02 2006 www.sick.com

Volkswagen Brussels New logic module for new logistics centre

Page 13

Direct or indirect? 2-D reading technology and direct part marking

Page 29

Controller‘s darlingAutomatic format adjustment via PROFIBUS-DP Hub

Page 34

S I C K ’ S C U S T O M E R M A G A Z I N E

320 %

safetyPLUS: safety and added value in one packagePage 30

Better safe than sorryBetter safe than sorry

: Editorial

insighttelegram++ SICK celebrates its 60th jubilee – the town of Waldkirch renamed Sebastian-Kneipp-Strasse as Erwin-Sick-Strasse in memory of the company’s founder, Dr. Erwin Sick – Anne-Kathrin Deutrich, Spokesperson of the Executive Board, went into retirement during the festivities ++ The new exhibit concept with touchscreens, which provide all-round information on products and their

varied application, was very well received at the Hanover Industrial Trade Fair (HMI) – the concept has been modified and expanded for SPS/IPC/Drives ++ SICK optimises delivery accuracy – targeted control of all internal processes for rapid product availability: the right goods, quality and quantity at the right time and at the right place – for measurable dependability. ++

Networking competences, offer-ing added value – worldwide

Dear Reader

We would like to introduce ourselves to you in this new issue of the SICK insight customer magazine. Since 1 July 2006 we have been responsible in the Executive Board of SICK AG for the areas of Factory Automation and for Finances, Personnel and IT. This transition has loomed large in recent months because the Spokesperson of the Executive Board for many years, Anne-Kathrin Deutrich, went into well-earned retirement on 30 September 2006.

The last quarter also gave us an opportunity to get to know the company SICK, meanwhile celebrating 60 years’ existence, from your point of view, the view of our worldwide customers and business partners. As a result, we have realised how important it is for you to obtain intelligent and complete sensor and control solutions from a single source. Which is why we intend to continue providing added value by concentrating more on OEM and end-customer advantages, and the networking of technical core competences with an international presence, as SICK already does – uniquely – in many cases, e.g. with the safetyPluS safety concept (please see Page 30).

Check it out for yourself: many of the applications presented in this issue of SICK insight show what we mean by solutions, and what added value customers re-ceive as a result. We would like to thank our customers for their support and col-laboration. At the same time, we would also like to persuade new users to report on their SICK sensor and control solutions in one of the future issues – please contact us.

But first, have a good read. With best wishes from Waldkirch

2/2006 03

Markus Vatter, Executive Board Responsible for Finances, Personnel, IT

Markus Paschmann, Executive Board Responsible for Factory Automation

: Contents 2/2006

04

Three dimensional measurement of channel systems

17

safetyPLUS: safety solutions throughout the entire machine life cycle

30

The world’s fastest camera system for contour measurement

36

In conversation with Anne-Kathrin Deutrich – looking back, and to the future

46

: TIT

lE T

OP

IC

: safetyPLUS .................... 30

: ProductsProduct News ...................................... 32Automatic format adjustment via the PROFIBuS-DP Hub .................. 34Magnetic cylinder sensors with two switching points ................... 35World’s fastest camera for 3-D measurement ............................... 36Evolution of multiple lightbeam safety devices .................... 37ASIC technology provides increased performance ...................... 38MM12 – greater functional and reliability reserves ............................... 38Mobile identification of DPM codes ... 39Masterly motor feedback solution ..... 40Magnetic positioning system .............. 41laser photoelectric switch with small optics and great intelligence ............... 41Wire-draw encoder now with HIPERFACE® interface ......................... 42High-end reading system for bar codes and data matrix ........... 43Maximum switching accuracy through 2-D magnetic field evaluation ............ 44

: Museum The Granville Museums in Vancouver offer miniature Technology ................ 45

: InterviewIn conversation with Anne-Kathrin Deutrich, Spokesperson of the Executive Board of SICK ..................... 46

: SICK TourSafety technology for Stankin’s training centre ..................................... 48Training & Education 2007 ................ 48SICK celebrates its 60th birthday ...... 49SICK supports Manchester Metropolitan university ....................... 49

SICK Poland receives Gold Medal ....... 49

: Book Corner The Travels of a T-Shirt in the Global Economy by Pietra Rivoli ......... 50

: Info Imprint/Service ................................... 51Trade fair dates ................................... 51

: Editorial ...............................03

: SICK Complete “unbreakable” position determination for 12-tonners ..................................... 06

Blue is “in” at BONITA ......................... 07

Bar-code readers at WMF ................... 08

: Applications μ-precise inspection of weld seams .. 09

Protecting rotary stations and lifts ..... 10

Fully automatic format adjustment for the world’s first metal laminating plant 11

Through lausanne by laser measurement ........................ 12

New logic module at new logistics Centre for Volkswagen Brussels ........ 13

A dazzling solution .............................. 14

Collision prevention at Volvo .............. 15

Checking type and installation of ventilator drives .............................. 15

Safety sensors at BMW ...................... 16

Three-dimensional measurement of shaft caverns .......... 17

ClV490 bar-code scanners at VIKING 18

Multifunctional interfaces with multiple opportunities ......................... 19

Tunnel contour measurement with the DMT10 ................................... 19

ImageTeam hand-held scanners at Bell .................................... 20

Compact photoelectric proximity switches for better window frames .... 20

Zero-pulse assignment at the press of a button ...................... 21

Safe production at John Deere in Brazil ............................ 22

Industrial chains inspected by 2-D smart camera .......................... 23

More safety for heavy traffic .............. 24

Robot guidance for meat processing 25

Intelligently organised safety ..............25

laser measurement technology for coal heaps ................... 26

Training in a safe and ergonomic environment ...................... 27

: Know-how Automation with laser photoelectric switches ........................ 28

Safe sensors and controllers ............. 28

2-D reading technology and direct part marking ...................... 29

insightBook Corner

Visit us at the SPS/IPC/DRIVES trade fair SPS/IPC/DRIVES 2006 in Nuremberg from 28–30 November 2006 Stand 7A-310 – Hall 7A www.mesago.de/sps Take the opportunity at SPS –

safetyPluS – the PluS in information for you:p Experts answer your questions on the new standards, applications, etc. at our

stand. Arrange an appointment now.p Practical focus: companies present their safety applications at the VDMA stand

(Hall 6 - 236). Wed. 12.00, Thur. 11.00Further information at: www.sick-safetyplus.com

: News

>> SICK has supplemented its series of compact, light and low-current safety la-ser scanners with the S200. Tasks that require Category 2 protection in com-pliance with EN 954 can now be imple-mented even more economically.

Safety laser scanner for horizontal and vertical use

Now also for Category 2!With a 270° scanning angle and a pro-tective field radius of 1.5 m, the latest addition to the new generation of scan-ners covers a protective area of over 5 m2. Numerous integrated functions and a 7-segment indicator for rapid commissioning, diagnosis and mainte-nance are the most important features of the new S200. Object resolutions of 70, 50, 40 or 30 mm are available, pro-viding reliable leg, arm or hand detec-tion. Whether for horizontal or vertical protection of hazardous points-of-op-eration and areas, vehicle approach protection, or monitoring distance – the S200 is the right solution for nu-merous stationary or mobile tasks in which cost-effectiveness and Category 2 safety are required.

05

Pietra Rivoli

The travels of a T-shirtA T-shirt on a journey. What path does a T-shirt take until its sale in a shop? Read for yourself on Page 50.

>> Those logging in at www.2d-code.com can profit doubly – once from the detailed information on the topic of 2-D codes and their identification, and a second time by winning an ICR840 2-D code reader.

Several thousand interested visitors have logged in at www.2d-code.com within a short period. All have found out about labelling and reading technologies – and some have even won a prize.

The lively interest shows the impor-tance of the topic of 2-D in many sec-tors. And SICK is providing one ICR840 2-D code reader each month in order to ensure that at least one visitor can also implement in practice the theoretical knowledge gained via the Internet.

Maybe you will be the next winner...

Now one ICR840 code reader each month

Win at www.2d-code.com

Series of articles on safety tech-nology in the specialist press

Finale in November>> SICK’s five-part series of articles cov-ering all aspects of safety technology ends with the publication of the article “Protective equipment for machines – protected but still unsafe?” in Issue 12/2006 of the specialist magazine “Sicherheit & Management”.

Over the year, “Sicherheit & Manage-ment” (only available in German) and the periodical :K reported on all aspects of machine safety in five articles:

1. Why Europe made machines safer2. The Machine Directive and safety:

from the standard to the norm3. Safe construction, integrated safety

systems, circulation without defects4. Triggering a stop, preventing a start,

safe operation5. Protective equipment for machines

– protected but still unsafe?

The overwhelming response to the arti-cles shows that they offered the right an-swers to resolve the questions and lack of clarity existing in many places.

Those who missed one or other of the articles can download them from the Internet at www.sick.com/insight/en

2/2006

Positioning system: SICK Complete

06

“Unbreakable” position determination for 12-tonners

“undercover” length measurement

>> Pfleiderer AG is one of the leading system suppliers for wood materials, surface treatment and laminated floors, among other things. Typical Pfleiderer products include untreated chipboard, flooring and decorative panels, laminat-ed panels or work surfaces. Gütersloh is one of 19 production sites in Europe and North America. At Works III – the surface treatment plant – several thousand chip-board panels are coated per shift.

Expanded production affects transport conceptThis transport system for stacked 11 m2

panels was equipped with new vehicles after the last production expansion in 2005. The 12-tonne transfer vehicles are extremely well equipped: an on-board control system with visualisation

and operation, energy and data trans-mission by PROFIBuS via an inductive system in the floor, and S3000 safety laser scanners from SICK to monitor the 170-metre-long drive path shared by the vehicles. A robust and precise solution for absolute vehicle position determina-tion was all that was still needed to fin-ish off the concept. Most of the potential solutions were discarded because they were not sufficiently immune to damage and misalignment.

Pomux KH53 – by far the best solutionThe Pomux KH53 magnetic positioning system proved to be the best solution. The sensor unit determines the actual position by means of non-contact scanning of ref-erence marks (with integrated permanent

magnets) mounted along the drive path, whose distance to one another represents a fixed position coding and which are iden-tified by magneto-resistive sensors. As a result of the non-contact technology, the system operates completely free of wear. And thanks to absolute position determi-nation, no reference run is required when a transfer vehicle starts up. users particu-larly appreciate the “superaccuracy”. No wonder – with a resolution of 0.1 mm, re-peat accuracy of 300 μm, and a scanning speed of 0.8 ms.

Active “underground” to prevent damageWith fork-lift traffic and transfer stations on both sides of the drive path, the risks of damage or misalignment are ever-present – and discouraged mounting of the reference marks along the side of the drive path. “Best stick them in the floor”, was the decision at Pfleiderer. A groove was cut into the floor along the drive path and levelled with non-absorbant sand, the reference marks were installed and the whole thing was then sealed at floor level with cast resin. This solution was ultimately also possible because the Pomux KH53 offers a reading range of 25 mm and thus reliably detects the per-manent magnets in the floor.

Pole position in costs comparisonThe two transport vehicles of the intial expansion phase have been in operation since December 2005. They carry out more than 300 transports per day and have never “lost” their position. And the costs side also works out well: compared to the purchasing and operating costs of other solutions, the Pomux KH53 paid for itself within half a year.

The wood material system supplier Pfleiderer in Gütersloh was looking for a robust and precise solution for determining the positions of four transfer vehicles active in five halls but using only a single drive path – Seli, the com-plete solution supplier and systems partner of SICK Vertriebs-GmbH, found the right solution with the Pomux KH53 linear length measurement system.

insightlInkYou can obtain further product information with the attached card under:INFO 201or on the internet at:www.sick.com/insight/enMore about the customerwww.pfleiderer.comThe S3000 safety laser scanner and the KH53 positioning system protect the drive

path and determine the positions of transfer vehicles

: SICK CompleteTextile industry

07

>> It’s not the ClV420 compact bar-code scanners for the identification of boxes, the ClV490 high-end scanners for read-ing the labels on the goods on clothes hangers, or the Wl9-2 series photo-electric switches on the roller conveyor systems. No, the WT18-3 is the most “fashionable” for the automation of the BONITA distribution centre.

Universal genius“The sensor is used on the transport sys-tem for the goods on clothes hangers and is a universal genius,” is how Paul Mess, Managing Director of msm automations gmbh & co. kg, describes his experience with the device. “It offers a scanning range of 1,000 mm, can detect even black clothes hangers or textiles with maximum reliability, and is not at all sen-sitive to the many and varied sources of interference near the conveyor systems, storage buffers and sorting plants.”

BONITA: feeling for combination fashionBonita has been selling ladies wear for demanding and fashion-conscious women under its Spanish name since 1986. With its combinable fashion col-

When automation follows fashion

Blue is “in”At BONITA, specialists in ladies’ wear, it is not only the collections that match perfectly in colour and style, but also the sensors at the distribu-tion centre in Hamminkeln near Bocholt, Germany. More than 8,000 I/O point photoelectric switches and bar-code readers in uniform blue attire dominate here.

lections, BONITA has developed into the leading ladies’ wear chain in Germany and Austria: the range is currently sold in more than 600 branches. The construc-tion of the new distribution centre was therefore intended to ensure the smooth initial stocking of branches with new col-lections, to provide 24-hour availability of goods to meet customer wishes, and to meet future logistical needs.

Fit for 50,000 unitsThe dynamic warehouse for goods on clothes hangers, automated by msm, forms the heart of the distribution cen-tre. “up to 50,000 units in the 28 stor-age buffers, and up to 6,000 storage or retrieval actions per hour do not permit any unnecessary plant downtimes – not if BONITA wants to guarantee the smooth filling of orders,” says Paul Mess. Which is why he chose to use the WT18-3 pho-toelectric proximity switch for object detection on the suspension conveyor systems, so often susceptible to critical environmental conditions.

“Dazzling” sensor availability The reason why the WT18-3 was se-lected is because the differing colours of

insightlInkYou can obtain further product information with the attached card under:INFO 202or on the internet at:www.sick.com/insight/enMore about the customerwww.bonita.de

the textiles, and the varying surfaces of the clothes hangers, generate an assort-ment of reflectivity signals for a scanner that can persistently affect scanning re-sults. Not only this, but persons, trans-ported goods, and light or dazzling ef-fects can cause a variety of interfering pulses in the storage buffers and sorting systems, and on the conveyor belts – po-tentially leading to spurious switching or false positives if conventional scanners are used. Not so with the WT18-3. “light, dark, patterned or interwoven articles of clothing are always reliably detected. Clothes hangers with optically differing appearances are also no problem,” con-firms Paul Mess. “In addition, passive or active interference of any type in the operating area is electronically identi-fied, suppressed and thus reliably cut out – ensuring the high availability of the plant.”

Top for ladies’ wear: the WT18-3 makes a considerable contribution to-wards assuring the proper supply of BONITA branches.

The WT18-3 photoelectric proximity switch detects clothes hangers or textiles with maximum reliability

Reading labels on goods on clothes hang-ers with the CLV490 high-end scanner

2/2006

logistics: SICK Complete

08

Bar-code readers in warehouse modernisation

More reading stations – greater logistical performance“Bar codes, not reflectors” was the motto during the modernisation of WMF’s central warehouse in Geislingen, Germany. viastore systems, the general contractor, chose WL9 photoelectric switches and C4000 safety light curtains from SICK, in addition to numerous CLV bar-code reading systems.

>> The modernisation of high-bay ware-houses is “in” – on the one hand because the material flow and control technology of first-generation warehouses are age-ing and, on the other hand, because modernisation is often the most efficient solution for space or licensing reasons. These were also the reasons why Würt-tembergische Metallfabrik (WMF) decid-ed on a comprehensive modernisation. WMF hired viastore systems to carry out the planning and restructuring of all in-tralogistical processes. This involved modernisation of the high-bay stackers, the conveyor technology, and the ware-house administration software, as well

as standardisation of the computer and control structures, and replacement of the reading technology.

More scanners offer greater func-tionality for material flow computerOne focus of the modernisation work was thus on reading technology. The old reflector system was replaced by the use of bar-code labelling. At the same time, the reliable bar-code scanners of the ClV420 and ClV430 series were chosen – the latter with oscillating mirror tech-nology. These bar-code readers offer in-dustrially proven technology with which the reading stations could be economi-

insightlInkYou can obtain further product information with the attached card under:INFO 203or on the internet at:www.sick.com/insight/enMore about the customerwww.wmf.de and www.viastore.de

High-bay stackers equipped with bar-code scanners and safety light curtains

cally set up. Thus each decision-making location in the material flow of the “new” WMF warehouse is equipped with a ClV. This not only results in greater process reliability, but the material flow compu-ter can also control the flow of material quantities more efficiently.

Leading table and kitchen productsAs an internationally leading product and service supplier specialising in table and kitchen products, WMF is particularly de-pendent on logistics that function well in order to promptly meet the needs of retailers (and thus consumers), as well as hoteliers and customers in gastrono-my. Availability, flexibility, upgradeability – all aspects of the old warehouse solu-tion were running up against their limits. Which is why viastore systems modern-ised 17 high-bay stackers and installed 15 new units. The entire stationary con-veyor technology, including its control components, and material flow and con-trol computer, was transformed.

The performance capability of WMF’s central warehouse could correspondingly be increased to up to 30,000 individual product picks per day to process delivery orders – while simultaneously shorten-ing order throughput times.

WL9 photoelectric switches – small and powerful

: Applications Steel industry

09

>> Displacement sensors with CMOS technology, like the OD Max, measure in the μ-range. They monitor the presence and position of objects, measure profiles and diameter, regulate processes and handle other quality inspection func-tions. At the automotive sub-contractor Tailored Blank Gent, which specialises in welded and formed parts, the task is to check that the weld seams on steel sheets welded to one another are per-fect. “At the same time it was necessary to install the highly precise sensor we needed in the smallest of spaces,” says Patrick De Coninck, responsible for the automation line at Tailored Blank Gent.

OD Max – the maximum solutionTailored Blank Gent decided on the OD Max for various reasons. The 30 mm version provides a measurement range from 25 to 35 mm and an accuracy of ±10 μm. It thus fulfils the application’s

μ-precise inspection of weld seams

5 million inspections per year

Tailored Blank Gent, a member of the Luxembourg-based Arcelor Group, has found the perfect solution for inspecting about 5 million weld seams per year – with the OD Max displacement sensor.

distance and precision demands. Thanks to its CMOS technology, the OD Max measures with μ-accuracy and extreme reliability even with reflective sheet and weld seam surfaces. The concept of a separate sensor and evaluation with an lC display is characterised by space-sav-ing installation, as well as simple com-missioning and operation. With four ana-logue outputs, five switching outputs and an RS-232 interface, this displacement sensor offers all the important methods of data output.

It’s not the looks but the profile that counts“We produce about 13 m. weld seams a year; of which 5 m. are inspected with the OD Max,” says Patrick De Coninck. Whereby 100% inspection is indispensa-ble. “If a weld seam in a weight-bearing part of a car chassis is poor (we call this an ‘irregular’ weld seam) it could be cat-

insightlInkYou can obtain further product information with the attached card under:INFO 204or on the internet at:www.sick.com/insight/enMore about the customerwww.arcelor.com

The OD Max displacement sensor meas-ures sheet and weld seam surfaces with μ-accuracy – even in the tightest of spaces

astrophic for the driver,” explains Patrick De Coninck. Although the defective weld seam may appear optically perfect, the OD Max detects it as defective on the ba-sis of it not reaching the defined height difference between the sheet and the weld bead.

Successful start at ArcelorThe positive experiences that Tailored Blank Gent have had with the OD Max have got around the Arcelor Group. A variety of other Group companies have adopted the inspection system with the OD Max, for comparable production en-vironments.

: Applications

10 2/2006

>> In addition to toilet paper and kitchen rolls, WEPA Mainz GmbH also produces damp hygiene tissues on a total of five processing lines. The production capac-ity is approximately 58,000 tonnes with a processing capacity of about 30,000 tonnes of tissue per year – a volume that also requires intralogistical trans-port between Production, the ware-house and Despatch. The use of the C4000 Palletiser ensures that persons in the vicinity of equipment, or machines and pallets, do not get in the way during automatic material transport.

Pattern-based monitoringThe C4000 Palletiser safety light curtain is electro-sensitive protective equipment in the highest possible safety category: Type 4 in compliance with IEC 61496 and SIl3 according to IEC 61508. It is also an intelligent sensor system that operates on the principle of self-learned pattern recognition, and can thus de-pendably differentiate between persons

insightlInkYou can obtain further product information with the attached card under:INFO 205or on the internet at:www.sick.com/insight/enMore about the customerwww.wepa.de

Protecting rotary stations and lifts

Safety for automatic tissue transportC4000 Palletiser safety light curtains at the Mainz works of tissue paper producer WEPA protect rotary stations and lifts on the pallet conveyor sections between Production, the warehouse and Despatch.

and pallets – providing reliable protec-tion of feed openings for automatic material transport in hazardous areas. At the same time, pattern recognition means that no supplementary muting sensors, indicator lamps, fencing and barriers, or swing flaps are required, minimising potential problems and opti-mising availability of the entire plant.

Collision-free tissue transport – even with differing pallet typesIn addition to other stations at which WEPA already employs proven mut-ing solutions from SICK, a safety-criti-cal access to rotary stations and lifts was recently equipped with the C4000 Palletiser safety light curtain. Pattern recognition for pallets is already deliv-ered in an activated state and simply requires installation. The monitoring function remains active when the sys-tem recognises the foot pattern of the Europallets used, so that the pallet can pass through the protective field without

stopping the plant. The hazardous move-ment stops if the pattern deviates from the programmed limit values or the pat-tern changes during transport. This even happens if a person walks along behind or alongside the pallet. In this case, too, a pattern is recognised – and evaluated by the C4000 Palletiser with a “not in order” signal. The automatic learning process takes place with each pallet. It is thus possible to use a mixture of pal-lets. The direction of movement can also be defined in the program. So access against the direction of movement also triggers a safe stop.

In many cases the safety, availabil-ity, supplementary functions, or savings resulting from lower installation costs make the C4000 Palletiser the right so-lution for automatic material transport in protected areas.

The C4000 Palletiser safety light curtain can reliably differentiate be-tween persons and pallets – no sup-plementary protective equipment is required on feed openings

Pallet transport

11

>> The automation concept of the NO-VuS 1200 employs automatic format adjustment with the integrated HIPER-DRIVE® positioning drive throughout. The motor, drive, absolute measure-ment system, and performance and

Fully automatic format adjustment for the world’s first metal laminating plant

Fantastic flexibilityThe NOVUS 1200 from the Nuremberg-based company Billhöfer is the world’s first laminating plant for metal packaging. During implementa-tion of this revolutionary coating concept, e.g. for bottle tops, stoppers, containers, tins or lids, the decision was also made to use equally revo-lutionary format adjustment with the fully automatic HIPERDRIVE® posi-tioning drive.

regulatory electronics are accommodat-ed in a compact housing. The absolute determination of orientation offers an unambiguous positional value for each axle position – no reference run is nec-essary when the laminating machine is

insightlInkYou can obtain further product information with the attached card under:INFO 206or on the internet at:www.sick.com/insight/enMore about the customerwww.billhoefer.de

Billhöfer has taken a totally new route with the NOVuS 1200. The production of surface-treated sheets takes place through lamination of the raw substrate with a protective foil within, as well as lamination with a previously printed foil on the outside. This completely does away with the spraying and drying stati-ons necessary for the conventional process. The raw substrate, with thick-nesses of between 0.1 and 0.4 mm, e.g. metal sheets, are de-stacked in the automatic sheet feed unit and then cleaned in a Corona unit, and provided with the surface charge necessary for the lamination process. The foil, with a thickness of between 12 and 23 μm, is coated with glue in an application system – straight off the roll and without contact – and then joined to the metal sheet in the laminating unit with an application force of 6 tonnes.

>> Metal lamination

started up. In terms of construction, the compact devices also fit perfectly into the tight spaces of the NOVuS 1200. Integration of the positioning drives in the PlC machine controller takes place by means of a PROFIBuS-DP plug-in module that is inserted and screwed in directly onto the standardised basis drive with plug & play.

HIPERDRIVE for all important axlesThe limit stops in the feed unit, the knife for cutting the foil edges, the width ad-justment for the application of glue, the positioning of the edge detection sensors, or the width and length ad-justments of the receiving system – all the format-relevant axles are equipped with HIPERDRIVE positioning drives. They allow adjustment of any panel for-mat between 500 x 500 mm to 1,200 x 1,200 mm, and any web width of be-tween 100 mm and 400 mm – at the press of a button and in the shortest of times.

Format advantagesThe end-users find this quite fantastic, as the positioning drives offer them flexibility and time savings. Adjustment at the press of a button is a “simple formality” and is very rapid: Billhöfer estimates that there is a 66% cut in for-mat adjustment time. Several product and batch changes per day, economi-cal laminating of both large and small batches, reduced need for personnel around the machine, just one format adjustment for frequently recurring orders, and documentation of the ma-chine parameters for quality control are the advantages most frequently cited by customers.

Regardless of the end-product, au-tomated format adjustment with HIPER-DRIVE makes a decisive contribution towards each user being able to exploit the new technology of metal lamination for their tasks – economically and with maximum flexibility.

Positioning drives on laminating plants offer flexibility and save time

: Applicationslaminating metals

: Applications

12 2/2006

insightlInkYou can obtain further product information with the attached card under:INFO 207or on the internet at:www.sick.com/insight/enMore about the customerwww.serpentine.ch

>> “Tomorrow’s urban mobility requires new approaches that take into account the wishes and requirements of local traf-fic suppliers and potential passengers,” says Bernard Saugy, Managing Director of CN Serpentine SA in lausanne. “In classic local public transport, aims such as minimised emissions, savings in energy and costs, no accidents, rapid progress in traffic without wasting time in traffic jams, frequent and preferably individual departure times, comfortable transport, and an acceptable price-per-formance relationship often contradict one another. This is not the case with Serpentine.” Which is why he is sure that his company is on the right path with this concept. Numerous international prizes appear to confirm this view.

To the conference or café by capsuleExternally, the Serpentine local transport system consists of a variable number of autonomous vehicles depending on the number of passengers. In addition to the capsules, there is the “MagnetoGlis-seur” magnetic vehicle guidance system along the drive path (which is also re-sponsible for the transfer of energy and information) as well as the central HB Traffic Manager, that administrates the vehicles, monitors the direction of trans-port of the capsules, manages the tick-eting, and is responsible for the safety of the entire system. “Each vehicle is in use 20 hours a day and only consumes 300 W of energy – that is 1/30 of the energy requirement of a car for the same distance,” says Bernard Saugy. The cap-sules on the drive path, along the banks of lake Geneva in lausanne’s Ouchy district, can be called up individually by SMS or e-mail. “This simple availability at any time made a major contribution to

Driverless and risk-free “Serpentines”

Through lausanne by laser measurementPublic but individual – “Serpentine”, a new autonomous system for trans-porting persons in local traffic, has been successfully tested in Switzer-land’s Lausanne. The heart of the solution concept, driverless personal capsules for up to five passengers, can be called up by e-mail or SMS. LMS Laser Measurement Systems support the vehicles’ safety systems by monitoring the drive path and thus preventing collisions.

their positive acceptance by users,” says Guy de Pourtalès of CN Serpentine SA and head of the lausanne project. “But the fact that the passengers felt safe in the capsules, which travel at about 15 km/h, was the decisive factor.” Towards which the lMS laser Measurement Sys-tems make a considerable contribution.

Drive path monitoring and collision prevention through laser measurementSerpentine takes care of the safety of pas-sengers with numerous safety features

“The lMS is mounted for forward vision so that the actual safety technology is only actually used in an emergency. It was the only system with which the geometries of the monitored fields could be taught-in path-specifically,” Guy de Pourtalès em-phasises. “Several signalling areas can be defined within the monitored field. This allows graduated responses. Per-sons who are far away are warned acous-tically, and if they continue approaching the capsule it goes into crawl mode until it reaches the defined safety distance and automatically stops – and only continues moving when the person has moved out of the way.”

“Our concept is the right one for the future,” says Bernard Saugy. Which may have already started – the company is currently carrying out other interesting projects, e.g. in Geneva, between the air-port and the city centre.

– prevention of wedging during entry and exit and during opening and closing of the doors, or emergency stop buttons for ac-tive interruption of the drive. Each vehicle is supported in this by a lMS laser Meas-urement System. It checks the drive path over the entire width and detects persons or obstacles at distances of up to 10 m.

Collision-free travel for driverless personal transport capsules supported by the LMS Laser Measurement System

Transport and traffic

: Applications

13

insightlInkYou can obtain further product information with the attached card under:INFO 208or on the internet at:www.sick.com/insight/enMore about the customerwww.volkswagen.com

>> The ZlM1 logic module, containing the logic for the accumulating roller conveyor and the magnetic valve, thus increases the flexibility of accumulating roller conveyors. As a result, the most varied of applications can be solved economically and with technical sophis-tication. The module can be combined with the most varied of optical or induc-tive SICK sensors – even with the “clas-sic” WTR1 accumulating roller sensor.

Increased flexibility for accumulating roller conveyorsThe automatic small parts store at Volkswagen’s logistics Centre in Brus-

New logic module at new Logistics Centre for Volkswagen Brussels

Greater flexibility for accu-mulating roller conveyorsVarying container sizes are no longer a problem for modern accumulat-ing conveyor systems such as those at Volkswagen in Brussels: contain-ers of differing sizes in any position on the conveyor section are reliably detected, accumulated and removed with the ZLM1 logic module and the MHL15 compact photoelectric switch.

sels was commissioned in January 2006 by EISENMANN, the general contractor. What is special about this accumulat-ing roller system is that goods of differ-ing dimensions (from 800 x 400 mm2 to 200 x 300 mm2) are transported on the same system. Two MHl15 units are located on each conveyor segment and connected to the ZlM1 logic module with an “OR” linkage, whereby the logic component and the magnetic valve form a space-saving unit. This achieves the targeted deceleration of both large and small containers. While the latter could theoretically be detected by using only a single photoelectric switch, it would

be stopped too late due to the braking arrangement necessary for the over-all system. The result: the light path of the photoelectric switch would be free again and the small container would “logically” be transported onwards.

Control of the accumulation and start functions in the accumulating roller con-veyor system takes place autonomously thanks to the logic module, which con-tains the most frequently used logic func-tions: single feed, single removal and block removal. This reduces the wiring effort required by the user compared to a star-shaped wiring concept, as well as the corresponding programming required in the connected external controller.

MHL15 – short and flush, ideal for conveyor systemsThe MHl15 photoelectric switch sim-plifes installation in or above a lateral branch as a result of its new type of mounting concept – with a flush cover ring and fixing nut – also providing a simple means of protecting the photo-electric switch from damage. The MH15 is also available as an energetic photo-electric proximity switch and a through-beam photoelectric switch.

Varying container sizes are no problem with the MHL15 compact photoelectric switch

The logic unit and the magnetic valve form a space-saving unit – with the ZLM1 logic module

Automotive

: Applications

14 2/2006

A dazzling solution

Photoelectric proximity switches for satellite protection

Mobile working platforms from Swedish producer MaxMove are very popular in the airplane industry. WT18-3 series photoelectric proximity switches ensure that the platforms also simplify everyday work in the space industry, e.g. at Boeing Satellites.

>> Göran Eckeström, the active partner and Marketing Manager of MaxMove, of-ten travelled from the northern Swedish town of umea to the American west coast to convince Boeing Satellites of the appli-cability of his mobile working platforms. In the end he succeeded – ultimately be-cause he could also offer a solution for detecting highly reflective black satellite surfaces and their solar cells.

Preventing floor collisionsThe manoeuvrable working platforms from MaxMove are used for bringing and readying materials and tools in the imme-diate vicinity of the satellites. They also prevent the use of step constructions or ladders on the satellites, which may be several metres tall. “Of course the very mobility of the platforms represents a risk of collisions with the satellites under

insightlInk

construction, which are spread out all over the works hall,” Göran Eckeström describes the problem. “It was not pos-sible to use conventional photoelectric proximity switches to detect the extreme-ly sensitive, black, highly reflective outer skins of the satellites and the solar cells mounted on them. So it’s a good thing that SICK Sweden could present the new WT18-3.”

Sensor’s dazzle suppression is dazzlingDazzle is one of the most common types of passive interference for opto-electronic sensors in industrial use. With the WT18-3, a scanner is available that eliminates precisely these interfering factors. It is the first device of its type to exploit a chip technology specially developed for scan-ners. The scanning distance and scan-ning range can be adjusted with extreme accuracy and reproducibility. At the same time, dazzle and reflections are electroni-cally suppressed, and thus reliably cut out. With their total of 18 photoelectric proximity switches each, the mobile plat-forms soon detect when they approach too near a satellite and respond by gen-erating an alarm signal.

“We really scored a bull’s eye with the WT18-3,” Göran Eckeström is pleased to say. And Boeing profits from the fact that the sensors’ light beams are the only form of contact between the working platform and the satellites.

A view of the works hall of Boeing Satellites

Object detection

You can obtain further product information with the attached card under:INFO 209or on the internet at:www.sick.com/insightMore about the customer:www.maxmove.se and www.boeing.com

: Applications

15

insightlInkYou can obtain further product information with the attached card under:INFO 210or on the internet at:www.sick.com/insight/en

>> Several gantry cranes share the same rails in Volvo’s works hall, e.g. between the laser cutting plant, manual welding stations and the welding robot cells. The task was to reliably prevent collisions both between the cranes themselves, and between the cranes and the hall walls. “We needed a collision prevention system that guaranteed the safety of our employees and met the demands of au-thorities,” says Tom Ericsson, a Mainte-nance Engineer at Volvo.

S3000 – the suitable sensorIn sensor terms, the task was solved with the S3000 Standard safety laser scan-ner. The device is mounted at the top of the gantry crane and vertically aligned. “The protective fields must be very long because of the crane operator’s insuf-ficient overview,” says Tom Ericsson. “Which is why we measured the brak-ing distance of the crane and then knew what protective field length the S3000 had to cover.”

UE440 and UE48 – the suitable control componentsThe uE440 safety controller handles the separate evaluation of the protective fields – allowing monitoring of the direc-

Collision prevention at Volvo

Flexible drive path protection for gantry cranesWhether forwards or backwards – the combination of a safety laser scan-ner and the UE440 safety controller prevents collisions in both directions. The UE440 safety controller evaluates the protective and warning fields; type UE48 safety relays generate the switching signal for the crane con-troller. A solution that is currently only available in this form from SICK.

tion of movement and the safe speed, as well as collision prevention. It receives the S3000’s safety-relevant signals via the enhanced function interface (EFI). A total of four uE48 safety relays are connected to the uE440. Two of them process the signals of the configurable signalling application diagnostic outputs (ADOs), providing detection of obstacles in the direction of movement. The two other uE48s receive their signals via the two output signal switching devices (OSSDs), with which the speed of the crane is reduced, or an emergency stop of the entire crane is initiated.

A safety laser scanner with protective fields that can be separately evaluated, which protects gantry cranes in both di-rections of movement without directional and speed information – this solution is currently only available from SICK.

>> The Czech single-purpose machine builder ADAX spol. s.r.o. has designed an installation inspection station for a producer of car air-conditioning systems, in which the CVS3 camera sensor differ-entiates between two types of ventilator drives while also ensuring correct instal-lation.

The CVS3 Contour Vision Sensor is a compact and user-friendly camera sen-sor with integrated illumination. Versions are available with operating ranges of 30 mm to 40 mm, and from 90 mm to 150 mm, depending on the task. The device detects the presence of objects, their shape, size and orientation and allows mounting processes, for example, to be designed efficiently and with a high level of availability.

The side view is decisiveThis inspection task could be ideally solved with the help of the CVS3. The device detects the ventilator drive from the side and can reliably differentiate between the two types on the basis of characteristic features. The PNP output switches if an incorrect part is detected. If the ventilator type is in order, the cam-era sensor determines the correct angle of orientation before insertion of the ven-tilator. ADAX was very enthusiastic about the simple and rapid implementation of the solution – as well as the camera sen-sor’s compact housing and reliability.

CVS3 – when it’s the contour that counts. INFO 211

Checking type and installation of ventilator drives

Getting the in-car climate right

Everything in view with the S3000 safety laser scanner – vertically

: Applications

16 2/2006

insightlInkYou can obtain further product information with the attached card under:INFO 212or on the internet at:www.sick.com/insight/enMore about the customerwww.bmw.de

>> Construction of the BMW vehicle works in North leipzig meant creating one of the world’s most modern automobile facto-ries. The 3-Series has been rolling off the lines here since spring 2005. up to 650 vehicles are to be produced each day in

Integration and monitoring of decentralised safety functions at BMW in Leipzig

Safety sensors with the best of contacts to PROFIsafeThe BMW works in Leipzig is one of the most modern production sites of its type. This is not only visible in the plant technology, but also in the safety technology. Electro-sensitive protective equipment directly con-nected to PROFIsafe increases availability in final assembly and improves the productivity of automobile production.

the medium term. Whether shell construc-tion, the paint shop or assembly – during planning of the works, particular attention was paid to ensuring flexible and expand-able communication structures – which were not to be impaired by the safety sys-tems employed.

Intelligent interfaces for in-situ safety communicationThese demands could be solved with the help of SICK uE4120 and uE4150 safety modules – which have two extra connec-tors for intelligent SICK safety compo-nents, e.g. the S3000 – without the need for long cable connections between sen-sors and controllers. The interface mod-ules have eight field signal inputs for the connection of active and passive, single- or dual-channel safety components up to control Category 4. The sensor connec-tions and system functions can be config-ured offline, i.e. without connection of a failsafe PlC. CDS configuration software, as used for SICK safety sensors, offers us-

ers a familiar look and feel. In operation, the uE modules provide maximum system transparency: all connected devices can be contacted, analysed and visualised directly via PROFIBuS. A sensor’s stored parameter data can automatically be transferred to the new device if the re-sults of remote diagnosis indicate that a replacement is necessary, minimising im-pairment of plant availability.

UE possibilities also for the X5 four-wheel drive vehicleThese interface modules allowed, among other things, the numerous S3000 safety laser scanners and MSl-Z multibeam photoelectric safety switches in the final assembly at BMW in leipzig to be di-rectly integrated in the works’ PROFIsafe communication structures. In addition to reducing interface hardware and instal-lation costs, the integration and monitor-ing of remote safety functions increased process efficiency, in particular. The sys-tem is also open for plant expansions or structural modifications.

BMW has exploited these advantages of intelligent interface technology again at its uS works in Spartanburg – for produc-tion of the X5.

Final assembly at BMW in Leipzig equipped with electro-sensitive protective equipment from SICK

Intelligent interfaces for safe in-situ communication

Automotive

: Applications

17

insightlInkYou can obtain further product information with the attached card under:INFO 213or on the internet at:www.sick.com/insight/enMore about the customerwww.eth.ch

>> Steep descents through vertical shafts, dampness, dirt and unforeseen conditions – not many people enjoy en-tering shaft caverns. And it will also no longer be necessary thanks to the Cav-ern Measurement System (CMS) devel-oped by ETH Zurich – to the relief of em-ployees at civil engineering authorities or engineering and surveying companies.

For renovating channels, and water and sewage pipe systems

Three-dimensional measurement of shaft caverns without entering themThe Institute for Geodesy and Photogrammetry at the ETH in Zurich (Chair of Geodetic Metrology and Engineering Geodesy, geomETH) has devel-oped a prototype of a new measurement system, based on the LMS Laser Measurement System, for determining the dimensions of shaft caverns. The solution is more precise and safer for personnel than conventional manual measurement.

Head first into the depthsMounted on a rotary table, the lMS200 goes head first into the depths on a tel-escope support. When it reaches the bottom, it is turned through 360° to make the measurement. During the measurement, the measurement data of the lMS200 and the current position of the rotary table compared to the origin

(zero point) are registered on a hard disk. “Darkness, dark walls or damp concrete surfaces – nothing impairs the operation of this 3-D measurement system,” en-thuses Hans-Martin Zogg of the Institute for Geodesy and Photogrammetry at the ETH in Zurich. The practically relevant measurement range lies between 1 m and 30 m. The result of a roughly three-minute all-round scan by the lMS200 is a cloud of points consisting of more than one million individual measurement points. The level of detail of the cloud of points depends on the resolution of the 3-D measurement system. Vertical resolution is fixed at 0.25°, while the horizontal resolution is infinitely variable. Thus even the smallest of channels, or the rungs on the entry ladder, are clearly visible in the cloud of points. The evalua-tion software of the CMS then provides a 3-D model of the shaft cavern.

The CMS has remained within its tight budget, not least because of the lMS200, making it interesting for poten-tial purchasers such as civil engineering authorities, city departments of works, or surveying companies.

Head-over-heels into the depths – the LMS200 laser scanner measures shaft caverns with 360° scanning

Civil engineering

: Applications

18 2/2006

insightlInkYou can obtain further product information with the attached card under:INFO 214or on the internet at:www.sick.com/insight/enMore about the customerwww.viking.at

>> VIKING, a member of the Stihl Group, produces and sells lawnmowers, ride-on mowers, garden shredders, lawn trim-mers, hedge trimmers, garden shears and motorised tillers of the highest qual-ity. “We wanted to achieve the same high level in the logistical chain to end-customers,” says engineer Harald Gan-ster, responsible for logistics at VIKING. “Therefore, in collaboration with SICK and the Steininger technical office, we have implemented a fully automatic out-going pallet inspection that is integrated in our SAP system.”

Automatic identification with real-time comparisonThe identification and checking of packed garden tools takes place fully automatically using two ClV490 bar-code scanners. The scanners identify the despatched devices on the basis of their EAN numbers and serial num-bers, and also check completeness on the pallet. The pallet, with its goods and their EAN and serial numbers, is turned through 360° on a rotary table

Delivery quality is also a product property

Ensuring that garden tools reach retailers in good timeIn order to optimise the flow of goods and prevent incorrect deliveries, the Austrian gardening tool producer VIKING relies on automatic inspections of outgoing goods with CLV490 bar-code scanners.

and scanned on all four sides. After all the data has been read-in and sent to the control system they are compared with the production and delivery data. Whereby the first EAN numbers deter-mine the type of goods and the assigned maximum pallet quantity and these are shown on a display. An error message is displayed if the EAN number does not match the data at the industrial ter-minal, and further processing can only take place after physical correction on the pallet and a new scanning process. The pallet stretch wrapping equipment is activated if all serial numbers tally with the values expected by the system. At the same time, the data are sent to a PC for further processing, from where they are transferred to the SAP system. This procedure reliably prevents incom-

plete or incorrect consignments while ensuring gap-free traceability.As Harald Ganster sums up: “100% tracking of all machine numbers and a gap-free quality chain to our end-custom-ers is now possible with the inspection capabilities of the ClV490. The identi-fication solution from SICK is therefore now an important component in our quality management.”

Fully automatic outgoing pallet inspection ensures a complete quality chain all the way to end-customers

The CLV490 bar-code scanner in use

Material handling

: Applications

19

>> Checking access, monitoring internal spaces or emergency stop are functions that minimise the risk of dangers on presses. The uE470 safety multifunc-tional interface maximises the benefits users gain from the central control and monitoring of safety functions.

Central monitoring and control of complex safety functions on presses

Multifunctional interfaces with multiple opportunitiesMachines and plants can be flexibly and efficiently protected with the uE470 pro-grammable safety multifunctional inter-face which is Category 4 in compliance with EN 954-1 and SIl3 according to EN 61508. A total of seven dual-chan-nel inputs, eight outputs – four of which can be used as safe output pairs – and bypass functions offer wide-ranging pos-sibilities of use. The menu-guided CDS configuration and diagnostic software supports users in the parameterisation of the uE470, and thus in the implemen-tation of complex safety functions, e.g. on the presses produced by Meyer.

UE470 multifunctional interfaces combine safety functionslarge presses work with forces of 10,000 kN, sometimes even more. Depend-ing on the workpiece, the tables of the presses may have dimensions of several square metres. This shows that both the access to presses and presence in the area of the table, e.g. while changing tools, must be protected. C4000 safety

Scanning distance sensor used for measurement

Tunnel vision

light curtains are proven for protecting access, while internal monitoring is a typical domain of the S3000 safety la-ser scanner. Finally, the emergency stop button allows the operator to switch off the machine directly when he or she detects a risk or a problem. When the press is switched on it needs safe logic to evaluate, for example, the Reset sig-nal initiated by the operator, or to bridge protective equipment in a safe operating state. The uE470 offers all the possibili-ties of receiving signals, processing them safely and according to the press cycle, and switching off the press in an emer-gency via the two output signal switching devices (OSSDs). Whereby the OSSDs on the Meyer presses are contacted in dif-ferent ways – either jointly, via the elec-tro-sensitive protective equipment and the emergency stop button, or via the emergency stop button alone.

The central monitoring and control of complex safety functions on presses – no problem with the uE470. INFO 215

>> Whether the correct location for bore-holes for explosives, or the thickness of the air-placed concrete applied – the DMT10 provides highly accurate data as a sensor for a 3-D tunnel profile meas-urement system.

The Bever 3D Profiler is a system so-lution from the Norwegian company Bever Control. It is installed directly on the tunnel drilling vehicle, and carries out both point measurements at the current vehicle lo-cation as well as simultaneous scans of a tunnel section several metres long. The DMT10 is mounted on an arm that pivots through all axes. Its measurement data is processed in a computer system that the company developed itself, and is visual-ised by the user as a 3-D graphic.

Precise, robust and economicalBoth technical and economic arguments supported use of the DMT10. “The de-vice offers a practical scanning range

of 20-40 m even with dark rock layers. It is also very precise, allowing the 3D Profiler to generate a picture of the tun-nel accurate to within a few millimetres,” says Thorvald Wetlesen, Managing Direc-tor of Bever Control. He is also convinced about the costs side of the solution: “The DMT10 is an industrially proven stand-ard device that we can exchange rapidly and easily if it becomes necessary.”

New DMT version offers new opportunitiesThe development engineers of Bever Con-trol already have the next improvements of their 3D Profiler in their sights – and thus also a further developed version of the DMT10. There is a new type of elec-tronic reflectivity adaptation, allowing re-al measurements within a time frame of 1 ms. “This will make our measurement system considerably faster and provide users with an even more detailed tunnel

profile,” Thorvald Wetlesen described the advantages provided for him and his customers.

Best by a long way – tunnel contour measurement with the DMT10. INFO 216

The distance to the tunnel wall is precisely measured with the DMT10

: Applications

20 2/2006

>> The Swiss meat processor Bell uses mobile ImageTeam hand-held scanners from SICK for the identification of animal cadavers and batches of meat to provide the legally stipulated traceability in the in-coming goods area and during processing.

The individual tasks at Bell were solved within the framework of batch identifica-tion with differing hand-held scanners. The advantages were that the application ben-efits of the devices balanced one another, and that the scanners could be purchased from a single source.

Versatile “ITelligence” for the iden-tification of animal cadavers with PDF417 codesMoving cadavers (transported on the over-head suspension conveyor system), vary-ing reading distances, differing attachment locations of the PDF417 labels, and harsh conditions resulting from the carving and cleaning operations – Bell decided to use a variety of IT hand-held scanners to meet the particular demands made by the vari-ous processes.

The IT3800 hand-held scanner is used for identification during the thin-

Traceability of meat products at Bell

“ITelligently” solved with ImageTeam hand-held scannersning out process and, to some extent, packaging. Its ergonomic design, com-fortably shaped handle, and convenient trigger provide user-friendly handling. The IT3800, inserted into its adjustable retainer, operates in self-triggering Pres-entation Mode at some work stations, where the operator needs to have both hands free.

The robust IT5800 hand-held scan-ner is also appreciated at Bell. As a re-sult of its long reading range of more than 2 m the device offers a high level of ergonomy, because large objects can also be identified on the roller conveyor feed station from longer distances.

The reading-in of PDF417 codes, e.g. on delivery of animal cadavers, takes place with the IT4800. Omnidirectional detection capability, enhanced reading distance, and an improved depth-of-field permit more comfortable work with the device.

Bell uses the IT5620 with its Blue-tooth module wherever the length of the spiral cable on the device is insufficient, or interferes with the work. This data ra-dio option allows the device to be used

Mobile IT hand-held scanners from SICK

within about 10 m of the basis station, and the reading information is trans-ferred online to the batch identification system. A high level of user-friendliness is achieved with a reading distance of 90 cm, a depth-of-field of 56 cm, and a wide reading window of up to 17.8 cm.

Traceability by means of PDF417 – “ITelli-gently” solved at Bell with mobile identifica-tion technology from a single source. INFO 217

>> Stürtz Maschinenbau has integrated an effective tool-break detection system in its plastic window frame production plants with the help of the WTB190T compact photoelectric proximity switch. The sensor detects even small drill bit diameters, but

Compact photoelectric proximity switches for better window frames

You’ll be sorry if the tool breaks ...is unimpressed by heavy background in-terference.

The small, precise red light spot that the photoelectric proximity switch gener-ates on the drilling or milling machine, and its accurate background suppres-sion, are the prerequisites for detecting drill bits, even with diameters of only 3 mm. During in-house tests and on-site commissioning, Stürtz employees profit from particularly simple parameterisa-tion of the device thanks to mode selec-tion, teach-in and button operation sup-ported by a menu display.

No screwing-in without drilled holesInsertion, sawing, drilling, reinforcement, seal shaping, welding, hinge and handle assembly – there are numerous auto-mated processes before a window frame has been produced from plastic profiles. If there were a hold-up in one area of the

processing station, e.g. because a drill bit or milling machine is broken, there would be a problem at some other point in the processing, e.g. during screwing-in of the reinforcements, because the drilled holes would be missing. The result: congestion in the production process, repair work, and sometimes even complaints from builders or end-customers. Now, however, the tool-break detection of the WTB190T provides the right overview. The photoelectric prox-imity switch signals a broken drill bit to the machine controller. The drilling station stops, the tool is replaced and the drilling process continues. This ensures that the profiles have all the holes needed by the screwing-in station.

Tool-break detection provides the customers of Stürtz Maschinenbau with greater process and product quality. Thus the WTB190T ultimately ensures more economical window production. INFO 218

: Applications

21

Zero-pulse assignment at the press of a button

Speedier diesel engine inspectionsThe British diesel engine producer Cummins Engine Company is speed-ing up its engine inspections. Thanks to the DRS60, alignment of an engine’s top dead centre with the zero-pulse of the incremental encoder no longer takes up to 30 minutes, but is now a matter of seconds.

>> The Cummins Engine Company is one of the world’s largest manufac-turers of diesel engines. In 2005 alone, the company delivered about 3,000 engines with 12, 16 or 18 cylinders. They are used as drive systems for gen-erators, locomotives, heavy vehicles and ships.

Inspection centre modernisedThe engines undergo comprehensive function tests as early as the construc-tion and development phase. Cummins runs three inspection cells for this purpose. Their technical equipment – including couplings, support brack-ets and encoders – has recently been modernised. A solution was sought for the rotative encoders, in particular, which would allow the top dead centre (TDC) of the cylinder to be aligned with the zero-pulse (reference) position of the inspection equipment more rapidly, easier and more accurately.

DRS60 ensures alignment in secondsThe test engineer used to have to turn the engine to the TDC, adjust the built-in encoder manually until the precise zero-pulse was found, and then put it

Simple electronic zero-pulse assign-ment at the touch of a button with the DRS60 encoder

on the testing equipment without any rotation of the shaft. The task was not only difficult, but also extremely time-consuming: it sometimes took more than half an hour to get the test rig ready. So it’s no wonder that Cummins was very interested when they found out about the DRS60 and its zero-pulse alignment at the press of a button while installed. Because, as explained above, while with most incremental encoders this is a complicated process, with the DRS60 the zero-pulse is simply aligned by pressing a button. The mechanical loosening and turning of the encoder that is otherwise necessary – and thus the risk of unintentional rotation – is no longer required. Of decisive impor-tance, however, is the zero-pulse align-ment: from 30 minutes adjustment to just a few seconds. All the test engineer has to do now is turn the engine to the TDC, mount the encoder, and press a button to align the zero-pulse.

Save time at the press of a button: zero-pulse assignment with the DRS60.

insightlInkYou can obtain further product information with the attached card under:INFO 219or on the internet at:www.sick.com/insight/enMore about the customerwww.cummins.com

Diesel engines from Cummins undergo wide-ranging functional tests

Drive systems

: Applications

22 2/2006

insightlInkYou can obtain further product information with the attached card under:INFO 220or on the internet at:www.sick.com/insight/enMore about the customerwww.deere.com

>> Deere & Company employ 38,700 employees worldwide. Their products in-clude agricultural, construction and for-estry machines, community technology, as well as equipment for the upkeep of lawns, grounds and golf courses. Deere & Co. have customers in more than 160 countries, with eleven production works worldwide – including Horizontina in Brazil. In 1998, for legal and safety at work reasons, the company faced the task of protecting the mechanical and hydraulic presses, press brakes and punching presses, as well as other pow-er-driven machinery used here, against the risk of accidents. As the company did not have any in-house safety spe-cialists they were obtained externally: from ACAO and SICK.

Greater safety, step-by-stepOne mechanical and one hydraulic press, as well as a press brake, were initially equipped with safety technology in a first

Safe production at John Deere in Brazil

From the first safety project to a solid safety partnership SICK, together with ACAO, its Brazilian sales partner, has implemented a variety of safety projects at John Deere Brazil during the last eight years. Good technical and economic advice, and professional implementation, have made close partners out of project participants.

joint project. Right from the start, the idea of combining safety functions with automation functions to support produc-tion was taken into consideration. One of the solutions was floating blanking, i.e. the variable cutting out of individual beams of the FGS safety light curtain at the moment when a work-piece is jutting into the protective field during process-ing. What at that time was still only possi-ble with a separate lCuP evaluation unit is now handled by an integrated compo-nent, e.g. in the C4000 safety light cur-tain. The project was concluded to the complete satisfaction of John Deere.

In the second project, too, in 2001, John Deere again employed the compe-tent partners ACAO and SICK – of course, we already had first-class in-house refer-ences. Now it was more than 20 presses and machines that had to be given state-of-the-art safety treatment. This time, operating experience from the machines originally equipped could be taken into

account, alongside the internal safety expertise that had developed at John Deere.

The logical consequence of this was a third project, in 2004, with over 35 machines using the same proven partnership – and the latest safety tech-nologies, e.g. the C4000, S3000, and a control solution in the form of various safety relays from the Intelliface product family.

Competent advice, professional im-plementation, continuous support and 100% commitment to the customer have been the keys to success for ACAO and SICK at John Deere over the years.

John Deere sells agricultural machines in more than 160 nations worldwide

Presses equipped with the latest sensor technology from SICK

Machine safety

23

>> Rexnord Kette GmbH in Betzdorf, Ger-many, produces drive, conveyor and flyer chains in the most varied of designs. “We produce almost 50 different chain sizes for flyers and rollers alone – as endless material or as lengths of chain,” explains Stefan Zimmermann from Rexnord Kette. As any chain is only as strong as its weak-est link, however, the company sought a robust, low-maintenance and user-friend-ly solution for 100% inspections of every chain to reliably detect defective links. Further requirements included automatic detection of differing chain types, as well as image and data output via Ethernet.

IVC-2D: the smart camera solutionThe system integrator given the job of solving this task, AKl-tec (specialists in demanding solutions involving image processing and laser measurement tech-nology, among other things) decided on optical inspection with the IVC-2D smart camera. “The system offers a wide-rang-ing software library that simplifies pro-gramming. The camera is designed for industrial use, it’s simple to operate, and has on-board Ethernet interfaces for rapid transfer of signal and image data,”

Industrial chains inspected by 2-D smart camera

No weak links in the chainRexnord Kette, a company that produces chains for industrial use, has done away with weak links. The IVC-2D smart camera – embedded within a complete inspection system from AKL-tec – knows no compromise when it comes to inspections.

says Rüdiger Elben from AKl-tec. “More-over, background suppression can easily be connected to the smart camera via M12 plug-in connectors and the illumina-tion time is controlled via the camera’s step program.”

From the feasibility study...After carrying out the feasibility study, AKl-tec developed the right mechani-cal inspection system, integrated the system components – smart camera, illumination, PC, display and PlC – and adapted the camera and PC software to the inspection program. “Thanks to the simple user interface of the IVC-2D it only took three days’ development time to get the first version operating,” says Rüdiger Elben. During inspection, the chain is fed into the inspection station and the chain type is automatically detected by the smart camera. Then each link of the chain is tested for different features, e.g. the presence of individual parts, height, parallelity, and the distance between the bolt and the plate. “The feeding process for the automatic inspection machine stops when a defective chain link is de-tected. The operator replaces the defec-

insightlInkYou can obtain further product information with the attached card under:INFO 221or on the internet at:www.sick.com/insight/enMore about the customerwww.rexnord.de and www.akl-tec.de

tive component and re-checks this area. There is no way that he or she can get around this inspection,” says Stefan Zim-mermann. After this process, the images captured and the statistical information on the chain are transferred to a higher-ranking embedded PC via FTP & TCP/IP protocol.

... to the “chain reaction”“Not a single defective chain link has been delivered to customers since the inspection table was commissioned,” Stefan Zimmermann cites one of the rea-sons for the somewhat different type of “chain reaction” – there are now more than a dozen of these systems in use. “The entire inspection process has been revolutionised,” he sums up. “The in-spection table offers a range of possibili-ties that were simply not available to us before. And with the information gained from archiving when the equipment has switched off we can not only determine where there might be potential plant de-fects, but also optimise the production of individual parts.”

Whether industrial or process chains – both profit from the IVC-2D smart camera.

The checking of industrial chains at Rexnord Kette was solved by a new inspection system with an integrated smart camera

: Applications

Happy about the revolutionary inspection process: Frank Kesseler from Rexnord Kette, Ralf Zöller from AKL-tec and Christoph Brinkmann from SICK (from left to right)

Inspecting industrial chains

: Applications

24 2/2006

insightlInkYou can obtain further product information with the attached card under:INFO 222or on the internet at:www.sick.com/insight/enMore about the customerwww.ectn.com

>> Those driving southwards towards the Gotthard tunnel along the A2 mo-torway in Switzerland pass the Erstfeld heavy transport measurement station a few kilometres before the tunnel. ECTN from Buochs has set up a profile meas-urement system for trucks at the existing weighing and inspection station, after receiving an order from uri canton’s civil engineering authorities and the respon-sible federal road authorities ASTRA. “Its task is to measure, detect and evaluate unauthorised height, width or length de-viations as the vehicles pass by slowly on their way to the static weighing system, in order to increase safety in the tunnel,” explains Richard Arnold, head of uri’s traffic police.

Three scanners for profile and length measurementsThe truck measurement system consists of two laser scanners on a gantry set up in front of the vehicle weighing system, with a third laser Measurement System installed on a mast with a jib directly behind the weighing equipment. As a result of their weatherproof outdoor de-sign they are suitable for use outside, and are also immune to extreme outdoor temperatures. The truck can drive into the plant as soon as the signalling sys-tem switches to green. The synchronised gantry scanners, each monitoring the entire drive path width, measure the left and right halves of the vehicle simulta-neously. The evaluation computer of the truck measurement system determines the actual vehicle width from these data. At the same time, the scanners generate the sectional profile information (height, width) that are evaluated and checked against pre-programmed tolerance val-ues. The third scanner (on the mast) de-tects the vehicle length while the truck

More safety for heavy traffic with lMS laser Measurement SystemsToo long, too wide, too tall? Truck profile measurement plants from ECTN AG with outdoor laser meas-urement scanners from SICK de-tect, without contact, whether vehicles conform to standard di-mensions or not.

drives through the measurement system. With the length information, the system can classify the truck automatically, de-tect over-lengths and localise any exces-sive profiles. The measurement data for the profile measurement are already available by the time the vehicle stops on the weighing system. When the truck has left the profile measurement system the signalling system switches to green again for the next vehicle.

Successful practical operationThe truck profile measurement system has proved its efficacy in practice. uri canton’s

police report that dangerous over-widths and over-heights, in particular, which are difficult to determine (because they can only be measured in point form) have again and again come to light and are always fol-lowed up and punished with fines.

Outdoor laser scanners on the truck profile measurement system detect whether the vehicles’ dimensions conform to legal stipulations

Traffic

: Applications

>> The English machine constructor TS Converting had to protect three hazard-ous points-of-operations on a particular machine. Two systems – a C4000 safety light curtain and a S3000 safety laser

Three monitoring areas, two safety systems, one safety controller

Intelligently organised safetyscanner – proved to be the right sensors. A uE440 configurable safety controller brings everything together to create a unique solution.

While the C4000 monitors the back of the machine, the S3000 is used to ensure safety on both the feed system and at the front of the machine, where power-driven shafts and cutting tools are located. The special feature here: because only the feed system or only the processing machine is active at any one time, the S3000 can alternately monitor both functions with two separate protec-tive fields.

Protective field activation and signal evaluation by the UE440The uE440 safety controller supplies the necessary information on which of the protective fields is to be activated. It also evaluates all the signals – including those of the C4000, and the three emer-gency stop buttons and a safety interlock that also contribute to the machine’s safety concept. Two supplementary func-tions of the uE440 are of significance to TS Converting. The Bypass function per-mits employees to approach the slow-running machine from the front or from the back during Setup Mode, without it being switched off by the safety equip-

ment. The integrated Override function only affects the laser scanner at the front. Its switch-off signal is suppressed when an employee has to work in the im-mediate vicinity of the hazardous point-of-operation in Setup or Quality Inspec-tion Mode.

The solution bears the signature of safetyPLUSThe development, implementation and future-orientation of the solution devel-oped with TS Converting bear the signa-ture of safetyPluS. With the safetyPluS strategy (see also P. 30), SICK is extend-ing its approach of integrated safety thinking and safety activity. Early involve-ment in the machine project allowed greater integration of safety technology aspects. The consequence: greater func-tionality through the optimum combina-tion of the individual functions and op-portunities offered by sensors, control systems and service performance. The plus for users: greater security – regard-ing the technology, the overall solution, future capability, and their investment.

TS Converting is – as shown by the above-mentioned application – satisfied with the one-stop safety shopping concept. INFO 224

The S3000 can monitor two functions alternately with two separate protective fields

25

>> The slaughter and conveyor technol-ogy producer BANSS has automated the processing of cadavers with lMS400 la-ser Measurement Systems.

The 2-D measurement values of two lMS400s, supplemented by the speed of the conveyor system, allows three-di-mensional measurement and display of the entire body surface of animal cadav-ers. The PC evaluation software of the cutting line then transfers the data to the robots in the cutting plant. From these measurement values, the robots’ control-lers generate the optimum vertical robot movement for each animal, e.g. to cut the rectum free or to open the abdomen and

Robot guidance for meat processing

laser measurement provides cutting data for animal cadavers

breastbone. up to 600 animals per hour can thus be processed efficiently.

High precision, rapid processing of measurement valuesThe high precision of the lMS400 is im-portant for use in the cutting plant. The large aperture angle of 70°, the fine an-gular grid of 0.1°, and the high distance resolution within the 3-metre range provide precise contour data on the ani-mal’s body – and thus equally precise control data for the robots. Furthermore, the data are quickly available as a result of rapid measurement value processing and real-time transfer.

The lMS400 is thus an efficient solu-tion for the automation of cutting lines in meat processing. INFO 223

: Applications

26 2/2006

>> The lD-lRS long Range Scanner from SICK AG is a laser scanner that scans its surroundings with laser pulses and gen-erates a profile with distance and angu-lar data. Thanks to its Ethernet interface, this data can be further processed in real time – as is the case at the power station. The device can really exploit its strengths when the detection of dark ob-jects over long distances is involved, and high-resolution results are required.

Laser measurement provides information on the location of particular coal typesThe coal for the power station is deliv-ered by train, temporarily stored in the coal bunker, and fed into the power sta-tion boilers via a rotary bucket excavator. Coal types of differing qualities are used

Coal heap measurement at an RWE Power brown-coal-fired power station

laser measurement technology for coal heapsAt a brown-coal-fired power station belonging to RWE Power AG a meas-urement solution has been developed with the LD-LRS laser scanner for the coal bunker, precisely detecting each heap of coal – without the de-vice costing “a heap”.

in order to ensure an optimum burning process. As the unloading of the train wagons is a manual process, it is nec-essary to determine exactly where the particular types of coal have been de-posited. In the case of certain “problem coals” this knowledge is particularly im-portant for the subsequent burning proc-ess. This is where the lD-lRS comes in. It measures the entire 250-metre-long heap after each delivery. For this pur-pose, a rail-borne measurement wagon (developed by ABB Automation GmbH in Cottbus, Germany) with an integrated lD-lRS travels along its section of the heaps and determines the current bulk material profile. The resultant 3-D and 2-D models of the heaps – calculated using software from Berlin’s AuCOTEAM GmbH – show the locations of the coals

insightlInkYou can obtain further product information with the attached card under:INFO 225or on the internet at:www.sick.com/insight/enMore about the customerwww.rwe.de and www.abb.de or www.aucoteam.de

in the bunker. The total volume is also calculated from this – both to enable re-orders to be made in good time, and to track the coal quality and quantity through the rotary bucket excavator and coal conveyor belts until it reaches the final burning process.

Maximum operating reliability due to long rangeThe scanner and data transfer wagon can be driven at a safe distance to the coal thanks to the long range of the lD-lRS (80 m with only about 10% reflec-tivity of the bulk material surface). This makes a decisive contribution towards the high availability of the heap meas-urement system – because the system is subjected to considerably less vibration and damage from flying shards of coal, or extreme contamination from the coal dust or other environmental effects.

In addition to profile measurement, the lD-lRS offers a collision prevention function for particular applications if it can be mounted directly on a coal exca-vator – real added value that really pays.

A rail-borne measurement wagon with integrated laser scanner detects coal stocks at Neurath power station

Used at a safe distance to the coal: the LD-LRS Long Range Scanner

Power stations

: Applications

27

insightlInkYou can obtain further product information with the attached card under:INFO 226or on the internet at:www.sick.com/insight/enMore about the customerwww.sew-eurodrive.de

>> With DriveAcademy, SEW-EuRODRIVE has built a modern training institute that is intended to provide a stimulating learn-ing atmosphere – not least with its ar-chitecture, which resembles a ship. “As a supplier of knowledge, DriveAcademy places great value on practical training, i.e. learning on and with the drives, safe drive systems, servo-linear motors, con-trollers and field distributors,” Johannes Beck, Manager of the DriveAcademy, de-scribes its philosophy. One of the largest of the 14 training rooms has thus been equipped with a wide range of plant tech-nology driven and controlled by SEW com-ponents, including conveyor belts, rotary

Training in a safe and ergonomic environment

SEW-EuRODRIVE’s DriveAcademy relies on SICK safety technologyJust in time for the company’s 75th anniversary, SEW-EURODRIVE will soon open the new DriveAcademy training institute in Bruchsal, Germany. C2000 light curtains and S3000 laser scanners from SICK, together with MOVISAFE 100 A safety monitors from SEW-EURODRIVE provide protec-tion for the up to 200 employees and customers a day undergoing practi-cal training on the drives and the plant technology.

tables, elevating shearing tables, gantries and converters. Here, practical knowledge is applied live, i.e. programming, commis-sioning, equipment tests and simulations of problems. “There is always something going on, there is almost always someone working on (or in) the equipment,” ex-plains Oliver Jäger, Manager of Functional Safety at SEW-EuRODRIVE. “We therefore had to ensure safety during training, with-out complicating access to the equipment with, say, barriers.”

“Flexi-“ yes, “Plexi-“ noInstead of fences or Plexiglas walls with doors or flaps, it is C2000 safety light

curtains, S3000 safety laser scanners, and MOVISAFE 100 A safety monitors that protect the roughly 200 trainees a day at the DriveAcademy, as well as the approximately 25 trainers. At the same time, they allow flexible and unhindered access to drive systems and equipment parts that are reliably monitored by MOVISAFE 100 A units. In this way, the DriveAcademy offers the ideal prerequi-sites for imparting and applying theoreti-cal and practical knowledge regarding drive technology in general, and drive safety technology in particular.

Technological knowledge has a half-life of about four years. The DriveAcad-emy therefore offers high-quality training, ensuring that employees and custom-ers are always kept up to date with the state-of-the-art in drive and automation technology. Safety equipment from SICK and safe drive systems from SEW-EuRO-DRIVE thus work hand-in-hand to ensure a protected and ergonomic environment.

Safe training environment: the plants of the DriveAcademy equipped with safety technology from SICK

Oliver Jäger from SEW-EURODRIVE and Volker Neuenhaus from SICK

Plant technology

28 2/2006

: Know-how

For small objects:

Automation with laser photoelectric switchesWhether in standard applications or those that make special demands of the sensors – laser photoelectric switches allow the reliable and eco-nomical solution of automation tasks in many situations.

Laser – the special light sourceunlike lED sensors, lasers largely gen-erate parallel light. This results in con-siderably longer photoelectric switch ranges, even with small housings. The narrow beam path also allows objects to be detected through tight openings in a machine. Finally, the sensors generate an extremely small, easily visible light spot on the target object, even over long distances – so that even the smallest of objects and features can be detected.

The laser “packaging” must suit the applicationSensors must be available in application-oriented housings to exploit the advan-tages of laser technology. With a total of eight series, SICK offers an appropriate housing to cover all installation and envi-ronmental conditions. Read more at www.sick.com/insight/en

>> The smallest of objects or features, easily visible light spot, long ranges on reflectors, and tight optical openings in the machine – the laser photoelectric switches or laser scanners of the eight different SICK series offer decisive ad-vantages wherever these conditions and requirements exist.

laser expertise has led to advantag-es with SICK for over 15 years, and not just in photoelectric switches. Our laser competence is also exploited to the full in other sensor systems: such as those for highly accurate distance and profile measurement, electro-sensitive protec-tive equipment, sensors for detecting contrasts, and readers for the identifica-tion of bar codes and 2-D codes.

Safe sensors and controllers

Think in terms of open solutionsWhether simple machines or complex production plants – safety is no longer simply a question of the sensors themselves, particularly in times of decentralised automation and network solutions. Control technology is increasingly the centre of attention – and with it, the demand for plat-form-independent and application-oriented complete solutions from a single source.

>> Standards are becoming more com-plex, technologies more demanding, the supplementary automation advantages of safety solutions have to be more ver-satile, but also individual – this back-ground, and the merging of safety tech-nology with standard automation, pose new challenges for machine producers. Today, the dominant trend is the desire for a safe complete solution. The basic prerequisite here is the comprehensive safety-application expertise and special-ist knowledge of solution suppliers. This is – if only for historical reasons – often considerably more likely to exist at pro-ducers of safety sensors than at “pure” control suppliers. Thus during the last 60 years SICK has developed a suitable sensor solution for almost every task, including interface components for ma-chine integration.

The targeted development of the first safe control solutions by companies that were originally pure control producers is, in contrast, relatively new. They almost always follow a proprietary approach, i.e. the control philosophy of the particular producer. The consequence: decisions are not made on the basis of the best possible application solution for the task but are, instead, dominated by the pro-ducer’s own control environment. The resulting system is inevitably often not the most technically or economically suitable solution.

As a result of these experiences, SICK decided to define safety as open for dif-fering control technologies, as well as an application- and customer-oriented solu-tion package. This safetyPluS approach offers users one of the widest portfolios of safety sensors, with open control so-

lutions for differing levels of integration and networking, based on decades of application and sector experience. Read more at www.sick.com/insight/en

29

: Know-how

>> There are many reasons for the in-creasing spread of 2-D technology – in many cases at the expense of the clas-sic bar code. While bar codes are a hori-zontal or vertical sequence of bars and spaces, 2-D codes can store information in both directions. They are therefore able to achieve a higher density of informa-tion or provide identification in a smaller

2-D reading technology and direct part marking

Direct or indirect – that is the question

Electronics production, automobile construction, medical and pharmaceu-tical technology, or document handling – the use of 2-D codes such as Data Matrix for object identification is continuing to gain ground. Direct part marking (DPM), i.e. the direct application of the code on the object itself, is particularly popular as a result of its robustness. The differing marking technologies, however, result in particular conditions of use.

space. A further advantage of 2-D codes is their high data reliability. The symbology integrates redundant data for correcting errors and for data reconstruction. This makes it almost impossible to read out incorrect data – unlike during the identifi-cation of one-dimensional bar codes. This can be of vital significance: just consider the identification of blood plasma bags.

Important in many processes: omnidirectionalityA further property is of decisive impor-tance in many situations: omnidirectional readability. The reason: 2-D codes have a matrix-like structure. Correspondingly, a two-dimensional identification unit is required to read them. In most cases, this is provided by a camera with an inte-grated area sensor (CCD or CMOS chip). Thus an image of the code can be cap-tured in any orientation. The reading de-vice knows where which data is located thanks to the so-called “finder patterns” integrated in the 2-D codes. These “align-ment aids” may be concentric circles, specially designed corner markings, or particular edge designs. Objects there-fore no longer require manual position-ing or turning – the code will be detected if it is present in the read window.

Marking technology influences reading technologyAs versatile as the identification possi-bilities of 2-D codes are – the labelling technology used has a major influence on the identifiability, e.g. of data matrix. Read more at www.sick.com/insight/en

2-D codes: a lot of info in a little space SICK offers powerful solutions for effi-cient 2-D code detection

: safetyPLUS

Those who speak of safety are less and less thinking of just the individual products that make equipment and machines safe. Safety is now a com-prehensive concept, as is sensor, control and application competence: i.e. safetyPLUS – the safety concept from SICK.

>> The world of safety is complex and dynamic: directives and standards in-teract with one another; technological progress offers new solution approach-es; new concepts are created on the basis of new demands which, in turn, can have normative or technological effects. Staying on top of all this, and offering safe system solutions while helping design innovative processes, can only be achieved by those who, like SICK, have offered practical safe sensor and control technology for about 60 years.

Safety means knowing where one is goingSix decades at the cutting edge of safety developments make SICK a competent contact for customers, users, standardi-sation committees and inspection organ-isations. Based on intensive dialogue, SICK offers:

p effective, complete solutions from a single source,

p seamless integration in all open system worlds,

p the most versatile sensor and switch portfolio – worldwide,

p uniform software for configuration and project planning,

p innovative safety control technology,p the world’s first safety controller with

an enclosure rating of IP 67,p a dense global competence network

of application engineers with first-class qualifications,

p worldwide service throughout the entire machine life cycle.

Tomorrow’s safety is thus called safetyPLUS.

Safe robot cells: greater integra-tion and greater functionality right from the startsafetyPLUS is available to both system integrators and end-customers. Austria’s Roboter-Anlagen-Technik GmbH (rob-an-tec) in Linz exploited safetyPLUS in their latest project.

The task was to ensure accident-free working processes during the produc-

Complete safety solutions for the entire life cycle

safetyPLUS – safety and added value in a single package

30 2/2006

safetyPLUS was fully exploited for a recently implemented project at Austria’s Roboter-Anlagen-Technik GmbH in Linz

safetyPLUS – the decisive PLUS in the safety: “We support you during all phases of the machine life cycle of your machines and plants – from project planning to modernisation.”

insightLINKYou can obtain further product information with the attached card under:INFO 227or on the Internet at:www.sick-safetyplus.com

SICK believes that safety technology means integrated safety thinking and safety activity. For one thing, greater integration means always keeping an eye on all safety-relevant aspects from the very first planning step to the ultimate modernisation of a machine: the risk analysis and safety concept, project planning and CE-certification with Safexpert software, commissioning and inspection, repair and modernisation. For another thing, greater integration in the form of comprehensive sensor, control and service solutions from a single source leads to more economical and future-oriented solutions – because greater integration also always means greater functionality. With its compre-hensive portfolio of products and services, SICK ultimately offers OEMs or users greater safety through one-stop safety shopping:

p advice on all safety-relevant topics,p the right solution for the current task,p any machine downtimes are rapidly and efficiently handled,p upgrading to meet the new demands of the future,p open solutions provide independence regarding suppliers,

technologies and systems,p competent support available worldwide at short notice, and thus ...p ... confidence – in having made the right decision with safetyPLUS.

>> safetyPLUS: greater integration = greater functionality = greater safety

tion of automobile fuel tanks on folding and welding robots at the end-customer Magna Steyr Fahrzeugtechnik AG. The two new robots, neighbouring one an-other, had interlinked processes. “We had already made contact with SICK during the initial planning phase so that we could achieve as efficient a safety solution as possible right from the start,” says Bernhard Eiber, Managing Director of rob-an-tec. “Building on a risk analysis, we worked out and assessed a variety of safety concepts together with SICK.” Be-cause of the technical process conditions, a C4000 safety light curtain proved to be the best solution on the welding robot while, in addition to another C4000, the cell of the bending robot was equipped with an S3000 safety laser scanner to monitor the internal space. Furthermore, a variety of working and end positions could be detected in the two cells with the help of non-contact safety switches, and this information passed on and used for controlling the protective equipment. The flexible UE4400 safety controller sys-tem was used to provide effective evalu-ation of the sensors’ data and for simple conversion of the safety logic. “Together with SICK, we developed an approach for the integration of all the safety systems in the control technology. The early engi-

Complete safety solutions for the entire life cycle

safetyPLUS – safety and added value in a single package

neering, programming and advance trials of the complex functions allowed a con-siderable reduction in the commissioning time at the location near the new Peugeot works in Slovakia’s Trnava. And now the early consideration of sensor and control solutions from SICK has really paid off.”

The UE44x7 series from SICK permits, for the first time, remote safety automa-tion without a control cabinet in situ in the field. The field controls can either be run in stand-alone operation – without any other safety controls – or together with other controllers in a combined network.

The “Fast shut-off” function with its ex-tremely rapid reaction times of under 8 ms – even in a combined network – combines the rapid reaction time of the individual controllers with the flexibility of networked solutions. This minimises the safety dis-tance between the protective equipment and the hazardous point-of-operation. The “Safety enable” function allows a standard controller to regulate the safety outputs of the UE44x7 – without using a safety con-troller in the application.

: safetyPLUS

31

The project also demonstrates how im-portant a dense international network of competence is, because the servic-ing work and the plant modifications that can be expected during the plants’ operating lives can be carried out or supported by SICK personnel on site. “As a result of the early collaboration with SICK as experts in sensors, control sys-tems and services, we can implement an intelligently integrated overall solution whose openness and range of functions now guarantee the end-customers a high level of safety at work, and a high last-ing level of investment safety,” Bernhard Eiber sums up. “That is exactly what we mean by safety, and what SICK means by safetyPLUS.”

Those who speak of safety are think-ing of the combination of sensor, control and service competence. Safe system so-lutions from SICK – safetyPLUS for users.

UE44x7 – the world’s first compact safety controller in IP67 technology

32 2/2006

: Products

>> This has been made possible by us-ing a suitable resolution of 2 mm that is – uniquely – not only applicable for

Letters, mailings and very flat or only slightly protruding objects – the new HLG light grid is the right solution when it’s important to reliably detect such flat objects on a conveyor belt or in an ejector chute.

>> As a result, users can parameterise devices in the above-mentioned series on the familiar PLC program interface. The advantages offered by the previ-ous version remain: trouble-free data exchange between the CLV and the PLC, integration of additional signals from, for example, photoelectric switches via the four digital inputs and outputs, as well

Detection of flat objects in rapid movement

Light grid performs precision work

The possibility of parameterising the CMF400 PROFIBUS module in the CDM420 connection module by means of a GSD file now makes it even more flexible. The bar-code scanners of the CLV420 to CLV450 series profit from this update.

as clock-pulsing of the reading device via the fieldbus.

Two new pre-assembled CDM420 variantsExternally, two new variants of the CDM420 are evident. The user can chose between a 9-pin D-sub plug or two M12 connectors for the PROFIBUS connection. Both CDM variants are available pre-assembled as ready-for-use devices with integrated pa-rameter cloning module and PROFIBUS module. The advantage: easier ordering and installation for the customer.

By the way: only SICK allows integra-tion of its hand-held scanners directly in PROFIBUS-DP. INFO 228

Software update for bar-code scanners and CMF400 PROFIBUS module

Parameterisation using GSD file

Product News:P

RO

DU

CT

NE

WS

a very low switching hysteresis and the currently fastest response time offered by such systems – just 3 ms – impor-tant for rapid postal sorting systems or packaging machines with a high throughput rate.

26 beams with an installation height of just 50 mmThe HLG High-resolution Light Grid offers a fixed detection height of max. 50 mm. Each of the two robust metal housings accommodate 26 transmitter or receiver elements. The teach-in of objects – supported by three indicator LEDs – and the synchronisation of the transmitter and receiver by cable guar-antee rapid commissioning and maxi-mum stability of the taught-in switching threshold. Apropos rapid: objects can be closely packed onto the conveyor belt in the goods distribution centre thanks to the extremely short response time. The HLG only needs the smallest of gaps (just a few millimetres) between the individual objects at a transport speed of 120 m/minute for the reliable detec-tion of the front edges. The switching signal can then be transmitted via either NPN or PNP.

High detection reliability for flat objects – the HLG is the right choice.

a small “exclusive” section but is con-stant over the entire detection area. This high resolution is accompanied by

33

: Products

>> Whether electronics production, au-tomobile construction or other industrial sectors – the two-dimensional Data Matrix code for the identification of components and assemblies enjoys widespread use. The machines, and the reading demands that must be met, are as varied as the ob-jects themselves.

Suitable for long ranges and a vari-ety of marking technologiesThe most important conditions are the range and the identification technology used. The ICR860 is characterised by high flexibility in both cases. Data Matrix codes can be just as reliably read over short dis-tances as over long distances – regard-less of whether code labels or direct part

Reading distances of between 0.2 and 2 m are the strength of the new ICR860 2-D reading device. Thanks to interchangeable lenses, compre-hensive illumination solutions, and the familiar user-friendly interface the sensor can be rapidly adapted to any task without additional software in-tegration.

marking (printed by needle, laser or inkjet) are used. Commissioning is user-friendly and takes place by means of Webserver technology. Calibration of the code reader has a familiar look and feel to it thanks to software based on CLV Setup. The program automatically determines the optimum reading field size and code reso-lution when the object distance and the focal point of the lens used are entered. As an option, the laser device can be inte-grated via an RS-485 or Ethernet interface for data transmission during operation.

Apropos resolution: those for whom the 640 x 480 VGA pixels of the ICR860 are insufficient can use the XGA reading device of the ICR862 – with 1,024 x 768 pixels. INFO 229

>> Encoders with a HIPERFACE interface are used in drive technology as motor feedback systems. As a result of their spe-cial design for drive technology they have a high temperature range, are often very small, and are also available in a variety of mechanical housings. The use of these encoders in automation technology would thus be extremely interesting for many customers if a suitable interface is avail-able. An appropriate interface conversion is necessary in order to allow the encoder data to be transmitted in a suitable form for SSI or PROFIBUS.

Adapters ensure appropriate connectionThe HIPERFACE SSI Adapter and HIPER-FACE PROFIBUS Adapter integrate mo-tor feedback encoders (as well as other

Interface adapter modules provide flexibility

Converting HIPERFACE to SSI or PROFIBUSWhether rotative or linear – all path measurement or position determina-tion systems with a HIPERFACE interface can now be flexibly connected to SSI or PROFIBUS with the help of the appropriate adapter module. CANOpen and DeviceNet versions are to follow soon.

path and position determination systems with a HIPERFACE interface) into the par-ticular industrial interface or fieldbus environment via M12 connectors. The advantage: the actual encoder remains compact, the device version remains unchanged and, in particular, flange or housing solutions can be achieved more rapidly and more economically.

Interpolation increases resolutionAn extremely high resolution of greater than 200,000 increments per revolu-tion is achieved because there is an evaluation of the encoder’s digital and analogue signals during the transition from HIPERFACE to SSI or PROFIBUS. It is therefore now possible to meet almost every application-specific demand.

The conversion modules for SSI and PROFIBUS are already available from stock. Further variants for CANopen and DeviceNet will follow shortly.

Far-sighted reading of Data Matrix

The long-range specialist

Product News

:PR

OD

UC

T N

EW

S

34 2/2006

: Products

Eight axles with a single hub

Automatic format adjustment via the PROFIBUS-DP HubThe hub concept of the HIPERDRIVE® automatic format adjustment drive offers reduced operating costs, lower wiring effort, optimised DP addresses in PROFIBUS, and space savings on the machine and in the control cabinet.

>> Precision, repeat accuracy, time savings and batch-related automation are the most important arguments for converting format adjustment from handwheels to automatic HIPERDRIVE® drives. At the same time, the entire proc-ess of axle positioning can be document-ed and becomes more comprehensible. The new HIPERDRIVE® Hub adds further

cost and data benefits to this list. Apart from the lower wiring effort, the system costs in particular are reduced by more than 40%, depending on the configura-tion, because up to eight HIPERDRIVE® units can be integrated in a PROFIBUS environment via a single hub. Simulta-neously, the hub’s Bus Interface & Con-trol Electronics (BICE) allows all eight

HIPERDRIVE® units to be contacted via a single DP address.

Practical experience shows: a drive seldom comes aloneA drive seldom comes alone – this was the decisive realisation that led to the de-velopment of the HIPERDRIVE® Hub. And it was the basis for a particular packaging machine producer’s requirement to inte-grate up to 70 format adjustment drives in the machines. In this case, conven-tional PROFIBUS connection technology would have looked like this: 139 plug con-nections for the PROFIBUS and 70 DP ad-dresses for the drives and the PROFIBUS DP repeaters required to maintain signal quality. Together with other participants, 139 DP addresses would have been required. In addition to the high space requirement and the enormous wiring effort, the other problem would have been that a maximum of only 125 participants can be addressed via PROFIBUS-DP.

HIPERDRIVE® Hub: performance distribution and data management in PROFIBUS-DPThe task can now be solved with the HIPERDRIVE® Hub because the entire format adjustment requires only 9 DP ad-dresses instead of the original 70. This is possible because each hub handles the performance distribution and data man-agement for up to eight HIPERDRIVE® format adjustment drives – but only re-quires a single address within the PROFI-BUS topography. Signal and communica-tion management takes place in such a way that the automation system knows the state of every single positioning drive and can also contact them individually. No re-programming of the control system is necessary to connect the hub – a sim-ple reconfiguration of the hardware is sufficient. Now only one cable is required to connect a drive instead of three. As a result, its plug-in module is considerably smaller and the unit is correspondingly more compact. The total length of the ca-ble laid is also shorter because the hub is installed directly on the machine and not in a remote switch box.

Up to eight HIPERDRIVE drives can be integrated in a PROFIBUS environment with the new HIPERDRIVE Hub

Format adjustment drive

35

: Products

insightLINKYou can obtain further product information with the attached card under:INFO 230or on the Internet at:www.sick.com/insight

Cost controller’s darlingNot only are commissioning engineers and constructors enthusiastic about HIPERDRIVE® Hub, but also cost control-lers. Because the comparison between HIPERDRIVE® with and without the hub shows a savings potential of about 30% in the purchasing of, for example, five drives including cable. If one compares the HIPERDRIVE® Hub solution with other offers on the market, the cost controller can even relish the prospect of purchas-ing cost cuts of 40%, depending on the configuration.

Magnetic cylinder sensors with two switching points

Teach me twice!>> The new MZ2Q cylinder sensor, with two switching points and many advan-tages, does a convincing job wherever two sensors were required in the past.

Two freely adjustable switching points in one sensor – that means occupying just one slot, lower installation costs, and less wiring on the pneumatic cylinder. And the switching points are easily taught-in – the sensor is therefore rapidly ready for action. The compact sensor housing is also advantageous: it permits completely sunken, and thus protected, installation in the slot. Also helpful: the short housing, which even allows the solving of miniature applica-tions in very short cylinders.

Position determination and object detectionAn important target application of the MZ2Q is object detection on grippers, clamps or presses in which a pneumat-ic cylinder with an extension of up to 50 mm acts as an actuator. Here the sensor allows both end positions to be reliably queried. Moreover, the MZ2Q is also suitable for applications in which the second switching points means a signifi-cant improvement in functional reliability. An advance signal can be used for target-ed reduction of piston speed before, for example, a piston reaches its final posi-tion: switching point 1 decelerates the movement, switching point 2 confirms that the end position has been reached.

MZ2Q: once mounted, twice taught-in, infinitely often switched. INFO 231

Summary: in constructive terms, HIPER-DRIVE drives are even more suitable when space is limited; in communication terms, even better when DP address lists are limited – and in cost terms, even bet-ter when budgets are limited!

>> HIPERDRIVE – the highly integrated mechatronic drive system for rapid and precise upgrading tasks

With torques of up to 20 Nm and drive rotations of up to 280 min-1, these drives are precisely aligned for meeting sector-specific requirements. “Intelligence” is integrated in the drive housing and relieves the higher-ranking PLC or control computer.

p The highly compact HIPERDRIVE® format adjustment drive is predestined for all tasks in which, in addition to mechanical strength and a high en-closure rating of IP 65, a wide-ranging functionality and high precision are also required. These positioning units do not replace all classic servo-drives, but can nevertheless be economically used to replace them for the absolute positioning of individual axles. These drives can exploit their special advan-tages to the full when high operational reliability is required. Decentralised and intelligent drive concepts such as HIPERDRIVE® simplify the system structure of a plant and drastically reduce the equipping and restart times of a production process, particu-larly in the case of packaging machi-nes, as well as in general machine construction.

During the setting up and equipping of machines the limit stops, rollers, tools and fixtures in all fields of machine and plant construction are mostly regulated by means of manual adjustment with the help of mechanical or electronic counters. With more and more demands on the part of the user regarding flexi-bility, smaller batch sizes and shorter delivery times, the equipping time of a machine or plant is increasingly becoming a major cost factor during the corresponding product changes.

p With HIPERDRIVE®, a powerful and compact positioning drive is available to users in machine and plant construction. It represents an ideal solution in terms of housing size, functionality, accuracy, mechanical and electrical installation conditions, simplicity of commissioning, servicing, and costs.

p The HIPERDRIVE® positioning drive contains the performance drive, the brush-free DC motor, the absolute value encoder, and the regulatory and performance electronics completely integrated in the smallest of spaces.

Performance distribution and data management in PROFIBUS-DP

36 2/2006

: Products

insightLINKYou can obtain further product information with the attached card under:INFO 232or on the Internet at:www.sick.com/insight

>> Ranger E opens up new areas of use for three-dimensional in-line inspection with up to 35,000 profiles per second, and more than 1,500 highly precise piec-es of 3-D data per profile. The MultiScan function of the Ranger E allows several different object features to be measured and evaluated simultaneously, e.g. grey value, dazzle, 3-D and laser scatter.

35,000 contour profiles/second, over 1,500 pieces of 3-D contour data per profile

The world’s fastest camera for 3-D contour measurementThe Ranger E camera system sets new standards in industrial 3-D contour measurement – with the world’s fastest measurement speed, extremely high accuracy, integrated 3-D data evaluation and the Gigabit Ethernet in-terface for rapid data transfer.

Rapid and reliable standard interfacesThe Ranger E has a Gigabit Ethernet in-terface to permit the 3-D co-ordinates cal-culated in the camera to be transferred to an evaluation PC in real time. Ranger E is the central component in an image processing system and can be integrated in the user’s analysis and inspection en-

Almost all applications profit from the Ranger E’s rapid and highly accurate 3-D contour measurement or its MultiScan function:p checking components in pick & place processes, examining soldering

paste, or inspecting circuit boards in the electronics industry,p robot guidance, unloading of trading units, and automatic

palletising in robotics,p checking tyres, surface inspections of tiles,p portioning meat, fish, or vegetables, assessing the quality of fruit or ba-

ked goods in the food industry.

>> Ranger E for in-line inspections:

vironment via the iCon API software com-ponent supplied. The RS-422 interface al-lows connection of an encoder for precise detection of the speed of the object in the measurement field.

Equipped to meet a variety of demandsWith five different versions, the Ranger E can be used for a variety of tasks. The image-processing sensor’s 3-D measure-ment system is available with two differ-ent resolutions, an optional high-resolu-tion line or two different infrared versions. All Ranger E devices have a robust metal housing and high immunity to ambient light – features that are important for in-dustrial use.

Further Ranger variantsThe Ranger family also contains two other variants. Ranger C offers the same per-formance features as Ranger E, but has an additional interface for connecting a camera. Ranger D is a brand new camera with which standard applications can be solved economically.

The Ranger E’s features offer new oppor-tunities for in-line inspection systems in the most varied of sectors.

The Ranger E camera system detects damaged elements during blister inspection

3-D camera

37

: Products

insightLINKYou can obtain further product information with the attached card under:INFO 233or on the Internet at:www.sick.com/insight

>> The M4000 series is available as Standard, Advanced, or Area versions, depending on the functions required. The new M4000 Advanced Curtain com-

Evolution of multiple light beam safety devices

Greater resolution = lower safety distanceThe M4000 series of multiple light beam safety devices has grown: there are two new Advanced Curtain variants with resolutions of 14 mm and 30 mm. These systems are mounted even closer to the hazardous area. This is especially advantageous for decentralised muting solutions in ma-chine environments with limited space.

bines the functions of the multiple light beams of the Advanced version with a multibeam concept offering consider-ably improved resolution.

The advantage: decentralised muting with the UE403 on the machine itselfThe basic function of the two M4000 Advanced Curtains is to protect access. Functions such as an RS-232 configura-tion interface on the device, beam cod-ing, restart interlock, external device monitoring, and SDL interface (Safety Data Link) for network or fieldbus inte-gration increase supplementary automa-tion advantages in many applications. The UE403 muting switching device (which can be mounted on the multiple light beam safety device itself) is used if the actual application requires reliable differentiation between persons and ma-terials during automatic material trans-port. With an M4000 Advanced Curtain it is now possible to set up an even more space-saving muting station, e.g. if one hazardous area closely follows another, or a hazardous machine is installed di-rectly behind a curve in the conveyor sys-tem. The higher resolution has the effect that a person is detected sooner and the switching signal is thus transmitted ear-lier. Hence the M4000 can be installed correspondingly closer to the hazardous area – shortening the muting station.

With the M4000 Advanced Curtain the protective system moves nearer the machine – advantageous wherever installation space for muting stations is limited.

Access protection

The M4000 Advanced Curtain multiple light beam safety device together with the UE403 switching device form an efficient solution for decentralised, conventional muting applications with automatic material transport

38 2/2006

: Products

>> Compared to conventional magnetic proximity sensors, these series have a switching accuracy considerably im-proved (given constant environmental conditions) and a precisely set hyster-esis. Thus magnets can now be detect-ed with a hitherto impossible precision

New short housing for magnetic proximity sensors

ASIC technology provides increased performanceApart from their reduced length, the new short housing variants of the MM08, MM12 and MM18 series of magnetic proximity sensors offer a number of other improvements – thanks to the use of new ASIC technology.

Magnetic proximity sensors are used to detect magnets. They are particular-ly suitable for use in harsh environments and for detection through non-magnetisable materials. They are mainly used wherever inductive sensors reach their technological limits, for example when long switching distances are involved.

>> Magnetic proximity sensors

Greater functional and reliability reserves

Better switching by farThe Advanced series from SICK expands the range of uses for magnetic proximity sensors – thanks to hitherto impossible switching distances.

>> The switching distance of the Ad-vanced series’ MM12 on standard mag-nets has been increased from 60 mm to 90 mm, while the MM18 series now offers an enormous 120 mm in addition to the former 70 mm – a hitherto impos-sible value in this sensor segment! And distances considerably greater than 120 mm can be achieved if stronger magnets are used.

This has three effects on potential uses for magnetic proximity sensors:1. Magnetic objects can now be detect-

ed over greater distances.

2. The detection of moving targets, or those that have up to now been con-sidered critical, now takes place with greater reserves of reliability.

3. Smaller magnets can be used at hith-erto “classic” switching distances, allowing the solution of new tasks. INFO 234

wherever maximum switching point ac-curacy is required. Further highlights are improved electromagnetic compatibility (EMC) and the possibility of meeting cus-tomer-specific requirements by adapting impulse length, switching point and hys-teresis. INFO 234

Magnetic sensors

39

: Products

insightLINKYou can obtain further product information with the attached card under:INFO 235or on the Internet at:www.sick.com/insight

>> Omnidirectional reading, high resolu-tion, good ergonomy and robustness are the basic demands for the industrial use of hand-held scanners. Both devices meet these demands in full. The reading of DPM codes, however, makes special demands of the laser technology: differ-ing surfaces, small codes, various mark-ing techniques, and highly reflective or weakly contrasting backgrounds are typical conditions that turn the identifi-cation of objects from a task into a chal-lenge.

Maximum performance requiredThe reading of DPM codes requires maxi-mum optical and decoding performance. The devices therefore have a high-reso-lution CMOS chip with which even small codes can be reliably read. The applica-tion-specific optics and special illumina-tion concept ensure optimum conditions during the reading of DPM codes. The il-lumination can be individually adapted to the application. It is therefore possi-ble to use dark-field illumination, for ex-ample – often required for the reading of needle- or laser-printed codes. On the other hand, the integrated diffuser al-lows the reliable identification of codes even if they are located on highly reflec-tive surfaces.

Cable or radio connection?The DPM hand-held scanner is available with a cable or as a cable-free variant with a Bluetooth radio module and a range of 10 m – providing flexibility and allowing equally good solution of both stationary and mobile applications.

Mobile identification of DPM codes

Handy advantages Production control, labelling tests, traceability, counterfeit prevention – the two mobile 2-D hand-held scanners of the IT6300 DPM series of-fer handy advantages wherever objects with direct part marking (DPM) require identification.

Whether bar code or 2-D code – there are basically two types of marking techniques for object identification: indirect marking of objects by means of an attached label and direct marking by inkjet, laser marking, needle pres-sure or chemical etching.

Indirect marking is generally less durable and no permanent fixing of the label to the object can be guaranteed. Its advantage: it is quicker and can, in most cases, be read without difficulty because even the smallest of labels produced using thermo-printers and thermo-transfer printers generate standard-compliant code contrasts and contours.

The advantage of direct part marking (DPM) is that the code becomes a fixed constituent of the object thus marked. Unlike a standard label, the directly marked codes are thus far more resistant to external influences. However inkjet, laser marks or needle prints sometimes have a property that makes reading more difficult: instead of the rectangular data cells defined in, say, the Data Matrix standard, these marking techniques often generate cells with round contours. Their contrast strengths vary far more that those of standard labels. This means that one must work with a wide range of code qualities.

Code quality, reflections, contrast strength – reading systems like the IT6300 DPM series used in industry are designed to meet all these condi-tions, and allow even difficult cases to be reliably mastered.

>> What’s special about DPM?

The hand-held scanners of the IT6300 series open up a wide area of use wherever the identification of directly marked objects is required

2-D hand-held scanners

40 2/2006

: Products

>> Mini-disk technology with optical code disk, compact circuit board in chip-on-board technology, HIPERFACE® interface and electronic type label – the stand-alone versions have taken over the technical components, and thus the fundamental performance features, of their “installation brothers”.

Equipped for direct installationThe SKS36 and SKM36 direct installa-tion versions with their robust IP 65 zinc die-cast housings, 6 mm full shaft, and servo face-mount flange offer all the prerequisites for mechanical connec-tion to a machine shaft. The same is true of the electrical connection technology: the choice of cable or M12 plug permits simple connection for energy supply and data transmission.

High performance and tough as nailsHigh operating speeds of 12,000 or 9,000 r.p.m., a maximum angular accel-eration of 5 x 105 rad/s2, and total incre-ment counts of 4,096 for the SKS36 or 4,0962 for the SKM36 demonstrate the devices’ powerful performance. But they can also take a lot. They can be used at ambient operating temperatures of 100°C, as well as on axles where par-ticularly high immunity to impacts and vibrations is required, e.g. on presses, rolling mills or cutting machines for structural steel.

Support the technological trends of drive producersThe stand-alone concept meets the connection requests of innovative drive producers for use on master axles very well, because drives increasingly have a second HIPERFACE® interface (in-stead of an expensive SSI plug-in card) for the connection of a control or path

insightLINKYou can obtain further product information with the attached card under:INFO 236or on the Internet at:www.sick.com/insight

Installation version for harsh operating conditions

Masterly motor feedback solution for master axlesThey look like encoders but are complete motor feedback systems for installation: the SKS36 and SKM36. Whether the single or multiturn version – both stand-alone options are suitable for use as robust and temperature-resistant path and command encoders for the master axles of machines.

encoder. The new SKS36 and SKM36 offer this interface standard serially and are thus ideally suited for control-ling the machine drive automation solu-tions of the future.

Incidentally, and perhaps of interest to all those for whom encoder features

are sufficient: the SKM36 is also one of the world’s smallest multiturn encod-ers with an integrated drive – and thus ideally suited for tasks in which space is limited and conditions harsh.

Motor feedback systems

41

: Products

>> The POMUX KH53 is an extremely precise, linear position determination system for cranes in handling and ware-housing systems or for rail-borne vehi-cles. The sensor unit determines the ab-solute actual position with great repeat accuracy by means of non-contact scan-ning of reference marks mounted along the drive path. These consist of alumin-ium profiles with integrated permanent magnets, whose distance to one another represents a fixed position coding iden-tified by magneto-resistive sensors. The system operates without any friction due to the non-contact technology employed. Moreover, no reference run is necessary on start-up thanks to the absolute posi-tion determination.

Improved positional tolerance

Magnetic positioning system fit for rough treatmentThe KH53 absolute linear encoder system in the new Advanced design is now also fit for applications in which the distance between the reading head and the reference marks is subject to large fluctuations.

Advanced version with improved positional toleranceWith the new POMUX KH53 Advanced, a system is now available whose positional tolerance has been increased to 20 mm. Thus the reference marks mounted along the drive path are also reliably detected even with relatively large positional tol-erances. Both the reading head and the reference marks of the proven POMUX technology were appropriately modified for this purpose. The Advanced version is available in two varieties: for measure-ment paths up to 54 m and up to 548 m. These cover most tasks in indoor and outdoor use.

The POMUX KH53 Advanced opens up new possibilities for crane position-

ing. A suitable system price, lack of maintenance, lack of mechanical wear, and its high reliability and availability even under adverse environmental con-ditions also make the system interesting for upgrading equipment. INFO 237

Separate optics and evaluation. Analogue and digital outputs can be combined

Laser photoelectric switch with small optics and great intelligence

>> The precise detection of small parts is one of the strengths of the new W130L series of laser photoelectric switches. They solve demanding detection tasks

even in hard-to-reach locations or where space is limited – thanks to small read-ing heads and intelligent configuration possibilities. An analogue output and a special optical head that generates a laser line with parallel light also allow sorting and regulatory tasks to be reli-ably solved.

The W130L provides the flexibility re-quired to allow users to put together their own specific combination of evaluation unit and optics. The series consists of an energetic scanner (WT130L), a photo-electric reflex switch (WL130L) and two through-beam systems (WS/WE130). The latter are differentiated by their laser optics: while the “Spot” variant generates a minute laser spot on the object, and can thus precisely detect even the smallest of parts, the “Line” version offers a 30-mm-wide laser line with parallel light. Combination with the evaluation unit, which has both switch-ing and analogue outputs, opens up interesting possibilities, e.g. the detec-

tion of small, inaccurately transported parts; the evaluation of parts; or their sorting according to size; as well as the regulation of web edges.

Evaluation units open up many configuration possibilitiesThe W130L series offers two different evaluation units – users can choose between either one switching output or the combination of switching and ana-logue output. Objects can be taught into the device very easily, despite the wide-ranging configuration possibilities, e.g. light/dark switching or switch-on/switch-off delay. And it is also possible to teach-in the device externally via the control wire. Depending on the task, the switch-ing frequency can be set to the optimum balance of accuracy and speed.

The W130L series thus offers an oppor-tunity to cover a wide spectrum of appli-cations with a single device family. INFO 238

42 2/2006

: Products

>> The new XKS is aimed at applications in which mounting space must be saved, a robust complete unit is necessary, and short-to-medium measurement lengths are the rule. Typical areas of use for this device are presses, stamping and spay-ing machines, wood and metal process-ing machines, apparatus construction or medical technology.

Replaces expensive supplementary interfaceThe XKS is used like a rotative stand-alone encoder for determining position. Thanks to HIPERFACE®, the XKS removes the need to implement a further interface in plants in which several drives with HIPERFACE encoders are already used for regulation. If the XKS is to be inte-grated in a fieldbus environment, this can be achieved with the help of inter-face conversion modules for PROFIBUS, and soon for CANopen and DeviceNet.

Whether SSI, TTL or HIPERFACE® – the se-ries of compact wire-draw encoders meets every communication requirement.

Compact solution for positioning and path detection

Wire-draw encoder now with HIPERFACE® interface

HIPERFACE® is an asynchronous semi-duplex interface that physically corresponds to the EIA RS 485 specification. It is now used by more than 70 drive producers from A (as in ABB) to Z (as in Ziehl-Abegg) – and has therefore become established as a standard on the market. Power is supplied to the encoder via two of the total of eight wires. Two further wires are required for the bi-directional, bus-enabled parameter channel via which, among other things, the absolute position data of, for example, an XKS is transmitted to the regulator in digitalised form. The two remaining pairs of wires provide the real-time process data channels. Sinus-shaped incremental signals are transmitted in analogue form via these wires and interpolated in the regulator. This non-digital process allows a high resolution to be achieved even at high r.p.m. rates. Thanks to HIPERFACE®, an interface standard is available for all common drives covering all applications with just one type of signal cable.

>> Standard HIPERFACE® interface – the interface standard

insightLINKYou can obtain further product or on the Internet at:www.sick.com/insight

With the new XKS, the HIPERFACE interface standard enters the series of compact, robust and precise absolute wire-draw encoders for measure-ment lengths of up to 5 m.

New wire-draw encoders

43

: Products

insightLINKYou can obtain further product information with the attached card under:INFO 239or on the Internet at:www.sick.com/insight

>> Integration and modularity deter-mine the structure of the ICR890. Thus the system has an LED illumination module, real-time focal control, and a high-performance decoder. The reading field covers conveyor belt widths of up to 1 m, at transport speeds of up to 4.8 m/s, depending on the resolution used. The depth of field lies between 600 mm at a resolution of 250 DPI and 1,600 mm at a resolution of 170 DPI, depending on the application and type of installation.

Top image quality and reading performanceThe ICR890 is designed for maximum im-age quality under all operational condi-tions. The omnidirectional system offers particular advantages, especially for:

p small bar codes that must be read at high speeds,

p dirty or weakly contrasting codes,p bar codes with highly variable module

widths, and p the identification of codes under foil.

Moreover, the ICR890 allows image cap-ture for OCR and video-coding applica-tions. The transmission of image data takes place in real time via the 2 Gbit Ethernet interface, so no special image-processing components (e.g. a frame grabber) are necessary.

High availability through modularityThe individual illumination and camera system groups are integrated in the en-tire system as modules, allowing rapid exchange. The ICR890 stores its param-eters on an SD card – which has proven itself as a compact, upgradeable and rapidly available storage medium for digital cameras. The previously stored parameters can be back-loaded from

With 2 GBit image data transmission

High-end reading system for bar codes and Data MatrixObjects require flexible, rapid and reliable identification in the distribu-tion centres of postal and package service providers, of mail order com-panies, and in the retail trade. The ICR890 high-end camera system sets new standards here. It solves even the most difficult of tasks and can be networked, e.g. with supplementary scanners or a volume measurement system, to create a complete identification system.

the ICR890’s SD card to the new mod-ule should replacement be required. Remote monitoring and diagnosis, allow-ing the further optimisation of system availability, is possible during operation with the help of the RDT400 software tool. No external PC is required for decoding the bar codes because the ICR890 has an integrated decoder in the camera. This leads to significantly great-er system reliability.

Suitable for complete ID systemsThe ICR890 can be networked with other sensor systems via its CAN-Bus

interface. Complete ID systems can be configured by connecting further scan-ners (e.g. for reading from the side) or a volume measurement system. These, then, only require a single interface to the host system – an important advan-tage for many users.

The new ICR890 offers almost “endless” possibilities wherever high-end code-reading demands must be met.

The ICR890 high-end CCD camera system for reading 1-D and 2-D codes, and for image output for OCR and video coding applications

High-end camera system

44 2/2006

: Products

>> The MZT6 magnetic cylinder sensor is used for detecting the position of pis-tons in pneumatic cylinders and offers considerably better switching accuracy, in addition to greater user-friendliness, and improved EMC and immunity to vi-brations.

Precise switching behaviourThis has been made possible by so-called 2-D magnetic field evaluation which, for the first time, allows areas beside the switching range to be reliably cut out dur-ing signal evaluation. There is therefore

Maximum switching accuracy through 2-D magnetic field evaluation

Magnetic cylinder sensor with no scattering of switching points

no “multiple switching” with the MZT6. Moreover, the MZT6 achieves a consid-erably more exact switching behaviour and a greatly minimised hysteresis: its switching point scattering of +/–5% is five times lower than is common with other cylinder sensors – regardless of the cylinder type and the field strength of the piston magnets. This also results in almost scatter-free hysteresis between the switching points. Applications with short and precise cylinder movements, in particular, profit from this improved accuracy.

Expanded temperature range, high enclosure ratingIn addition to its reliable switching be-haviour, the MZT6 is characterised by its great robustness. The sensor can be op-erated within an expanded temperature range of from –30°C to +80°C because its very low power uptake minimises its own warming. Supplemented by special extrusion technology, the new MZT6 also offers maximum tightness up to IP 69K, as well as immunity to temperature shocks.

Proven benefits retainedIn other respects, the new MZT6 exploits the mounting and application advantag-es of its predecessor. It fits all common T-slots, can be inserted into the slot from above, and is reliably fixed without any special tools. During operation, its firm fixing ensures that the switching points remain exactly where they have been taught-in.

At the 2006 Hanover Industrial Trade Fair (HMI) SICK presented sen-sors with a completely new type of chip technology which, among other things, provide hitherto impossibly precise switching behaviour. The MZT6 magnetic cylinder sensor is the latest example.

insightLINKYou can obtain further product information with the attached card under:INFO 240or on the Internet at:www.sick.com/insight

Particularly precise and robust: The new MZT6 magnetic cylinder sensor

Magnetic sensors

: Museum

>> Whether with a virtual tour or video – visitors can prepare themselves in ad-vance for the highlights awaiting them in the museums.

Largest public collection of model railwaysThe Model Railway Museum on Gran-ville Island houses the world’s largest collection of model railways and toys on public exhibition. Among other things on

The Granville Museums in Vancouver

offer model ships and railways

Fans of model railways and faith-fully scaled models of ships will cer-tainly get their money’s worth at the Granville Museums in Vancouver, Canada.

view are several historical locomotives and trains of differing gauge (gauge 0, gauge G, standard gauge, etc.) as well as numerous photo and diorama shows. The impressive range of model railway systems, and their detail, give an idea of the incredible patience involved in con-structing the five-line networks.

An Eldorado for aficionados of model shipsThe Model Ship Museum is right next door. It accommodates an impressive international collection of model ships, submarines, warships, aircraft carri-ers, freighters, tugs, yachts and toys. The Ship Museum exhibits classic ships such as HMS Bounty, Admiral Nelson’s HMS Victoria or the German destroyer Bismarck as scale models. The star of the Museum is undoubtedly the 350 kg 4-metre model of the British battleship HMS Hood from the Second World War. It took model constructor Rodney Hen-driksen more than 20 years to build.

Miniature technology

45

«en miniature»

Technology[ ]

International guests are welcomeWith their model ships and railways, the museums present technology in mini-ature from all parts of the world. So they are correspondingly prepared for inter-national guests – especially on the home pages www.modelshipsmuseum.ca and www.modeltrainsmuseum.ca – available in 15 languages.

46 2/2006

: Interview

Retain the proven, weigh up the new, think long term

Continuity and innovation – the right mix determines success30 September 2006, the day of the company’s 60th anniversary, was also the last working day for Anne-Kathrin Deutrich, Spokesperson of the Ex-ecutive Board of SICK AG. In conversation with SICK insight she reviews how the small Black Forest company became a global player in sensor technology.

SICK insight: What did you think of SICK when you joined it in early 1992?

Anne-Kathrin Deutrich: I came to SICK as the successor to the Commercial Manager during an exciting time. The then Managing Director and later Execu-tive Board member, Volker Reiche, had initiated a new strategic alignment that

SICK insight in conversation with Anne-Kathrin Deutrich – Spokesperson of the Executive Board of SICK AG until 30 September, 2006

was intended to create a company with professional internal and external struc-tures from the family business Erwin Sick GmbH. “Improvements everywhere” was the aim – particularly regarding greater market share in the core sectors, ac-cess to new fields of application, greater closeness to the customer, and being more innovative than the competition.

SICK insight: What measures did SICK take at the time to re-align itself?

Anne-Kathrin Deutrich: We identified the importance of research and develop-ment as well as the creation of a mar-ket- and customer-focused corporate organisation as long-term factors for success. The budget for R&D was con-sequently greatly increased. This was not so straightforward during the 1993 recession – but looking back, this step provided the technological basis for SICK’s subsequent success. The PLS safety laser scanner is just one of the many examples worthy of mention. At the same time, we expressed our new type of customer focus in automation, safety, environmental and identification technology. As a result, we were better able to implement customer wishes, and could also better take into account the special aspects of the particular areas of business – with short-term component business here, and long-term project business there. Further key actions were the introduction of comprehensive proc-ess controlling, the evaluation of results, the creation of new work processes, and the qualification of our employees.

SICK insight: What significance did in-ternational business and the topic of acquisitions have for the development of the company?

»Over 70% of Group sales take

place abroad«

Anne-Kathrin Deutrich: Without the in-ternationalisation introduced at the time we would undoubtedly not be a global player in sensor technology now. We are in leading positions in the world markets of Europe, America, and Asia through-out all our fields of business. Over 70% of Group sales take place abroad. This all started with the founding of the first subsidiaries – initially in Europe, then overseas. We are now represented by over 40 subsidiaries or participations in

47

: Interview

Retain the proven, weigh up the new, think long term

Continuity and innovation – the right mix determines success

more than 40 countries. SICK then be-gan making acquisitions in the late 90s. In addition to purchasing brands, we paid particular attention to the sensible rounding out of technologies that would advance our cause in our core areas of business. This, too, has paid dividends – consider, for example, the rotative sensors of SICK STEGMANN, the laser technology of SICK IBEO, the extractive gas analysers of Maihak or the camera expertise of SICK IVP. These successes were possible because we remained true to our long-term thinking, i.e. aiming for substantive returns on investment and not merely quick profits.

SICK insight: You mentioned technology. Technologies also depend on having the right technologists, i.e. employees. What makes SICK interesting for qualified em-ployees?

Anne-Kathrin Deutrich: The improve-ment of personnel work was one of the most important tools in the re-alignment of SICK, and still is. We rely on the per-manent qualification of our employees, while at the same time also require new colleagues who bring new topics and technologies to the company. It’s easier to find such people nowadays than it was ten years ago. This is partly because of the attractive, modern work-places that SICK offers – just look at all the new buildings that we have put

up in recent years. We can be proud of our modern management culture that encourages employees while also chal-lenging them. Then there is a new qual-ity of life that seems to make the region around Freiburg more attractive to many applicants and their families than some urban centres of population without any real leisure value. Moreover, we under-take projects that support families in the company and in the region, e.g. the youth centre, or afternoon homework assistance for our employee’s children. Finally, SICK as an Aktiengesellschaft (a form of private limited company) has also become an open, well-known com-pany, whose solid and innovative reputa-tion is an important, even decisive, factor for some new employees – and for many customers too, by the way. On looking back, it is apparent that we succeeded in converting a supposed locational dis-advantage into an actual locational ad-vantage.

SICK insight: Where do SICK’s future challenges lie, and what is the recipe for success in the future?

Anne-Kathrin Deutrich: The challenges are varied and we are already facing them. Take the example of complete solutions. The trend is clearly away from component business. It will always be necessary, of course, but the increasing-ly complex demands of OEMs and end-customers require intelligent complete solutions consisting of sensors, control technology and services. Thanks to our internal structures, our technological competence, and our worldwide pres-ence, SICK is already very well placed as, for example, the Automotive Sector Management shows. Competition – particularly internationally – will become increasingly harsh. We have observed this, but also see that we can decisively help shape competitive processes by implementing our corporate mission statement “Independence, Innovation, Leadership”. Technological change is taking place in ever-shorter cycles, which means that the importance that we attach to R&D – also in terms of the percentage of profits re-invested – will increase further, especially considering that sensor, control and service technol-ogy is becoming increasingly software-dependent. Meeting the challenges with new solutions will thus be an important part of the recipe for future success. An-other aspect – of this I am quite sure – is to maintain our technological lead. It will all depend on an appropriate mix of the proven and the innovative.

SICK insight: Ms Deutrich, thank you for this conversation. We wish you all the best for the future!

47

: SICK Tour

>> This collaboration is expressed in the KUKA-Stankin-SICK Educational Technological Centre, where students of engineering science and industrial

Safety technology for Stankin’s training centre

To Russia with best wishesStankin, Moscow’s University of Technology and Mechanical Engineering, has gained two important partners for their training centre: KUKA as a robot supplier and SICK as a partner for machine safety.

professionals can explore state-of-the-art robotics and safety-oriented auto-mation, and improve their programming knowledge.

Robot technology from KUKA and safety solutions from SICK

Safety technology for two robot cellsSICK’s contribution to the training centre consists of providing electro-sensitive pro-tective equipment and intelligent safety controllers that ideally support the various functions of the two KUKA robot cells set up side-by-side – so the robots can work individually or co-operatively. The safety control configuration differs depending on the mode employed. If the two robots operate separately, the larger cell is pro-tected with a vertical S3000 laser scan-ner towards the smaller cell. The door in the partially existent protective fence is protected by an i200 safety interlock. Parallel to this, a C4000 safety light cur-tain monitors access to the smaller robot cell, while the above-mentioned S3000 provides protection towards the larger cell. The signals from the sensors in the two cells are consolidated, evaluated and co-ordinated by a UE440 compact safety controller, which also handles the task of upgrading from separate to co-operative cell operation. Now only the C4000 and i200 are active, while the safety function of the S3000, through whose protective field the work-pieces are passed, is con-sequently switched off.

This safety configuration gives the KUKA-Stankin-SICK Educational Tech-nological Centre one of the world’s most innovative solutions in the area of safe sensor and control technology. It is also safe to assume that it is no disadvantage that the sensors and controllers are both available from a single source. INFO 241

>> Whether constructors, Project Manag-ers, Managing Directors or users – practi-cal knowledge is important for them all, though with differing emphases. Given the continuously increasing interest and the specific needs for information, SICK is again offering user training and specialist seminars for a variety of target groups in 2007.

The trainers – both our own special-ists and experts from Trade Associations, federations or EU organisations – pro-vide participants with access to all the important topics dealing with automa-tion, safety, identification and process

measurement technology appropriate for their questions and needs.

Major interest, prompt registrationOur “Training & Education 2007” bro-chure provides a detailed overview of the topics and dates of the target-group-oriented events. It can be downloaded as a PDF file from the link below, or re-quested from us directly. The number of participants is limited in order to ensure an optimum transfer of knowledge. We also provide up-to-date information on current topics and dates at: www.sick.com/seminare.

Training 2007: target-group-oriented practical knowledge

48 2/2006

49

: SICK Tour

>> Dr. Erwin Sick founded an engineer-ing office in Vaterstetten near Munich on 26 September 1946. Very practically, the up-and-coming company moved to its current headquarters in Waldkirch on its tenth anniversary, in 1956. SICK em-ployed 25 employees then. Today – 50

From a Munich-based engineering office to a Group active worldwide

SICK celebrates its 60th birthdaySICK celebrated the company’s 60-year existence at the end of Septem-ber. Since its founding, the company has developed into an independent Group active worldwide. Continuous innovations, and a technological and price lead, have ensured that SICK now has a leading position in numer-ous markets all over the world.

>> Whether students, industry profes-sionals or researchers – they all profit from the support provided by SICK for the Automation Systems Centre (ASCent) at Manchester Metropolitan University.

As ASCent is also the UK’s PROFIBUS International Competence Centre, they were naturally delighted (according to Dr. Andrew Verwer, ASCent’s Centre Manager) to receive the PROFIBUS- enabled safety laser scanner, laser distance measuring system and multi-turn absolute encoder. The SICK sensors will be used on a training rig. Their task will be – and how could it be otherwise

SICK supports Manchester Metropolitan University

Profiting from PROFIBUS sensors

in Manchester – the automated handling of a football.

So if England happens to become World Champion in four years time one will at least know where they learnt their tricks ...

>> SICK Poland was awarded this year’s Gold Medal at the AUTOMATICON trade fair in Warsaw – thanks to the IVC-3D in-telligent camera sensor.

The trade fair took place for the twelfth time, and the number of ex-hibitors had never been so great – and likewise the competition vying for the AUTOMATICON 2006 Gold Medal.

Despite the harsh competition, in the end even the most famous of rivals could be beaten to the highly sought- after prize. The reason? The jury consid-ered the IVC-3D – including its technical documentation and application descrip-tion – unparalleled in its class.

SICK Poland is very happy about re-ceiving the Gold Medal and passed on the jury’s praise to SICK IVP, the produc-er of the intelligent camera sensor.

Award at the AUTOMATICON trade fair

SICK Poland recei-ves Gold Medal

Company founder Dr. Erwin Sick

years later – the SICK Group, as one of the technological and market leaders in factory and process automation, em-ploys more than 4,200 personnel world-wide. Sales reached almost EUR 600 m. in 2005.

60 years of SICK means 60 years of innovation in sensor technology – from the invention of the auto-collimation photoelectric switch and the safety light grid, through gas analysers and bar-code reading devices, to the laser scanners, camera systems and communication in-terfaces of today. Dr. Erwin Sick, who died on 3 December 1988, developed techno-logical milestones over decades. He was largely responsible for the innovative cor-porate culture that still makes SICK the technological leader in sensors. SICK will set further standards in robustness, flex-ibility and innovation on its way to devel-oping the intelligent sensors of tomorrow.

50 2/2006

I accept that it may not be the best sea-son to be talking about T-shirts. Thick jackets and

overcoats would be more appropriate. But it was July when I read the book for this Book Corner, about 35°C it was. And just thinking about wearing anything more substantial than a T-shirt

made me glow (ladies glow, men perspire and horses sweat). I found the title interesting, started going through the book and learnt, on the one hand, a whole lot about cotton and the production and path taken by a T-shirt and, on the other

hand, about interactions in the world economy.Author Pietra Rivoli was confronted, among other things, by the question “Who made your T-shirt?” during an anti-globalisation demonstration at Georgetown University, This spurred the Professor of Economics to take a journey to check out the arguments of globalisation opponents. A journey that followed the global route of a T-shirt, from the growing of the cotton to the ultimate disposal of the clothing. It first took her to Texas because, along with China, the USA is one of the world’s largest cotton producers. There she met cotton farmer Nelson Reinsch and his family. He took her on a journey through the history of growing and producing cotton in the US. She learnt a lot about the geographical development of cotton growing; the working conditions; slavery; the natural enemies of cotton and the resultant crop failures; and the symbiosis between researchers, government programmes and farmers’ own inventiveness.

Having gained a deep knowledge of cotton and its history she travelled to China, where her T-shirt had been produced. There she got to know about the sweatshops (embroidery and sewing factories) that are a thorn in the side of the opponents of glo- balisation because young women work there under almost inhuman conditions. How- ever

Rivoli was surprised to find that the girls themselves did not feel that the work was so bad there, because it allowed them to escape even harder work on the land or, in some cases, forced marriages – and thus gain a minuscule amount of freedom. Although the work is very hard, given these situations the country girls consider it a good job. Accord-ing to Rivoli this is the main factor of China’s success: young women who are compliant and willing to work.

Back in the USA she made her way to Maryland, where prosperity is not unusual and each year the average citizen throws away 68 pounds of material and textiles, or takes them to a collection point. She explains what happens to the collected clothes and then travels to Tanzania to see what would happen to her T-shirt.

Rivoli graphically describes the problem with “downward cost competi-tion” and what this means for the world economy; and that other influ-ences (such as automation and technical progress) pose far greater risks for jobs in the “expensive” world.

This is a very easy book to read as the author understands the art of writing without being overbearing, and her aim is to learn together with the reader – in order to be able to reach a joint judgement at the end. The goal is to focus awareness on interactions. She masters the trick that must form the basis of such “material histories”: the con-stant transition between factual information and the abstract. She re-flects on each event in a generalised way. I have learnt a lot about the

history of the worldwide cotton and textile industry over these 300 pages, but have also gained a better insight into global interactions.

The author’s summation is that there is no global free trade, that political influences such as subsidies, lobbyists or customs barriers keep cotton production alive in the USA, that the dominance of politics masters the market in the global trade in textiles, that global capitalism and the workers’ rights movement are not adversaries, and that her lasting impression of the journey is how well the people involved in the T-shirt business communicate with one another – they all understand each other because the trade connects them all, worldwide.Summary: a book to be recommended. Clearly written and enlightening.

: Book Corner

The Travels of a T-Shirt in the Global Economy

This Book Corner is written by Ingrid Rathfelder, Editor of the SICK insight e-mail newsletter

“The Travels of a T-Shirt in the Global Economy”John Wiley & Sons Inc. ISBN: 0-471-64849-3

I accept that it may not be the best sea-son to be talking about T-shirts. Thick jackets and

overcoats would be more appropriate. But it was July when I read the book for this Book Corner, about 35°C it was. And just thinking about wearing anything more substantial than a T-shirt

made me glow (ladies glow, men perspire and horses sweat). I found the title interesting, started going through the book and learnt, on the one hand, a whole lot about cotton and the production and path taken by a T-shirt and, on the other

hand, about interactions in the world economy.Author Pietra Rivoli was confronted, among other things, by the question “Who made your T-shirt?” during an anti-globalisation demonstration at Georgetown University, This spurred the Professor of Economics to take a journey to check out the arguments of globalisation opponents. A journey that followed the global route of a T-shirt, from the growing of the cotton to the ultimate disposal of the clothing. It first took her to Texas because, along with China, the USA is one of the world’s largest cotton producers. There she met cotton farmer Nelson Reinsch and his family. He took her on a journey through the history of growing and producing cotton in the US. She learnt a lot about the geographical development of cotton growing; the working conditions; slavery; the natural enemies of cotton and the resultant crop failures; and the symbiosis between researchers, government programmes and farmers’ own inventiveness.

Having gained a deep knowledge of cotton and its history she travelled to China, where her T-shirt had been produced. There she got to know about the sweatshops (embroidery and sewing factories) that are a thorn in the side of the opponents of glo- balisation because young women work there under almost inhuman conditions. How- ever

Rivoli was surprised to find that the girls themselves did not feel that the work was so bad there, because it allowed them to escape even harder work on the land or, in some cases, forced marriages – and thus gain a minuscule amount of freedom. Although the work is very hard, given these situations the country girls consider it a good job. Accord-ing to Rivoli this is the main factor of China’s success: young women who are compliant and willing to work.

Back in the USA she made her way to Maryland, where prosperity is not unusual and each year the average citizen throws away 68 pounds of material and textiles, or takes them to a collection point. She explains what happens to the collected clothes and then travels to Tanzania to see what would happen to her T-shirt.

Rivoli graphically describes the problem with “downward cost competi-tion” and what this means for the world economy; and that other influ-ences (such as automation and technical progress) pose far greater risks for jobs in the “expensive” world.

This is a very easy book to read as the author understands the art of writing without being overbearing, and her aim is to learn together with the reader – in order to be able to reach a joint judgement at the end. The goal is to focus awareness on interactions. She masters the trick that must form the basis of such “material histories”: the con-stant transition between factual information and the abstract. She re-flects on each event in a generalised way. I have learnt a lot about the

history of the worldwide cotton and textile industry over these 300 pages, but have also gained a better insight into global interactions.

The author’s summation is that there is no global free trade, that political influences such as subsidies, lobbyists or customs barriers keep cotton production alive in the USA, that the dominance of politics masters the market in the global trade in textiles, that global capitalism and the workers’ rights movement are not adversaries, and that her lasting impression of the journey is how well the people involved in the T-shirt business communicate with one another – they all understand each other because the trade connects them all, worldwide.Summary: a book to be recommended. Clearly written and enlightening.

: Info

51

insightLINKWeitere Infos erhalten Sie mit der Karte am Ende des Magazins unter:INFO 121or on the Internet at:

insightSERVICE

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

Phone +49 7681 202-0 · Fax +49 7681 202-38 63 · info@sick.deCo-ordination: Anette Gasche · Customer Magazine Project Manager · Anette.Gasche@sick.deSpecialist editor: TOP MEDIA · Dirk S. Heyden · 69469 Weinheim · info@topmedia-weinheim.deLayout: johnson][braun Direktwerbung · 76133 Karlsruhe · jb@johnsonbraun.deTranslator: Richard Dennis · 79194 Gundelfingen · richarddennis@t-online.dePrinting: Druckerei Furtwängler · 79211 Denzlingen · info@druckerei-furtwaengler.dePictures: SICK AG, www.ausloeser-fotodesign.de, Cité de l’AutomobileIndividual contributions may be reproduced after prior consent. Please contact us at: Phone +49 7681 202-3878 · Errors excepted · Subject to technical change

SubsidiariesAustralia Phone +61 3 9497 4100 · +1800 3 3480 2 – tollfree sales@sick.com.auAustria Phone +43 22 36 62 28 8-0 office@sick.atBelgium/Luxembourg Phone +32 2 466 55 66 info@sick.beBrazil Phone +55 11 5091 4900 sac@sick.com.brChina Phone +852 2763 6966 ghk@sick.com.hkCzech Republic Phone +420 2 57 91 18 50 sick@sick.czDenmark Phone +45 45 82 64 00 sick@sick.dkFinland Phone +358 9-25 15 800 sick@sick.fiFrance Phone +33 1 64 62 35 00 info@sick.frUnited Kingdom Phone +44 17 27-83 11 21 info@sick.co.ukIndia Phone +91 22 2822 7084 info@sick-india.com Italy Phone +39 02 27 43 41 info@sick.itJapan Phone +81 3 3358 1341 support@sick.jpNetherlands Phone +31 30 229 25 44 info@sick.nlNorway Phone +47 67 81 50 00 austefjord@sick.noPoland Phone +48 22 837 40 50 info@sick.plRepublic of Korea Phone +82 2 786 6321/4 kang@sickkorea.netRussia Phone +7-495-775-05-34 denis.kesaev@sick-automation.ruSingapore Phone +65 6744 3732 admin@sicksgp.com.sgSlovenia Phone +386 (0)11-47 69 990 office@sick.siSpain Phone +34 93 480 31 00 info@sick.esSweden Phone +46 8-680 64 50info@sick.seSwitzerland Phone +41 41 619 29 39contact@sick.chTaiwan Phone +886 2 2365 6292 sickgrc@ms6.hinet.netTurkey Phone +90 216 587 7400 info@sick.com.trUSA Phone +1 (952) 941 6780 info@sickusa.com

More at www.sick.com

SICK Vertriebs-GmbH Schiessstr. 56 D-40549 Düsseldorf Germany Phone +49 211 53 01-0 Fax +49 211 53 01-100 e-mail info@sick.de

SICK AG Erwin-Sick-Str. 1 D-79183 Waldkirch Germany Phone +49 7681 202-0 Fax +49 7681 202-38 63 e-mail info@sick.de

Trade fairs · Imprint · Contacts

Trade fair dates GermanyTrade fair Location Dates 2006/2007VISION Stuttgart 07/11–09/11 2006

SPS/IPC/DRIVES Nuremberg 28/11–30/11 2006

i+e Freiburg 25/01–27/01 2007

LogiMAt Stuttgart 13/02–15/02 2007

HANNOVER MESSE Hanover 16/04–20/04 2007

Control Sinsheim 08/05–11/05 2007

Trade fair dates EuropeTrade fair Location Dates 2006/2007EMAF Porto, PT 14/11–18/11 2006

POLLUTEC Lyon, F 28/11–01/12 2006

SCS AUTOMATION & CONTROL Paris, F 05/12–08/12 2006

Elektro Vakbeurs Hardenberg, NL 12/12–14/12 2006

AIDC Arnheim, NL 06/03–07/03 2007

Dansk Emballage Messe Odense, DK 06/03–08/03 2007

CFIA Rennes, F 06/03–08/03 2007

WIN – World of Industry Istanbul, TR 08/03–11/03 2007

Automaticon Warsaw, PL 13/03–16/03 2007

Total Processing & Packaging Birmingham, UK 15/05–18/05 2007

Trade fair dates worldwideTrade fair Location Dates 2006AUTOMATION St. Petersburg, RU 14/11–17/11 2006

ISA Show Sao Paulo, BR 23/11–25/11 2006

ProMat Chicago, USA 08/01–11/01 2007

SAFETY IN ACTION Melbourne, AUS 20/03–22/03 2007

ISC West Las Vegas, USA 28/03–30/03 2007

INTERMACH Bangkok, TH 09/05–13/05 2007

NMW Melbourne, AUS 22/05–25/05 2007

Austech Melbourne, AUS 22/05–25/05 2007