefits provided by the programmable abso-
lute and incremental encoders from SICK.
>> When it comes to possible cost re-
ductions in procurement, warehousing,
and service logistics, too, the DFS60
incremental encoders, the AFS60 abso-
lute singleturn encoders and the AFM60
absolute multiturn encoders from SICK
are a well-rounded affair for many drive
manufacturers, machine builders, and
system integrators.
encoders become usable universally
thanks to programming
In many places, the freely programma-
ble encoders from SICK provide crucial
added benefits beyond their technical
functionality. Due to the continuously
variable setting of the number of lines
desired, they can be adjusted as accu-
rately as never before. Moreover, it is
possible to define the zero-pulse width
depending on the application. Finally,
the DFS60 offers the possibility of indi-
vidually adjusting the voltage levels of
the TTL or, respectively, the HTL interfac-
es at the output side. Overall, therefore,
every programmable encoder can be set
exactly as required for a given applica-
tion and directly ex warehouse at that,
which ensures availability and usability
at short notice.
Programmable in a user-friendly way
even when already installed
In order for the added benefit of the ver-
satile encoders from SICK to be available
to machine builders and integrators with-
out any additional expense, great impor-
tance was attached to easy-to-operate
programming of the number of lines, ze-
ro-pulse width, zero set, and output level.
Programming takes place by means of
the standard output line of the encoders
whether using the PC-supported PGT-
08-S standard programming tool or
particularly in the case of maintenance,
service, or adjustment work using the
pocket-sized stand-alone PGT-10-S pro-
gramming tool. Both tools even permit
the cloning of settings once determined
to as many encoders as desired an es-
sential saving of labor when it comes to
applications recurring regularly.
Particularly with the encoders installed in
particular, the possibility of being able to
actuate the encoders by means of their
RS485 standard interface constitutes a
decisive advantage. By contrast, in the
case of devices with DIP switches, pro-
gramming via the controller is just as im-
possible as the cloning of configurations.
Moreover, depending on the device, there
are cumbersome handling of PG connec-
tors and difficult-to-reach programming
plugs both very time-consuming.
Source code available
OEMs and machine builders who wish to
carry out programming directly by means
of the HMI of their equipment can re-
quest the source code from SICK for in-
tegration.
The bottom line: flexibility, fast avail-
ability, straightforward service options,
efficient material management in this
way, the DFS60, AFS60, and the AFM60
are programmed for success in the
years ahead as well.
universal solutions for rotary path measurement
Programmable encoders
gaining ground
Encoders
39
: Products
Small codes, omnidirectional orientation, different contrasts and
resolutions, large field of view, changing reading distances the
image-based code reader ICR849-2L FlexLens from SICK offers
utmost flexibility in practical use.
>> The ICR849-2L FlexLens delivers con-
vincing performance due to superb read-
ing characteristics. On the one hand,
these are achieved by means of the in-
tegrated four-megapixel CMOS imager,
which allows, for example, reaching a
resolution of 0.35 mm in a field of view
measuring 300 mm x 300 mm. In this
way, one can reliably detect a code the
size of a pinhead on an area greater than
A4 format (roughly US letter size). In ad-
dition, C-mount interchangeable lenses
permit flexible adaptation of the code
reader to the respective reading situa-
tion. Apart from that, the image process-
ing sets new standards. With its dynamic
parameter switching, the integrated de-
coder ensures with only one setting reli-
able decoding of low-contrast or directly
marked codes in any orientation.
Industry-compatible integration
In terms of both mechanics and control
technology, the ICR849-2L FlexLens
meets all the requirements of industry-
compatible integration. The metal hous-
ing with an IP 65 enclosure rating is
very easy to mount; configuration of
the device is simple and thus saves
time and costs by means of live
image and auto setup. The M12
Ethernet connection technology
for fast image and data transmis-
sion constitutes the standard in
many user industries. In addition,
the code reader is equipped with a
serial interface. Via CAN, one is able
to connect several devices to form one
network practical when requiring multi-
sided reading. By way of external con-
nection modules, fieldbus environments
such as PROFINET, PROFIBUS, and De-
viceNet are also open to the ICR849-2L
FlexLens.
object identification, retraceability,
and product piracy protection
Due to its performance characteristics,
the code reader is the ideal solution for
various tasks in logistics automation.
One particular focus of use is goods
identification in automated medicine
Four-megapixel code reader for pharmaceutical,
logistics and automotive industries
Ideal for small codes
in a large field of view
Image-based code readers
storage systems: Here, the device sup-
ports both uninterrupted retraceability
and effective protection from product
piracy with respect to medicines.
40
: Products
Alarm without intruder, intruder without alarm for the design
of exterior perimeter protection, it is essential to rule out both.
The LMS53x laser measurement sensor from SICK featuring
multi-echo technology provides the decisive performance edge
for these applications.
>> The LMS53x is a 2D laser measure-
ment sensor designed specifically for
security applications with long ranges
in the outdoor area. For holistic secu-
rity, particular importance is attached
to early detection when it comes to pe-
rimeter protection. Horizontal surfaces,
e.g. yards, access roads, or roofs, can be
monitored by the sensor just the same
as vertical planes such as walls, fences,
or faades. The LMS53x meets the re-
quirements of Environmental Class IV
of EN 50131 (VDE0830), in accordance
with the test methods of EN 50130-5,
i.e. the device can be installed for two-
dimensional monitoring of an exterior
perimeter fully exposed to weather. How-
ever, it is also suited for monitoring tasks
in interior areas having harsh ambient
conditions.
modular system structure,
high-performance optics
The system consists of three compo-
nents: the sensor head with the sender-
receiver optics and data evaluation, a
plug-in security application module, each
featuring specific, individually adjustable
settings and parameterization, as well as
an integrated parameter memory. These
components permit simple and quick
connection or replacement of a device.
With its novel, particularly light-intensive
sender optics, one can detect intruders
radially at long ranges common for ex-
terior perimeters up to 65 m. Even low-
re-flective shady characters are visible
Security laser scanner featuring multi-echo technology
Reliable exterior perimeter protection
without a flaw
>> multi-pulse technology
The multi-pulse technology improves the tried and tested pulse-time-of-flight
measurement and is capable of carrying out an evaluation of up to five return
impulses after an emitted pulse at scanning speeds of up to 100 Hz. In doing
so, the LMS53x generates more measurement data for position and distance
detection that is even more precise. Furthermore, due to the added amount
of measured values per angle beam, the measurement and detection results
become independent of weather and other ambient conditions to an extent not
achieved previously. Thus, it is possible to effect fast and reliable detection of
stationary as well as moving objects even in poor visibility caused by rain, fog,
or dust.
Laser measurement technology
41
: Products
With stoptime detection as a motion control function block, SICK
extends the portfolio of safety control solutions by an easy-to-inte-
grate and economical solution for safe drive monitoring.
>> Machines such as palletizers, mixers,
and packaging and milling machines
are kept moving by drives. The function
block of stoptime detection determines
the end of a coastdown/braking action
of a drive. The signal generated by the
function block can be used to unlock
safety gates or prevent the restart of the
drive. This is the task carried out by stop-
time detection, the new function block of
motion control.
Integrated flexibly into Flexi Soft
Stoptime detection is available as a func-
tion block in the new free-of-charge Flexi
Soft Designer. Using the logic editor of
the Flexi Soft Designer software, it can
be integrated directly into safety control
projects featuring Flexi Soft without any
additional module. It is possible to con-
nect up to four sensor or encoder sig-
nals (24 V signals) to a function block for
monitoring the motion of a drive. These
HTL signals require no additional spe-
cial hardware but are instead introduced
on digital input cards into the controller,
thus allowing a very efficient way of imple-
menting a 1b Stop category. Activation of
the function block takes place by means
of its drive control input. In this way, the
motion control function guarantees a high
level of machine availability, increases in
productivity through faster and yet pro-
tected intervention into the machine, as
well as safe access to the equipment in
the case of set-up and maintenance mea-
sures. Just download Flexi Soft Designer
at www.sens-control.com and use the
simple, intuitive programming interface
featuring the new function block of stop-
time detection.
Stoptime detection with the
Flexi Soft safety controller
Motion Control: monitoring
zero-speed safely
to the scanner up to 40 m. Given appro-
priate positioning, it is possible to reach
ranges within the detection diameter of
up to 130 m or, respectively, up to 80 m
at an object reflectance of 10 %.
Using multi-echo technology against
nuisance or false alarms
The decisive element for the perfor-
mance edge in security applications is
the new multi-echo technology. It enables
the laser sensor to detect reliably any ob-
ject- or weather-related interference or
multiple reflections, thus reducing sub-
stantially the rate of both nuisance and
false alarms something confirmed so
far by TVs ongoing acid test.
Ideal for alarm verification
This high level of reliability makes the
LMS53x a very efficient, dependable, and
universal detection solution. Moreover,
the device is cut out for being the ideal
supplemental or alarm-verification sys-
tem which can be combined with detec-
tion methods that are physically different,
e.g. thermal imaging cameras, motion
detection video technology, radar, capaci-
tive proximity detectors, ground detection
and fence protection systems, as well as
electromechanical detector solutions.
Whether as stand-alone technology or in
combination using the LMS53x guar-
antees reliable and economical exterior
perimeter protection.
The LMS53xx laser measurement sen-
sor from SICK
Safe control solutions
Diagram: function block of
stoptime detection
+
More information
on page 45
+
42
: Products
Immediately available in all markets: the automation light grid MLG Up-
grade. It provides convincing performance because of numerous innova-
tions, including integrated CAN bus, two analog outputs, and a software
solution for universal pallet identification.
>>The modular light grid MLG Upgrade is
a versatile automation solution configu-
rable in a modular way for both switching
and measuring 2D object detection. The
new system delivers convincing perfor-
mance due to improved ease of opera-
tion and integration. A refined teach-in
method permits a choice between high
sensitivity and high functional reserve or
teach-in using the automatic mode. The
CAN bus in the MLG Upgrade simplifies
wiring and allows cost-effective network
integration. The two analog outputs
spare the effort of separately evaluating
upgrade of the mLg automation light grid
New features, new possibilities
SICK extends the portfolio of inductive
safety switches with the IN3000 Direct
product family. Featuring two cylindri-
cal versions, two OSSD safety capable
outputs and approval for performance
level d, the devices have what it takes
as ideal solutions for safe position
monitoring.
>> Inductive safety switches detect the
presence or absence of metal, thus
recognizing, whether the machine com-
ponents are in a safe position or have
already moved beyond it. In terms of
technology, they are right in line with cur-
rent developments, since due to their
non-contact principle, they are free from
wear and particularly in harsh environ-
ments require significantly less main-
tenance than electro-mechanical posi-
tion switches, for instance. However, the
IN3000 Direct series has even more to
offer than only a reliable function.
easy integration, fast response
The IN3000 Direct inductive safety
switches are available in small and ro-
bust M12 and M18 cylinder housings
with 4-pin M12 plug connectors. They
present the possibility of flush and non-
flush mounting positions and are suited
for operating distances up to 8 mm.
LEDs visualize the sensor status, allow-
ing quick functional diagnosis on loca-
tion. Their response time is even faster:
It is possible, in less than a millisecond,
to output direct signals to a safety con-
troller by means of the two OSSD switch-
ing outputs, thus stopping dangerous
machine movements.
Inductive safety switches: innovative series introduced
Cylindrical construction with a future
the measuring results. The 12-pin M12
connector provides many outputs for set-
ting up different measuring zones. In this
way, one can solve even complex appli-
cations without added special software.
universal pallet verification integrated
For height detection and checking for
projections in material handling and
warehousing systems, the MLG Upgrade
provides efficient software for pallet veri-
fication. It is suited for the most diverse
High end automation light grids | Non-contact safety switches
43
: Products
extremely rugged
The IN3000 Direct product family stands
out due to its high level of insensitivity to
shocks and vibrations. A factor contribut-
ing to the long service life of the sensors
is that they are easy to clean par-
ticularly important for use in areas with
heavy contamination or high hygienic
standards.
PL d and SIL2
All safety sensors of the product fam-
ily meet PL d in accordance the series
meet PL d in accordance with EN ISO
13849-1 and SIL2 in accordance with
IEC 61508 or, respectively, SILCL2 in
accordance with EN 62061. In this way,
the IN3000 Direct become an economi-
cally attractive solution wherever the risk
analysis does not stipulate the highest
safety categories.
Rugged, small in design and versatile in application, the new W8 Inox miniature
photoelectric sensors have their sights set particularly on applications in the
food, beverage, and pharmaceutical segments as well as in machine tools.
>> The W8 Inox is the logical complement
to the portfolio of stainless steel sensors
from SICK. The product family includes
through-beam and photoelectric retro-
reflective sensors, energetic photoelectric
sensors, as well as those featuring back-
ground suppression depending on the
application used for close or far ranges.
rugged sensors for harsh applications
The sensors of the W8 Inox product
family are very well prepared for clean-
ing processes, rinsing and disinfection
agents, as well as drilling water and
drilling oils that affect conventional sen-
sors adversely. The high-quality 1.4404
(316L) stainless-steel housing featuring
an IP 69K enclosure rating, the chemi-
cally and thermally resistant front screen
made of PPSU, as well as the operator
control mechanically very resistant due
to the PEEK high-performance plastic
withstand even the harshest loads dur-
ing production and cleaning.
Specialized in space-saving and simple
installation
The W8 Inox sensors permit space-
saving and simple installation: They are
compatible with the mounting system
Photoelectric sensors: Inox portfolio complemented
Strong in confined, harsh environment
types of pallets, is more precise and
easier to integrate than multiple photo-
electric sensors, and ensures fast com-
munication with plant control.
Protected against deflections
For tasks in vertical lift systems, which
due to their mechanical design bear the
risk of deflections, SICK has reduced the
aperture angle on the receiver by approx.
70 %. In this way, one can dependably
avoid false measurements and switching
signals, achieving a high level of avail-
ability.
new: detection of internal and
external contours
Detection of internal and external con-
tours was developed specifically for use
in paint installations. This approach
makes it possible to control the paint
installation or, respectively, align a paint-
ing robot in such a way that paint is ap-
plied only where paint is required. This
optimizes processing time and saves
paint consumption.
using a M3 thread that has been estab-
lished in the market and possess a min-
iature housing that is nearly identical to
that of the W8 Plastic. Even when space
is scarce on the machine, the option of
connection technology either as a 2-m
cable, an M8 plug or a 300-mm connect-
ing cable with an M12 plug guarantee
fast installation. The same applies to
commissioning: After just a few adjust-
ments, also depicted graphically in the
operating manual, the sensors are ready
for operation. Thanks to high-perfor-
mance LED technology, perfect detection
results are ensured during operation.
The W8 Inox product family for diverse
uses offers ruggedness and availability in
many applications.
Miniature photoelectric sensors
44
: Products
Along with the success of the Inspector product family in a broad
range of applications came calls from customers for versions for
special use.
>> What took shape as a result are
two new device versions as well as a
network-capable tool for monitoring mul-
tiple Inspectors for improved quality and
throughput.
Well-positioned to guide your applica-
tions
Position detection for counting, picking,
or aligning parts, as well as visual guid-
ance for robots, gripper and handling
devices, but also the positioning of auto-
mated guided vehicles or lifting gear on
aisle stackers using reference marks are
typical applications of the new Inspector
P30. The vision sensor features various
so-called locator tools, ensuring top
detection reliability with respect to both
objects that are taught in or that vary in
shape. Data regarding the position or ori-
entation are recorded highly accurately,
with output made possible via Ethernet
and direct digital outputs. This allows
machines to carry out rapid working pro-
cesses, e.g. when gripping and separate-
ly packaging sweets. Depending on the
operating environment, different optical,
filter, and lighting versions are available.
Powerful luminescent inspection
with 2D vision
The Inspector I40-LUT does not oper-
ate with visible light but with UV light
instead. Its task involves detecting lu-
minescent material so-called lumi-
nophores within a space of definable
size. Luminophores can be applied or
added economically during the process
of manufacturing goods, e.g. to adhe-
sives and paints in furniture production,
as a cutting mark on wood and textiles,
or as an invisible product marker used
to protect from product and brand name
piracy. During inspection by the Inspec-
tor I40-LUT, the light source of the vision
sensor utilizes UV emitted light to excite
the luminophores to illuminate, i.e. to
reflect light in the visible spectrum be-
tween approx. 420 nm and 750 nm. The
great advantage of the I40-LUT is the
fact that it can detect the marks within a
larger area and independent of position
Positioning, visual guidance, luminescence detection, and network
New versions of the
Inspector vision sensor
and orientation. On top of that, the vision
sensor is capable of evaluating both the
patterns and amount of luminophorous
marks, thus enabling it to provide addi-
tional information on the quality and type
of a test object. Integration to a PLC us-
ing EtherNet/IP as well as the option of
transmitting images continuously to an
external FTP server permit industry-com-
patible incorporation into the respective
production environment.
advanced monitoring of Inspectors
Inspector Viewer is the new accessory
that allows advanced monitoring of In-
spector vision sensors networked to-
gether. However, it does not end there:
In addition to live visualization, for in-
stance, when checking labels or logos,
the Inspector Viewer, operable by means
of a touch screen, also permits rapid ad-
justment or new teach-in of the devices
as well as cloning and transferring of
configurations effected previously. More-
over, the Inspector Viewer is capable of
carrying out statistical evaluation of test
result and trends. It is possible to con-
nect all variant types of the Inspector
product family. The Inspector Viewer may
also serve as an FTP server, continuously
saving the images transmitted by the In-
spector sensors. Network integration
takes place using Ethernet a USB in-
terface for reading out image data or
configurations is also available.
P30, I40-LUT, and Viewer the vision sen-
sor product family is growing along with
customers requirements and wishes .
What would you have an Inspector inves-
tigate for you?
P30, I40-LUT, and Viewer the new
Inspector versions
Vision sensors
45
: Products
Flexi Link, the new extension function of the Flexi Soft safety
controller from SICK, permits the interlinking of up to four Flexi
Soft stations thus making it the safe solution for complex
applications.
>> When modules become machines,
often their individual safety solutions
also have to be combined into a safe
whole. Flexi Link fulfills this function by
making it possible to configure, emulate,
manage, and diagnose up to four Flexi
Soft stations by means of a network. This
is achieved with the help of the Flexi Soft
Designer parameterization tool and
thus without any additional hardware
and the associated wiring expenses.
Safety configuration in accordance
with plant progress
Through the modular concept, Flexi Link
enables the machine builder to plan a
full development of the plant, to incor-
porate it completely in the safety appli-
cation, and yet put only individual parts
into operation. Plant components can
be both integrated into a combination
of machines following completion of the
configuration or uncoupled temporar-
ily, e.g. for maintenance purposes. This
approach allows planning projects in
advance while commissioning individual
machine components later or, respec-
tively, again after uncoupling without
renewed adjustment on location. In mod-
ular machine building, this makes com-
plete commissioning in case of a plant
extension redundant, permitting continu-
ous diagnosis of the integrated Flexi Link
system. The fast evaluation and preven-
tive error detection thus possible lead to
increases in productivity both for the ma-
chine manufacturer and for the end user.
Flexi Link is the innovative solution for
enabling machine components with Flexi
Soft controllers to exchange safety in-
formation. In this way, one achieves the
greatest possible flexibility, particularly
when it comes to complex projects. You
may find more information on Flexi Link
at www.sens-control.com
Ideal for flexible machine designs and interlinked facilities
Flexi Link: networking safety
controllers reliably
Safe control solutions
+
More information
on page 41
46
: Products
Screw in, connect, ready to go thats how simple level measure-
ment is using the MHF15 optical level switch from SICK. The sen-
sor is ideally suited for detecting water-based media in process
tanks, containers, and pipes.
>> The MHF15 is an optically scanning
level switch that stands out due to a sim-
ple, rugged, and solid sensor construc-
tion. Thanks to its stainless steel housing
featuring an IP 69K enclosure rating, the
sensors tip made of robust polysulfone,
and the high-quality workmanship, even
the most adverse conditions both inside
and outside of containers and pipes can-
not damage the sensor.
uniquely easy to install
Hardly any level switch is as easy to in-
stall and commission as the MHF15.
The sensor, the size of a thumb, even fits
into the most cramped installation set-
tings and with its G1/2" thread features
a common process connector. Once
screwed in, all thats left is connecting
the MHF15 electrically. Matching the
medium when commissioning is just as
unnecessary as repeated recalibrations
in long-term operation. This plug & play
Compact, corrosion-resistant, and cost-effective
Level detection, plug & play
Detecting inductively, evaluating analogously in many processes,
one requires precisely this combination. The response from SICK
is called IMA. The new product family of inductive analog sensors
is convincing due to extremely high detection ranges and precise
position detection.
When intermediate positions are of interest as well
Inductive plus analog
>> Whether in tensile stress monitoring
of films and paper, continuous polling of
linear movements, absolute angles or
distance detection, or in gap and thick-
ness measurement in many automa-
tion processes binary data often do not
suffice. In this context, the IMA product
family from SICK provides custom-made
sensor solutions for analog detection in
your application.
High sensor-based
performance potential
Detection ranges between 4 mm and
40 mm without blind-zone area, resolu-
tions in some cases of less than 1 m,
high repeat accuracies between 0.3 mm
and 0.6 mm at minimum temperature
drift the sensors of the IMA product
Level sensors
47
: Products
design ensures minimum costs for inte-
gration, operation, and maintenance.
Better optically: level detection,
dry-running and pump protection
Simple, compact, and rugged, the
MHF15 is the ideal sensor for maximum-
minimum monitoring in tanks and con-
tainers and dry-running as well as pump
protection in pipes. The level switch can
be used at process temperature of up
to +55 C and process pressures up to
16 bar (1,600 kPa). Easy handling and
great cost benefits make the MHF15 a
convincing alternative to mechanical
level sensors such as electrodes, float
switches, or vibration switches.
Optimum because optical: level detec-
tion with the MHF15.
family combine large detection ranges
and extremely small tolerances. In this
way, it is possible to detect reliably even
longer paths without any added mechan-
ical components. Furthermore, the IMA
devices require significantly less space
than conventional analog sensors while
offering identical operating distances.
Construction sizes for any sequence of
movement desired
Six construction sizes are available for
different tasks and sequences of move-
ment: M8 and M12 with an analog volt-
age signal from 0 to 10 V as well as two
M18 and M30 versions, each with an ad-
ditional power output from 4 to 20 mA.
With their output signal proportional to
distance, the IMA product family offers
the possibility of solving the most diverse
automation tasks both in a precise and
economically reasonable way.
Inductive sensors for any machine design
Flat, compact, and rugged
When things become cramped inside a machine, they come into
play: the IQ Flat inductive sensors from SICK. Flat in design, they
are convincing because of simple installation, rugged construc-
tion, and increased operating ranges.
Inductive proximity sensors
>> The IQ Flat product family consists
of four sensor variants overall, featuring
construction heights between 4 mm and
10 mm. IQ04 and IQ06 in a plastic hous-
ing have operating ranges of 1.5 mm
and 3 mm, respectively, and they can be
mounted using only one bolt. For both of
them, readjustment is just as unneces-
sary as in the case of the IQ20 and the
IQ25. The latter are particularly rugged
due to their metal housing and suitable
for operating ranges of 7 mm and 5 mm,
respectively.
Easy to mount and reliable above all,
however, being flat and compact the
sensors of the IQ Flat product family are
suited for extremely space-critical tasks.
Checking for presence in handling sys-
tems that are becoming increasingly
more cramped is just as much part of the
job as positioning of component carriers
in electronics production or detection of
workpieces in presses and molds.
48
: Products
Motor feedback systems
Fewer costs, reduced space requirements, more security of in-
vestments and machine safety the EKS36 and EKM36 motor
feedback systems from SICK with HIPERFACE DSL
(digital servo
link) open up new possibilities for the architecture of servo drive
systems.
>> In the future, it will be possible by
means of the HIPERFACE DSL
protocol,
purely digital for the first time, to realize en-
coder communication using only two wires
integrated into the motor cable. This offers
a series of benefits.
HIPerFaCe DSL
heres whats
behind it
HIPERFACE
is an asynchronous half-
duplex interface that has become estab-
lished in the market for many years as a
standard, used today by more than 70
drive manufacturers. Their servo drive sys-
tems consist of two separate components,
the controller, and the motor. Until now,
two separate connection cables for energy
supply and data transmission connected
them to each other. Integrating both cables
and thus being able to do without one of
the two M23 connection plugs each was a
wish expressed frequently by many manu-
facturers of motors and controllers.
Now this wish comes true with
HIPERFACE DSL
. The interface permits

interference-free data transmission be-
tween controller and motor via two lines
integrated directly into the motor cable.
Data communication is modulated onto
the supply voltage. Special methods and
the use of pulse transformers make sure
that the encoder signal is decoupled
from interference on the motor output
cable, allowing transmission for up to
100 m.
Cost-effective, safe for machines, and
future-proof
The data transmission, certified in terms
of safety technology in accordance with
SIL3 (IEC 61508) or performance level
e (EN ISO 13849-1), saves the separate
motor feedback cable and one M23 con-
nection plug each on the motor as well as
the controller. This cuts connection costs
but also warehousing expenses for motor
manufacturers and machine builders in
half, also reducing the space necessary
on the motor and the controller. Finally,
as a market-oriented solution, HIPERFACE
DSL
offers high security of investment for

electric drive technology especially as
the construction of the EKS36 and EKM36
motor feedback systems features the
36-mm housing diameter customary in
the market thus requiring no mechanical
modifications.
electric drive technology: motor feedback purely digital
New drive architectures by means of
HIPERFACE DSL
digital interface
49
: Products
An evolution in size, coupled with a revolution of application opti-
mization and flexibility thats the new compact safety laser scan-
ners of the S300 Mini product family from SICK.
>> The construction height of only 116
mm makes the S300 Mini the worlds
most compact safety laser scanner of
its kind. The space miracle in yellow
allows installation with minimum space
required, while at the same time it is
designed so flexibly as to meet the de-
mands of the most diverse operating
conditions and user wishes. Moreover,
obviously the S300 Mini series fulfills not
only the technical safety requirements
of performance level d in accordance
with EN ISO 13849 as well as SIL2 in
accordance with IEC 61508, but also
the demands on opto-electronic safety
equipment in accordance with Type 3 of
IEC 61496.
Safety in pure form: the S300 mini
Standard
SICK designed the S300 Mini Standard
as a basic technical solution. The range
of the 270 protective field is 2 m, with-
in which one can program a triple field
set with one protective and two warning
zones. The device features one pair of
OSSDs (output signal switchting device)
serving as a direct switching output.
Safety in pure form as provided by the
S300 Mini is required in numerous sim-
ple tasks when economic efficiency mat-
ters, for instance, using the S300 Mini
Standard as a wear-free replacement of
tactile pressure sensitive mats, and as a
safety sensor for protecting simple AGVs.
Safety deluxe: S300 mini remote
When there is minimal installation
space, combined with the requirements
of complex safety applications, the S300
Mini Remote safety laser scanner is the
appropriate solution. By using this de-
vice, one can realize up to 16 triple field
sets ideal e.g. for AGV applications but
also for automated forklift trucks or rail-
mounted transverse distribution cars.
On top of that, by means of the latest
generation of the EFI (enhanced function
interface), and by using the Flexi Soft
safety controller from SICK, it is possible
to combine up to four electro-sensitive
protective devices, e.g. two S3000 Ex-
perts and two S300 Mini Remotes, into a
network. By doing so, one can easily im-
plement even complex protective tasks.
Whether in area protection on sta-
tionary machines or in detecting obsta-
cles in the case of autonomous vehicles
in both instances, the S300 Mini de-
livers convincing performance due to its
high level of flexibility, ease of integra-
tion, and reliability.
Safety laser scanner in miniature design
Small but select
>> S3000 expert
The new S3000 Expert checkmates safety gaps. Featuring 64 fields, up to 32
monitoring cases, and an extremely long protective field range of 7.0 m, the device
is a very flexible and thus perfect high-end solution for countless applications in
intralogistics, in warehouses and shipping companies, as well as for loading and
shipping areas involving heavy-duty vehicles. In combination with Flexi Soft safety
controllers from SICK, one can also configure an efficient system of scanners.
www.sick.com/S300mini
Safety laser scanners
50
: Products
User-friendly, reasonably priced, and precise that is how the new
WFS fork sensor from SICK presents itself. The slender construc-
tion, simple setting, and short response times allow top perfor-
mance detecting the most diverse labels.
>> By introducing the WFS, SICK com-
pletes the portfolio of fork sensors with
a product that is designed specifically for
detecting non-transparent labels on di-
verse carrier materials as well as for dou-
ble sheet detection. The WFS achieves
special process accuracy by its position-
ing directly on the dispenser edge of a
label feeding mechanism and due to the
short response time of only 50 s.
extremely easy to integrate
The WFS fork depth of 42 mm, fork
width of 3 mm delivers convincing
performance due to reliable detection
even in the case of min l signal differ-
ences between the label and the carrier
material and because of easy integration
and operation. The slender fork shape
permits optimum process and space-
related mounting solutions if required
using a special mounting rod. Commis-
sioning is fast and simple, as setting
occurs by means of dynamic and static
teach-in either using two push buttons
on the device that can also be used for
fine-tuning, or via the control line. Dur-
ing this external teach-in, one can adjust
the taught-in switching threshold accord-
ing to need, guaranteeing reliable label
detection at any time. Special feature:
the switching output is active even dur-
ing the teach-in process, ensuring not a
single label is missed.
The WFS is the reliable and economi-
cal solution when it comes to detecting
the most diverse labels dependably and
accurately even at high speed but with
minimal adjustment expense.
new fork sensor: lithe and lissome and more
Label detection
made easy
Fork sensors
51
: Products
Precise, easy to operate, and fast the redesigned WL12G-3
small photoelectric sensor sets the new standard for detecting
transparent objects such as glass, PET bottles, and films.
>> By reliably detecting transparent ob-
jects ranging from thin-walled PET bot-
tles to highly transparent film the old
W12G from SICK has already set the
best-in-glass standard for detecting
transparent materials. The redesigned
WL12G-3 small photoelectric sensor re-
mains true to this benchmark.
robust and compatible in terms of
connections
On the outside, the new WL12G-3 relies
on tried and tested virtues. The metal
housing as well as the connection tech-
nology are identical to the W12-3 prod-
uct family. For numerous customers, this
mechanical and electrical compatibility
facilitates switching to the new photo-
electric sensor for glass detection.
ease of operation is of high
importance
Commissioning of a WL12G-3 is fast and
simple: align the WL12G-3 to the reflec-
tor, push the button, finished! setting
sensitivity by means of teach-in saves
time. For optimum adjustment to appli-
cation conditions, one can choose two
operating modes via teach-in. The 360
status LEDs, visible from all sides, guar-
antee fast polling of the sensor status
and thus facilitated, more effective sen-
sor diagnosis.
Device availability in adverse, extreme
operating conditions!
Whether faced with damp settings or
splash water, ambient light, or strong
electromagnetic fields the WL12G-3s
are very reliable and extensively inde-
pendent of influences from the envi-
ronment. The switching frequency was
increased to 1.5 kHz ideal for high ma-
chine speeds. The rugged housing with
an optional Teflon coating provides the
stability that guarantees sensor avail-
ability in an industrial setting and en-
sures uninterrupted production.
Seeing the application through the
eyes of the sensor
The WL12G-3 is available optionally
as an I/O variant. Integration of the
WL12G-3 at the sensor/actuator level
into automation systems allows the re-
alization of preventive maintenance and
repair measures.
WL12G-3 crystal-clearly the best
solution for reliable detection, counting,
and sorting out of transparent objects.
The photoelectric sensor for transparent materials
Detecting a hint of nothingness
reliably
Small photoelectric sensors
52
: Products
>> The S700 extractive gas analyzer
belongs to the most successful pro-
ducts of SICKs process automation. The
successful series has been completely
revised and enlarged. The successor
GMS800 uses the measuring principles
NDIR, thermal conductibility, O
2
mea-
surement as well as UV resonance ab-
sorption spectrometry (UVRAS) and non
dispersive UV photometry (NDUV) in a
flexible way. With currently six analyzer
modules, one gas module, I/O modules
and different housing types, the low-
maintenance system can cover a huge
range of extractive measurement tasks
and situations. Thanks to the very latest
in software, the GMS800 offers now all
necessary interfaces to allow the con-
nection with a process control system or
a remote control. The use of the device in
facilities subject to approval is no prob-
lem thanks to the qualification test ac-
cording to EN 15267-3.
The GMS800 can measure individu-
ally over 60 gas components in the pro-
cess gases of chemical and petrochemi-
cal plants. It can detect for example the
concentration of hydrogen sulfide (H
2
S) in
reactive or sour gases. By monitoring CO
the system can be set to allow the early
detection of fire in coal mills and silos and
monitors the danger of explosion by stack
gas in furnaces or coke ovens. In the hy-
drogen production the GMS800 records
even the smallest concentrations of CO
in H
2
.
The new all-rounder is suitable for
the monitoring of lowest toxics in power,
cement and waste incineration plants as
well as in the pulp and paper industry.
With the UV analyzer DEFOR, the GMS800
is ideal for gas turbines, in power plants,
DeNO
x
plants or desulfurization plants
to measure the smallest concentrations
of SO
2
, NO and NO
2
. NO
x
is controlled by
measuring NO and NO
2
directly and by
adding it up to NO
x
in the analyzing de-
vice. This way CLD analyzers or NO
2
con-
verters become unnecessary.
Gas analyzers
With the successor GMS800, SICK has notably enlarged the field
of application of the approved extractive all-rounder S700 in the
area of gas analysis. Part of the new product family is, for example,
the multifunctional DEFOR photometer module for measurements
in the UV range. With this product even the smallest concentra-
tions of NO, NO
2
and SO
2
, for example in the exhaust of gas tur-
bines can be detected. The very latest in evaluation electronics
and the Ethernet connection for data transfer and remote control
make the GMS800 even more interesting for equipment and sys-
tem manufacturers.
the new gas analyzer system gmS800
performs even better than its predecessor
One for all
53
: Service & Support
Further information:
www.sick.com/safety/en
The highest quality standards, consistent and documentable
procedures, as well as independent evaluation are what distin-
guishes the accredited safety services SICK offers, among other
things, for fulfilling the requirements of the German Ordinance on
Industrial Safety and Health (German: Betriebssicherheitsverord-
nung BetrSichV).
>> The experts trained eyes miss neither
safety deficits nor potential improvements
related to processes and efficiency.
machinery Directive (mD) and
BetrSichV constitute the basis
The item relevant above all for manu-
facturers is the EU Directive on Machin-
ery. It describes abstract requirements
concerning the safety of machinery
and plants that are defined clearly by
EN standards: However, operators, too,
must pay attention to the MD. First, in
the case of essential changes to exist-
ing machines and plants, they become
themselves manufacturers as defined
by the Machinery Directive, i.e. they
must take care of the entire process of
CE marking. Secondly, operators cannot
plead that by using machines conform-
ing to CE, they were released from their
responsibility by the manufacturer, for
they must ascertain or, respectively, have
someone ascertain that the equipment
used in their operation is in good order
from a safety perspective. The founda-
tion of this is the Ordinance on Industrial
Safety and Health (BetrSichV). Suitable
protective measures and checks are
essential basic elements of the safety
concept set down in the BetrSichV. The
measures called for in particular include
checks prior to commissioning as well
as recurring checks of safety features
on machines. In this context, the regula-
tions specify that only persons qualified
to do so can carry out these inspections.
SICK: accredited safety and
decades of experience
SICK is accredited by the DAkkS, the Ger-
man Accreditation Body, as an inspection
center in accordance with IEC or, respec-
tively, EN ISO 17020 and thus capable of
carrying out technical safety inspections
and approvals if new, redesigned, and
modernized machines and plants and
of certifying this with SICKs own inspec-
tion seal. More than 100 trained safety
experts worldwide are endowed with
wide-ranging application knowledge and
due to the expertise derived from more
than 15,000 safety inspections annually,
they are well versed in the application of
the relevant directives and standards. As
persons at home in the field, they have
command of the skills needed for ma-
chine design that conforms to directives
and standards, and the expert knowl-
edge required for their operation.
Particularly interesting for
operators: plant walk-through
With a view to the requirements of the
BetrSichV, the so-called plant walk-
through for operators is particularly valu-
able. Developed by SICK, this procedure
provides a simple and quick assessment
of the current safety status of machines
and facilities operating in production.
The safety experts from SICK identify the
most important safety aspects on all of
the machines and facilities within a pro-
duction plant, subsequently prioritizing
them according to risk potential and for-
mulating recommendations for effective
safety strategies. Using this planning in-
strument, which in addition can be used
for cooperation with the supervisory au-
thorities, allows improving machine safe-
ty specifically as well as preventing risks
of injury for employees and liability risks
for those responsible in the company.
Whether manufacturer or operator,
whether EU Machinery Directive or the
BetrSichV with the portfolio of safety
products and services, SICK manages to
reconcile the demands by customers for
productivity with the safety of personnel
and machines.
Safety inspections
With accreditation
and a trained eye
Safety inspections
54
: SICK tour
A quality brand: SICK Sensor Intelligence.
Since 2002, SICK STEGMANN GmbH (Inc.) has been part of SICKs Group of
Companies, completing with innovative products SICKs range of services. So
far, the encoders and motor feedback systems had been marketed success-
fully under the SICK-STEGMANN brand name.
35 years of SICK USA
founded 24 March 1976
20 years of SICK Singapore
founded 28 June 1991
20 years of SICK Finland
founded 16 October 1991
>> More than 100 invited guests from
Germany and abroad took in a program
of events featuring many cultural high-
lights. The guests were welcomed on
Brhls Terrace, where they enjoyed
Twenty years ago, SICK Engineering
GmbH in Ottendorf-Okrilla near Dres-
den was founded. A good reason for
celebrating in style the anniversary
of the subsidiary that specializes
in flow measurement and emission
monitoring.
>> In the future, the consistent mar-
ket presence under the SICK umbrella
brand will emphasize the affiliation of
SICK STEGMANN GmbH with the SICK
Group even more clearly. Along with this
adjustment of the brand name, the prod-
ucts of SICK STEGMANN GmbH will also
integrate completely into SICKs portfolio
in terms of appearance. This ensures
conveying a homogenous appearance of
a strong and innovative corporate group,
particularly from a sales perspective.
The legal designation of SICK STEG-
MANN GmbH is unaffected by this. All of
the product approvals and certificates re-
main in effect.
>> As of 1 December 2010, SICK AG
has been present in South Africa with
its own subsidiary. SICK Automation
Southern Africa (Pty) Ltd. in Roodepoort
near Johannesburg offers clients the en-
tire range of sensors, system technology,
industry expertise, and services of the
SICK Group.
SICK founds subsid-
iary in South Africa
the grand view of the Elbe River at night
over a glass of mulled wine. During the
subsequent welcome dinner at the Hil-
ton in Dresden, they all had a chance
to get to know each other in a friendly
get-together and raise a glass to the
anniversary. The evening was set aside
for the highlight of the festivities: The
historic building ensemble of Deutsche
Werksttten Hellerau in Dresden pro-
vided the atmospheric setting for an
evening event to which management
of SICK Engineering GmbH warmly wel-
comed all employees and guests.
Subsidiaries
celebrate!
The high growth rates in the processing
industry as well as steady growth of the
South African economy overall make the
country an interesting market for the
high-quality products from SICK. The de-
cision to cooperate with M&M Systems
Automation one of SICKs distributors
to date in forming the joint venture of
SICK Automation Southern Africa, was
therefore both logical and forward-look-
ing. The newly founded company aims at
developing the market on a broad basis
by utilizing expertise, application knowl-
edge, and services.
SICK is present in South Africa as well
Birthday party in Dresden
SICK Engineering GmbH
celebrates 20
th
anniversary
55
: SICK tour
>> On the initiative of SICK and with
active help from Industrial Safety Sys-
tems, an information day took place
on 4 November at the VDMA (Associa-
tion of German Mechanical Engineer-
ing Institutes) in Frankfurt dealing with
Safety Documentation. The highly topi-
cal issue drew 135 interested design-
ers from different segments of machine
building to Frankfurt. The focus was on
the essential planning steps as well as
obligations for documentation for the CE
marking of a machine. With the help of
the safetyPLUS trade fair machine from
SICK, participants actively discussed the
steps from risk assessment to preparing
a safety concept and all the way to the
concluding evaluation of conformity. In
the exhibition accompanying the subject,
the experts had a chance to check out
for themselves SICKs range of services
starting with product solutions all the
way to safety services. The unanimous
tenor of the event was: successful overall
concept with interesting specialist contri-
butions and entertaining presentation.
Acting as host of the Annual General Meeting of PEMA (Port Equipment Manu-
facturers Association), in February SICK invited international port equipment
manufacturers to the Customer Center of SICK AG in Waldkirch. Recent years
saw the establishment of three new committees for safety, technology, and en-
vironment in the port industry. In the context of the meeting, these committees
addressed topics such as Safety standards and guidelines on quay cranes.
>> Efficient sensor solutions for the pro-
duction of semiconductors, printed circuit
boards, solar modules, and thin-film solar
cells are the themes on which the latest
SICK Industry Guide informs. Featuring
numerous application examples and prod-
uct recommendations, it gives an excellent
technical overview of automation options
in the area of electronics and the solar in-
dustry. Now available in English.
A copy can be ordered at:
Kundenservice@sick.de
or as a download at www.sick.com
neW: Industry guide
Electronics and
Solar Industry
>> Since the end of February 2010, SICK
has been a member of PEMA, which in-
cludes not only system integrators but
also consultants for the port industry. As
a result, SICK was able to welcome in-
ternational companies like Konecranes,
Cargotec, Terex, Baltkran, Hans Knz,
Cavotec, Conductix Wampfler, Vahle, TTS
Port Equipment, Identec Solutions, APS
Technology, AME, ABB, Siemens, TMEIC
GE, RAM, Bromma, Stinis, and others
to Waldkirch. Among the participants
was also the ICHCA (International Cargo
Handling Coordination Association) as
well as additional guest speakers deal-
ing with environmental and safety topics.
Overall, the event proved a resounding
success it turned out to be almost a
family get-together of port equipment
manufacturers, integrators, and consul-
tants, all of whom were networked very
well with each other.
SICK hosted PEMA
VDma Information Day
Safety Documentation featuring safetyPLUS
machine
No one making it to Fort Myers, Florida, on business or plea-
sure, should miss a visit to Edison & Ford Winter Estates .
After all, this place witnessed the writing of a chapter in the
history of automobile development.
Automobile development
under bamboos and palms
When geniuses vacation together
>> Thomas Alva Edison has earned
world fame with his more than 2,000
inventions and over 1,100 patents. The
items sprung from his brainwaves and
research work include, among others,
the toaster, the record player, the movie
camera, the further development of the
light bulb, and the telephone. To take
a break from his labors, in 1885 Edi-
son bought a property on the Caloosa-
hatchee River in Fort Myers. The decisive
criterion in this was bamboo growing on
the land. Edison then examined the fi-
bers as part of his recreational activities
for suitability as conducting filaments for
light bulbs.
Edison was not only an inventor but
also managed his own large-sized enter-
prises, such as the Edison Illuminating
Company. One of his most famous em-
ployees was Henry Ford, who started up
his own business, however, based on his
hobby, automobile engineering. Close
business cooperation between the two
men resulted in an equally close friend-
ship, causing Henry Ford to purchase
his own villa in 1916 next to Edisons
Seminole Lodge, called The Mangoes,
named after the countless mango trees
on the property. Thus, they were able to
join forces even during their holidays to
pursue ideas regarding automotive de-
velopment. Henry Ford and his vehicles
were not the only ones benefiting from
Edisons thirst for action; so did a certain
Harvey Firestone. In the 1920s of the
20th century, the two brought hundreds
of rubber trees from all corners of the
world to Fort Myers in order to conduct
research into a source for natural rub-
ber that could be cultivated and used in
America. Together with Henry Ford, they
founded the Edison Botanic Research
Company in 1928. Today, the first tree
a Ficus benghalenis, which Firestone
gave to Edison in 1925 as a four-foot
seedling, is reportedly the second larg-
est specimen worldwide.
At the Edison & Ford Winter Estates in
Florida, one finds a series of innovations
from the past
: SICKinsight
[plus]
01 2011
56
Homes, gardens, laboratory, museum
when visiting the Edison & Ford Winter
Estates, one is surrounded by the aura
of a special place. Southern mansions,
hundreds of trees serving not just for
relaxation but also for research, a park
with one of the first swimming pools in
the United States, a landing stage and
benches with magnificent views over-
looking the Caloosahatchee and a
plethora of exhibits from Edison and also
a few vehicles from Ford, e.g. the famous
Model T as a pickup and as a camper.
Worth a visit
www.edisonfordwinterestates.org
S
u
b
s
i
d
i
a
r
i
e
s
australia Phone +61 3 9497 4100
+1800 3 3480 2 tollfree
sales@sick.com.au
austria Phone +43 22 36 62 28 8-0
office@sick.at
Belgium/Luxembourg
Phone +32 2 466 55 66
info@sick.be
Brazil Phone +55 11 3215 4900
sac@sick.com.br
China Phone +852 2763 6966
ghk@sick.com.hk
Czech republic Phone +420 2 57 91 18 50
sick@sick.cz
Denmark Phone +45 45 82 64 00
sick@sick.dk
Finland Phone +358 9-25 15 800
sick@sick.fi
France Phone +33 1 64 62 35 00
info@sick.fr
germany Phone +49 211 5301-301
kundenservice@sick.de
great Britain Phone +44 17 27-83 11 21
info@sick.co.uk
Hungary Phone +361 371 26 80
office@sick.hu
India Phone +91 22 4033 8333
info@sick-india.com
Israel Phone +972 4 999 0590
info@sick-sensors.com
Italy Phone +39 02 27 43 41
info@sick.it
Japan Phone +81 3 3358 1341
support@sick.jp
netherlands Phone +31 30 229 25 44
info@sick.nl
norway Phone +47 67 81 50 00
austefjord@sick.no
Poland Phone +48 22 837 40 50
info@sick.pl
republic of Korea
Phone +82 2 786 6321/4
info@sickkorea.net
romania Phone +40 356 171 120
office@sick.ro
russia Phone +7 495 775 05 30
info@sick.ru
Singapore Phone +65 6744 3732
admin@sicksgp.com.sg
Slovenia Phone +386 (0)1-47 69 990
office@sick.si
South africa Phone +27 11 472 3737
info@sickautomation.co.za
Spain Phone +34 93 480 31 00
info@sick.es
Sweden Phone +46 8 680 64 50
info@sick.se
Switzerland Phone +41 41 619 29 39
contact@sick.ch
taiwan Phone +886 2 2375 6288
sales@sick.com.tw
turkey Phone +90 216 528 50 00
info@sick.com.tr
united arab emirates
Phone +971 4 8865 878
info@sick.ae
uSa Phone +1 (952) 941 6780
info@sickusa.com
More at www.sick.com
>> Imprint
: Info Trade fairs Imprint Contacts
>> Visit SICK at the trade Fair!
trade fair dates germany
Trade fair Location Date 2011
Cemat Hanover 05/02 05/06
Control Stuttgart 05/03 05/06
interpack Dsseldorf 05/12 05/18
Sonepar-Partnertreff nord-ost Hanover 05/14 05/15
PVSeC Hamburg 09/05 09/09
PoSt-eXPo Stuttgart 09/27 09/29
moteK Stuttgart 10/10 10/13
inter airport Munich 10/11 10/14
Fakuma Friedrichshafen 10/18 10/22
VISIon Stuttgart 11/08 11/10
FmB zuliefermesse maschinenbau Bad Salzuflen 11/09 11/11
Productronica Munich 11/15 11/18
SPS/IPC/DrIVeS Nuremberg 11/22 11/24
trade fair dates europe
Indumation Brussels, BE 05/18 05/20
SPS/IPC/DrIVeS Italia Parma, IT 05/24 05/26
Vision & robotics Veldhofen, NL 05/25 05/26
swisst.fair Zurich, CH 06/16 06/17
Verpackung & Logistik austria Vienna, AT 09/21 09/22
PPma show Birmingham, UK 09/27 09/29
trade fair dates worldwide
national Postal Forum San Diego, US 05/01 05/04
CaneCt 2011 Toronto, CA 05/16 05/18
rosupak 2011 Moskow, RU 06/14 06/18
Cemat asia 2011 Shanghai, CN 10/24 10/27
Industrial automation Show 2011 Shanghai, CN 11/01 11/05
Further trade fair dates with SICK worldwide at www.sick.com/fairs
Publisher: SICK AG Postfach 310 79177 Waldkirch Germany www.sick.com
Phone +49 7681 202-0 Fax +49 7681 202-38 63 info@sick.de
Project management: Stephanie Rott Stephanie.Rott@sick.de
Specialist editors: TOP MEDIA Dirk S. Heyden 69469 Weinheim info@topmedia-weinheim.de
pr-bro hensel Roland Hensel 90571 Schwaig pr-hensel@t-online.de
Layout: ad:johnson Kommunikation 76133 Karlsruhe info@adjohnson.de
translator: Dr. Erwin D. Fink 79106 Freiburg info@transmedia-translations.com
Printing: Druckerei Furtwngler 77211 Denzlingen info@druckerei-furtwaengler.de
Pictures: SICK AG, www.ausloeser-fotodesign.de, fotolia, iStock
Individual contributions may be reproduced after prior consent. Please contact us at:
Phone +49 7681 202-3878 Errors excepted Subject to technical change
SICK AG Erwin-Sick-Str. 1
79183 Waldkirch Germany
Phone +49 7681 202-0
Fax +49 7681 202-38 63
info@sick.de www.sick.com
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SICK AG | Waldkirch | Germany | www.sick.com
Reliable documentation, modern packaging
Everything is in motion both in complex packaging lines, as in downstream processes.
SICK offers 2D code readers, RFID reading devices, and 2D & 3D camera sensors and
camera systems for sorting, documentation and product tracing during material fow.
They detect the important detailed information, so that products and packaging are
reliably identifed and distributed into the modern goods economy.
Proftable logistical chains
through tracing
Seeing details, understanding the big picture
11283_Branchen-AZ_Verpackung_210x279-4_wf.indd 1 04.03.11 11:06
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> Identifying

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