SICK Magazine

A secured future
insight
S 3000 Safety Laser Scanners
A secured future
S 3000 Safety Laser Scanners
Page 30
Interview at SICK-STEGMANN
Opportunities of the drive
technology growth market
Page 38
2003
www.sick.com
1
SICKs customer magazine
DME 5000 Laser Distance Measuring Systems
The new kind of distance
measurement
Page 26
Quicker, better and more economical production: SICK
combines many years automotive expertise with interna-
tional application experience. SICK is your all-round sensor
partner as a result of our tailor-made services, innovative
device technologies, and world-wide proximity to customers.
Further info at www.sick.com
Your worldwide supplier of
sensor solutions:
for even more than you expect.
Sol ut i ons f or t he aut omot i ve i ndust ry
Opt i mi se product i on processes,
ensure qual i t y.
All-round competence in the new
Branch Guide. Ask for it now with
an e-mail to automotive@sick.de
Innovations
Sector know-how
All-inclusive
supplier of sensors
Global presence
Service and support
world-wide
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SICK AG Sebastian-Kneipp-Str. 1 79183 Waldkirch Germany Phone +49 7681 202-0 Fax +49 7681 202-3609
Industrial Safety Systems Auto Ident Industrial Sensors
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03 Editorial
insightTELEGRAM
++February 2003: SICK trainee Andreas Kuri is
the German champion in the Technical Drawing
category. He will now represent Germany in the
World Skills Competition in St. Gallen, Switzer-
land, where more than 500 young specialists
from 35 nations are competing.++
++DT 2: analogue distance sensor for contin-
uous distances. Photoelectric proximity switch
with 4-20 mA analogue output and measure-
ment range of 50 300 mm. Infrared device
covers interesting industrial close-range areas
of use, including occupancy checks of double-
depth spaces in small parts stores, or slack
detection in paper machines and plastics cal-
enders.++
++On the occasion of her 80th birthday Gisela
Sick, widow of company founder Erwin Sick
and Honorary Chairperson of SICK AG, was
awarded medal for special services to business
in Baden-Wrttemberg for lifes work.++
STEGMANN joins SICK
On 1 October 2002, SICK took over the STEGMANN Group with its approximately
600 employees worldwide, a leading producer of encoders and actuators for
automation. SICK has hereby complemented its product portfolio in the area of
sensorics for factory automation. Encoders are used for automation tasks by
practically all SICK customers and thus ideally supplement SICKs sensorics
programme for factory automation. Moreover, SICK has now gained an excellent
position in the growth market of controlled drive technology. Innovations such as
SSI for absolute encoders (4 instead of 24 wires), or CoreTech for incremental
encoders (all impulse numbers can be programmed and delivered within 48
hours), and the patented zero-impulse teach-in, simplify mounting and commis-
sioning to the benefit of our customers. In the area of drive technology the new
type of integral drive (HIPERDRIVE) automates format adjustments on packaging
machines. For the end-user this means lower wiring costs and higher process
reliability brought about by an integrated absolute value encoder.
The strengths of STEGMANN, such as technological leadership in encoders in
conjunction with development and production expertise in mechatronics, ideally
complement the possibilities offered by SICKs worldwide Sales and Service
organisation with over 30 subsidiaries, on-site consultancy, and worldwide
availability of products, systems and services to offer a complete range of
industrial sensorics for our customers.
Use your experience to obtain optimum solutions from us. You will find more
information on SICK-STEGMANN on Page 38, and on the Internet at
www.sick-stegmann.de
We hope that you will enjoy reading this issue and visit us at the HMI in Hall 9,
Stand F 54.
Friedrich Keglowich
Managing Director
SICK insight 1/2003 04 Contents
Applications
..................................................... 3
Its all blue at A.T.U. ......................... 6
Trespasser on company grounds
Inspector Laser investigates ............ 7
A new way to protect access............ 8
DS 60 allows mining of ore
by remote control ............................ 9
Laser systems protect Berlins
Underground from sprayers ........... 10
The ICS 100 camera sensor
watches out for labels ................... 11
The largest omniscanner system
at Spains largest department
store chain.................................... 12
Trend-setter USA: modern
warehouses run on laser distance
measurement ............................... 13
CLV 432 medication
for rapid storage............................ 14
Vending machines for umbrellas..... 15
Brazil: Ronaldinho-like sensor
controls unloading of wagons......... 16
Pallet commissioning
from all sides................................ 17
Cascaded safety in AL-anodised
housings....................................... 17
SICKs OPS omniscanner
the king among Peugeots lions...... 18
Keeping nurses posted via the tube 19
The largest slice of the cake .......... 20
The WT 2 aligns wafer boxes.......... 20
Rushing around at 90 kph
driverless...................................... 21
Self-check-in with ALIS................... 22
Reliability minimises
service costs ................................ 23
................................................... 24
Small design, great performance:
the new W 9L laser photoelectric
switch .......................................... 25
DME 5000: the new kind of
distance measurement..................... 26
M 18 fibre-optic cable sensors
always fit...................................... 27
Ultrasound sensors
join SICKs range........................... 28
CoreTech
encoders
have the knack.............................. 29
S 3000 safety laser scanners:
the time is ripe for the future ......... 30
Contour detection during rotation with
the new ICS 110 camera sensor .... 31
New connection module allows
cloning of bar-code scanner
parameters ................................... 32
OD Hi: CMOS sensor for
-precise detection........................ 33
MZT 6 magnetic cylinder sensors:
reliable mounting
reliable switching .............................. 33
WT 190T: high-end scanners
meet challenging demands ............ 34
Flexible cylinder-shaped safety ....... 34
ATM 60: Multiturn shaft encoder
with Multi-Bus interfaces ............ 35
Luminescence scanners vs. fakes.. 36
Futuroscope, France....................... 37
Interview at SICK-STEGMANN......... 38
SICK wins Grand Prix in Poland ...... 40
DeviceNet Safety joint venture ....... 40
Safety Inspections:
accreditation expanded.................. 41
Training......................................... 41
Business rocks! ............................ 42
e-mail newsletter ........................... 42
Imprint/Service ............................. 43
Trade fairs..................................... 43
Book Corner
Products
SICK Tour
Know-how
HMI Special
Info
6
Its all blue at A.T.U.
LMS protects from sprayers
SICK at the HMI 2003
10
S 3000: the time is ripe for the future
30
24
Museum
Editorial
SICK insight 1/2003
05 News in brief
insightBOOK CORNER
Anne Stalfort/Sybil Volks
Business Rocks!
Some are born to lose their heads and
some are born to use them.
Alan Parsons Project
Do you want to spice up your day with
fresh quotations? Find out more on
Page 42.
The new V 12-2 series:
greater power, lower prices
SICK in the TOP TEN
of best employers
Powerful ranges, flexibly designed
switching outputs and teach-in comfort
are the highlights of the new V 12-2
family of photoelectric switches in
M 12 cylinder housings. They also have
increased switching velocities and a
shorter design all features that posi-
tion the V 12-2 as a front-runner.
The V 12-2 is completely compati-
ble with your predecessor V 12-1 se-
ries. The upgrade can thus be carried
out on a simple 1:1 basis but the op-
portunities for the user have improved
considerably. They can now detect ob-
jects over longer ranges and at higher
speeds, select between light- and dark-
switching outputs, and get the sensors
operating quicker with teach-in and LED
status indicators. And the shortened
design takes up much less mounting
space in the machine.
Inflation-proof price structure
The new V 12-2 also proves that more
performance need not cost more.
Thus, for most switches, it is not only
the technology but also the price that
has been adopted 1:1 and the price
of the through-beam version has even
been reduced. INFO 102
The competition, Germanys Best Em-
ployer 2003, implemented for the EU
by the business magazine Capital and
a research and consultancy institute
from Cologne, has brought it out into
the open: SICK is in the TOP TEN of
Germanys best employers and is
... are features of the new automated
guided vehicle (AGV) from tbm auto-
mation + anlagentechnik GmbH from
Kremsmnster in Austria. In addition to
the technological highlight the non-
contact energy supply provided by the
new Inductive Power System this
new AGV catches the eye with its
smart-like design. But instead of rely-
ing on the reactive airbag safety of the
road vehicle, the logistical smart de-
pends on active scanning by the PLS
safety laser scanner that monitors the
route and thus prevents collisions.
INFO 101
the best-placed industrial com-
pany.
All companies in Germany with
more than 50 employees were
invited to take part in the com-
petition, in which 123 ultimate-
ly participated. Written employ-
ee questionnaires were instru-
mental in deciding the winners.
The result thus reflects the
high level of attractiveness of
SICK as an employer in the eyes of its
own workforce. The winner in the large
company category (with more than 500
employees) was Microsoft Germany,
and Munich-based Skytec AG won in
the small and medium-sized company
category.
Smart design,
laser-strong
safety ...
Important trade fair dates
SICK does not only exhibit at the HMI, but also has some interesting things on
show at the follwing trade fairs. Why not visit us?
SEMICON Europe Munich Hall A 2, Stand 354 1st3rd April
ident.de Wiesbaden Hall 9, Stand 931 A 6th8th May
first branch was opened in 1985, com-
pany founder Peter Unger was already
aiming to provide drivers with a combi-
nation of specialist shop and workshop
with a wide range of services offering
professional one-stop shopping from A
for aerials to Z for zinc-based primers.
The concept has really taken off since
then: more than 400 branches have
been opened nation-wide within 17
years. And the expansion is continu-
ing, Jochen Haag, Operational Manag-
er of A.T.U.s DC in Werl, looks ahead.
40 new locations are added annually,
with a total of about 1,000 new jobs
and by 2012 we should have 650
branches.
>> The distribution centre (DC) was re-
alised by WITRON Logistik + Informatik
GmbH as the main contractor. They
chose sensorics from SICK because
the systems are widespread in ware-
house and conveyor technology and are
highly reliable, as well as offering easy
maintenance and service, says
Stephan Schmid, the WITRON Project
Manager responsible for the DC.
A.T.U.s combined concept is
the ignition key to success
A.T.U. behind these three initials
there is a successful corporate con-
cept of a very special type. When the
SICK insight 1/2003
SICK sensors at A.T.U.s distribution centre 06 Applications
Its all blue at A.T.U.
A superlative logistical solution
This prospect necessitated the building
of a second DC in Werl (the first is at
the companys headquarters in Wei-
den). The site was carefully chosen:
many of the future branches that will be
supplied from Werl will be in the nearby
north and north-western regions of Ger-
many. The DC is accordingly dimen-
sioned. The buildings facade is about
600 m long. The interior space totals
over 1 million m
2
. More than 100
ramps are available for loading and un-
loading trucks. There are a variety of
storage areas inside the building com-
plex. There is space for 750,000 arti-
cles in the five-aisle high-bay wheel rim
warehouse. The eight-aisle high-bay
tyre warehouse holds half a million
tyres. 47,000 pallets can be stored in
the high-bay pallet warehouse, with its
16 storage and retrieval devices; and
the 12-aisle container stores offer
111,500 spaces. The total length of
the container conveyor technology, and
the routes of the storage and retrieval
devices and traversing transport vehi-
cles is almost 10 km.
Over 400 branches of Auto-Teile Unger, A.T.U. for short, supply
Germanys drivers with more than 70,000 different articles.
From A for aerials to Z for zinc-based primers almost all arti-
cles are available at all times or at short notice. This is ensured
by the new distribution centre in Werl, among others, where
more than 6,000 blue sensors are in use on conveyors and in
high-bay warehouses.
Trespasser on company
grounds Inspector
Laser investigates
Instead of employing imaginative TV detectives to clear up un-
solved burglaries, the security equipment supplier Mller-elec-
tronic from Ennepetal relies on preventive measures and the
support of Inspector Laser. Disguised as an LMS laser meas-
urement system, the latter monitors entrances and open spaces
on company grounds where something tempting is being stored
even if it is only scrap stainless steel.
>> Dark shapes, shady goings-on, sus-
piciously unsuspicious vehicles noth-
ing escapes the laser eye. The LMS is
on watch day and night, seven days a
week if it has not been turned off by re-
mote control, e.g. while goods are being
delivered. Otherwise the tamper-proof
system carries out an optoelectronic
cross-examination of every nook and
cranny, keeping an eye on the grounds
of an aluminium works for example.
No chance for trespassers
The LMS is part of a complete security
concept developed by Mller-electron-
ic. As soon as a trespasser is detect-
ed, on foot or motorised, they are in
the detectives sights. The guards are
immediately alerted and the end-user
informed by SMS and e-mail. The
alarm-triggered illumination system in
the companys grounds is activated,
and the recording rate of the video
monitors is raised to improve subse-
quent identification. The culprits can
be arrested using information obtained
through video recordings of persons
and vehicles called up remotely via LAN
and ISDN.
Flexible detection methods
Inspector Lasers flexible detection
methods are highly convincing. It can
monitor even larger areas alone with-
out requiring assistants. Whether larg-
er or smaller grounds it adapts to
every task and is immediately on duty
with very few instructions. Disguises
are of no assistance to trespassers:
thanks to its perfect vision, the Inspec-
tor can rapidly detect even the darkest
of shapes.
The laser measurement system monitors company grounds 24 hours a day
Container conveyor lines at Auto-Teile
Ungers Distribution Centre, equipped
with more than 6,000 blue SICK
sensors
SICK insight 1/2003
Building security with LMS at Mller-electronic 07 Applications
Blue sensor power provides
best storage backbone
Unlike the hazardous goods store (e.g.
for oils or antifreeze), also accommo-
dated in the DC, and the bulky goods
store (e.g. for exhaust pipes or roof
boxes), the above-mentioned ware-
houses are fully automated. Most of
the total of 290 km of cable that has
been laid is to be found here as are
the more than 6,000 blue photoelectric
switches, proximity switches, distance
sensors and bar-code readers. They
supply the warehouse control system
with all the necessary status informa-
tion from occupancy checks, position
and amount detection, identification
tasks, or checks for height and projec-
tions, providing the optimum ware-
house backbone. Whether a rear win-
dow heater switch or a radio, whether
hub-caps or hazard flasher switch,
whether battery or brake linings every
hour up to 8,300 order items are
processed at the DC to put the A.T.U.
branches in pole position in customer
service.
insightLINK
You can obtain further information with
the attached card under:
INFO 103
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.atu.de and www.witron.com
insightLINK
INFO 104
www.moeller-electronic.de
SICK insight 1/2003
C 4000 Entry/Exit Safety Light Curtains at DaimlerChrysler 08 Applications
A new way to
protect access
The self-learning C 4000 safety light curtain: protecting access
to a transport system for car bodies. Its entry/exit monitoring
function reliably differentiates between persons and materials
without the need for supplementary sensoric, structural or con-
structional measures.
>> DaimlerChrysler (DC) would rather
have had the C 4000, with its self-
learning mobile entry/exit suppression
function, yesterday than tomorrow
so impressed was, and is, the man-
agement by this solution.
New safety concept
No muting sensors, no mobile barriers
(swing doors), no special construction-
al solutions this is a completely new
type of safety concept. The C 4000 can
be used to differentiate between an
employee and a transport vehicle (skid)
loaded with a car body. Information on
the maximum permissible size of an
object, entry to and exit from the pro-
tective field, the self-learned object dis-
tances within the protective field and
their alteration, are the criteria for
switching off the machine.
At DC the C 4000 is parameterised
in such a way that it can reliably distin-
guish between the transport sledge
brow posts (that can be arranged in dif-
ferent ways depending on the skid in-
volved) and the legs of an employee,
on the basis of the above-mentioned
criteria and independently of the direc-
tion of transport.
Brow post or baggy trousers?
Meeting just one of the switching-off
criteria is sufficient to stop the haz-
ardous motion of the transport system
at DC. A wider leg, or non-conforming
entry or exit of the protective field, or a
leg distance that is changing inappro-
priately, leads to a response by the
safety equipment as this means that
a person, and not a transport skid, has
been detected.
Simple installation and
upgrading
DC has profited from the new C 4000
Entry/Exit system not only in safety
terms, but also in terms of installation-
friendliness namely lower mounting
costs than those offered by other solu-
tions, and reduced maintenance and
repair costs for individual mechanical
and electrical components during plant
operation. Moreover, it is relatively
easy to upgrade the system if neces-
sary because a compact standard de-
vice is involved.
insightLINK
INFO 105
www.daimlerchrysler.com
Safeguarding access to skids transporting car shells
SICK insight 1/2003
DS 60 Distance Sensors at ore mine in Sweden 09 Applications
Remote control of processes in the ore mine
LKABs state-of-the-art ore mine in Sweden
DS 60 allows mining of
ore by remote control
IT in mining many processes are remotely controlled, e.g. the
loading and route control of the automated dumpers, at LKABs
ore mine in Kiruna, Sweden. DS 60 distance sensors protect the
85-tonner from collisions with the pit gallery walls.
>> Modern IT solutions, e.g. the re-
motely controlled drilling, removal and
transport of ores, make mines eco-
nomical and competitive. LKAB in
Kiruna has been using innovative tech-
nology for 30 years and can thus with-
stand competition from the major
South American pits.
Collision protection for
unmanned 85-tonners
Processes taking place at a depth of
one kilometre are remotely controlled
from the 7th floor of LKABs adminis-
trative building. After drilling and blast-
ing, the seams (that have a height of
up to 55 m) are mined. Electrically driv-
en, automated guided vehicles that can
handle loads of 85 tonnes then collect
the ore for processing, whereby the
transporters must sometimes move in
reverse. DS 60 distance sensors en-
sure that there are no collisions with
the gallery walls.
Measure, warn, stop
The scanning sensors measure the dis-
tance between the vehicle and the
walls. If a measurement exceeds a
stored warning distance of 60 cm, out-
put 1 of the sensor triggers a corre-
sponding alarm signal at the trans-
porters control system. The DS 60s
second switching output is activated
when the vehicle is only 30 cm from
the gallery wall. This signal brings the
85-tonner to an immediate stop.
Permanent availability
The operating conditions, e.g. the
brightness, the dust content of the air,
the temperatures, or the surface of the
pit walls, have no effect on reliable sys-
tem function. The devices are perma-
nently available thanks to their high en-
closure rating and immunity to shock
and vibration.
insightLINK
INFO 106
www.lkab.com
Did you know that
LKAB is considered the worlds
most modern ore mining works. The
company is responsible for 4% of iron
ore production worldwide, and is one
of the leading producers of high-
grade iron-ore products and one of
the worlds largest suppliers of pal-
lets. 80% of production goes to Eu-
rope a good third of which is des-
tined for Germany.
SICK insight 1/2003
Securing the Berlin Underground against graffiti sprayers 10 Applications
Laser systems protect Berlins Under-
ground from sprayers
In order to prevent underground vehicles shunted onto sidings
from being disfigured by graffiti sprayers, Berlins transport oper-
ators (the BVG) monitor particular tunnel areas with vandal-proof
LMS building security sensors.
>> In 2001 the BVGs Underground De-
partment were running about 1,400
underground vehicles. Outside peak
traffic periods, and during the nightly
breaks in operation, trains are accom-
modated on loop lines and sidings.
These are mostly in underground tun-
nels and can be reached by simply
crossing the tracks. To prevent the ve-
hicles in the tunnel areas being left at
the mercy of vandals the BVG has in-
stalled, among other things, LMS laser
measurement systems developed for
building protection purposes a tamp-
er-proof system that reliably detects
persons and signals, and raises the
alarm via the existing emergency call
and information system.
Infrared carpet of light rolled
out for unwanted visitors
The LMS building protection sensor is
based on actively scanning laser meas-
urement technology. The sensor is a
laser scanner with potential-free relay
outputs, e.g. for triggering a camera.
The scanner detects persons inde-
pendent of the brightness of the build-
ing and surroundings by emitting a
fan-shaped laser impulse up to 180
wide and evaluating the time-of-flight of
the individual reflected impulses. Its
high immunity to interfering light en-
sures that the LMS retains its full de-
tection capabilities even when deliber-
insightLINK
INFO 107
www.bvg.de
SICKs LMS Outdoor laser
measurement system
Monitored field geometry can be
configured as required
Tunnel monitoring helps make this sight is a thing of the past
ately dazzled. Ranges of up to 80 m
can be reliably monitored with this in-
frared light carpet. The geometries of
the monitored fields can be divided up
and assigned to specific stations, tun-
nels or platforms, as required. Its pro-
tective armoury against tampering in-
cludes a security code to protect de-
vice access.
Sprayers caught
This security technology has already
had its first successes. Graffiti
sprayers have been caught red-handed,
and the vehicles did not need to be tak-
en out of operation to clean up the graf-
fiti. This saves the BVG millions every
year.
SICK insight 1/2003
ICS 100 Camera Sensors: flip-lid recesses detected at Clever Stolz in Kleve 11 Applications
insightLINK
INFO 108
www.cleverstolz.de and www.bosch.de
>> A bottles flip-lid recess is decisive
in achieving correct alignment. If the
ICS 100 detects that it is facing the
front, the label can be stuck on by the
machine. If it is not detected the bottle
is diverted out of the conveyor system,
turned through 180, and then reintro-
duced into the process.
Developing a taste for it
The machines producer, Bosch, had al-
ready developed a taste for the ICS 100
before the Clever Stolz project. Thanks
to its visualisation module and short cy-
cle times with extremely high resolution,
a wide variety of inspection applications
can be solved with the camera sensor
from SICK even in high-speed plants.
Not to mention its high reliability, partic-
ularly in the face of ambient light inter-
ference. This is achieved as a result of,
among other things, integrated homoge-
neous illumination of the teach-in and
search field, and the soft shutter func-
tion of the ICS 100, by which interfer-
ence is reliably eliminated.
User-friendly image processing
The user-friendliness of the image pro-
cessing is particularly important for
Clever Stolz as the end-user. Changes
are easily carried out thanks to simple
operation and parameter-setting via the
visualisation module. Moreover, sever-
al different groups of taught-in images
can be stored.
The example of flip-lid recess de-
tection demonstrates that the ICS 100
can meet a variety of the practical de-
mands made by machine constructors
and end-users.
The ICS 100 camera sensor
watches out for labels
The ICS 100 camera sensors at Clever Stolz in Kleve watch out
for labels or, more precisely, for the correct alignment of, for ex-
ample, ketchup and mayonnaise bottles before labelling. As a re-
sult of its numerous possibilities and industrial reliability, people
there (but also at plant constructor Bosch) are really enthusias-
tic about it, particularly about its easy use and parameterisation.
The machine only attaches a label if the flip-lid recess is facing the front
SICK insight 1/2003
OPS Omniportal Scanner systems at El Corte Ingls, Spain 12 Applications
>> El Corte Ingls is the largest chain
of retail branches in Spain. Several
hundred businesses throughout the
country are supplied from the new dis-
tribution centre in Madrid.
Identification without
limitations
In order to achieve automatic, prompt
and comprehensive supply of all its
branches, El Corte Ingls required a
complete solution for the identification
of in-coming goods for its distribution
centre regardless of where, and in
what quality, or how many bar codes
were on the articles. This challenge
was solved with 18xx-Series OPS omni-
portal scanners with 18 reading
heads per portal, these are the most
complex systems that have ever been
constructed by SICK worldwide. This in-
stallation was realized by SICK Spain in
collaboration with SICK AG.
Conveyor system widths of between
600 mm and 855 mm, transport
speeds of between 0.7 m/s and 2.74
m/s, RS 422 and Profibus DP inter-
faces, and differing reading tasks show
how flexibly the OPS can be adapted to
meet individual limiting conditions.
Software ensures top reading
performance
With several thousand different suppli-
ers, the systems must cope with the
most varied of bar-code label qualities.
In order to achieve this, the OPS soft-
ware was further developed in such a
way that it automatically adapts to the
circumstances: depending on the code
type, code length, code identifier, etc.
Plug & play flexibility
simplifies optimisation
At the same time, in co-operation with
SICK, while installing the systems El
Corte Ingls modified and optimised
numerous tasks in which supplemen-
tary reading directions were added.
This was achieved rapidly and easily
thanks to the simple addition of indi-
vidual scanners using plug & play. This
also ensured high availability of the
OPS in running operation (and thus al-
so the distribution centre) as defective
code-readers can quickly be replaced
without having to reset parameters.
The largest omniscanner system at
Spains largest department store chain
High reading power, flexibility, and availability characterise
SICKs most complex OPS omniportal scanner system yet. It en-
sures that the complete range of goods are available in good time
at the branches of El Corte Ingls, the Spanish department store
chain.
18 reading heads per portal
identify in-coming goods
insightLINK
INFO 109
www.elcorteingles.es
SICK insight 1/2003
DME laser distance measuring system in warehouses at HK Systems Inc., USA 13 Applications
Trend-setter USA: modern warehouses
run on laser distance measurement
HK Systems Inc. is North Americas leading total solutions
provider for automated material handling and supply chain soft-
ware. For new plants or warehouse modernisations the company
has long relied on DME sensors from SICK for determining dis-
tance and position.
Example of use: DME sensors provide precise distance and position detection
insightLINK
INFO 110
www.hksystems.com
>> Initially the DME 2000 with ana-
logue output; then the DME 3000 with
RS 422, SSI and field bus interfaces;
and now the new DME 5000 with spe-
cific design variants for automatic
small-parts stores and high-bay ware-
houses the laser distance measure-
ment systems from SICK reflect the
change in customer requirements and
technologies. They are used for dis-
tance measurement on storage and re-
trieval devices within their aisles
known as the X-direction as well as
for determining the position of the lift-
ing equipment of such devices in the Y-
direction.
HK Systems: storage
technology from A for auto-
mobile to Z for zabaglione
Since 1996 we have been using the
devices for new warehouse buildings
as well as for the modernisation of our
own and other producers plants, re-
ports Larry Kaiser, an engineer at HK
Systems Inc. The spectrum ranges
from chassis stores in automobile
spraying plants to deep-frozen stores
for frozen products and ice cream.
DMEs update old warehouses
Small dimensions, high-level reliability,
low installation costs, and a variety of
interfaces play a vital role in HK Sys-
tems loyalty to the DMEs. These ad-
vantages are very important: not only
for new plants, but also particularly
with regard to the numerous ware-
house modernisations, says Larry
Kaiser. And it is precisely here, in such
modernizations, that experts believe
there is still enormous market poten-
tial, as many systems from the pio-
neering age of automated warehouse
technology urgently require a contem-
porary revamp which almost always
also involves a modernisation of the
position-determining system with DMEs.
SICK insight 1/2003
CLV 432 Bar-code Scanners in portal frames at AstraZeneca 14 Applications
>> The scanner portal, which scans
both the loaded pallets and the car-
tons on them, has considerably simpli-
fied and accelerated storage process-
es compared with the previous manual
identification solution.
Centralised supply for the
German-speaking market
AstraZeneca, and its high-quality med-
ications for a variety of indications, is
one of the five leading international
and national companies in the pharma-
ceutical industry. The modern logistics
centre is located at its Wedel site,
where all sales for the German-speak-
ing market are processed. Part of this
centre consists of a conveyor belt that
handles the supply of raw goods to the
packaging area and is responsible for
transporting the finished goods to the
fully automated high-bay warehouse.
The finished goods are packed in stan-
dard cartons with a bar-code label and
are stored in these cartons until their
subsequent delivery. They must be au-
tomatically scanned on the production
lines, packed onto pallets, and the
warehouse management system kept
CLV 432 medication
for rapid storage
It wasnt the doctor or chemist that AstraZeneca consulted, but
SICKs application engineers, when they wanted a prescription
for an effective bar-code scanner solution for their logistics cen-
tre. The medicine: CLV 432 bar-code scanners in a portal frame-
work integrated within a CAN Bus network.
informed. An automatic countercheck
must ensure that there are no mix-ups
in the finished goods on their way from
the production line to the warehouse.
Lack of space led to
portal solution
The task was made more complicated
by the relatively small amount of space
available between the two conveyor
systems, meaning that scanners are
only 120 mm from the Code 128 bar
code to be scanned, so oscillating mir-
ror scanners could not be used. A por-
tal solution was implemented with 19
CLV 432 bar-code scanners with
SMART technology. The scanners are
connected to one another via a CAN-
scanner network, with connection to
the AS 400 host computer achieved us-
ing an Ethernet-LAN connection.
Things go quicker
automatically
The automatic scanning system, devel-
oped by AstraZenecas Technical De-
partment in co-operation with SICK,
scans the bar code on the pallet, and
all the bar codes on the standard car-
tons in which the finished goods are
packed, and transmits this data to the
warehouse management system via an
interface. The data are compared with
that of the production lines, and after
this inspection the pallet is assigned a
storage space. If there is a spurious
reading or other error, the pallet is re-
turned along the conveyor system and
must be checked by an employee. All
these tasks take place during the run-
ning storage process so that the trans-
port of finished goods can be carried
out considerably quicker.
A portal solution with 19 bar-code readers scans pallets and cartons
insightLINK
INFO 111
www.astrazeneca.com
SICK insight 1/2003
Umbrella dispensing machines in London 15 Applications
>> The vending machines were intro-
duced in London last autumn and were
snapped up. Whether at the Hilton Ho-
tel, the London Underground or the
West 1 shopping centre on Oxford
Street 4.99 and a credit card is all
one needs to avoid precipitation. If the
bad weather front is more serious than
at first assumed, and the umbrellas
are running out, Rainbuster transmits
data on the current stock available via
GPRS mobile phone. But the vending
machine is also useful when the sun is
shining it then sells disposable cam-
eras.
Norwegian sensor input
So when, in the near future, nobody in
the British Isles or elsewhere need get
wet in the rain, and people can snap
away to their hearts content in sunny
weather, this will also be thanks to the
resourcefulness of SICKs engineers in
Norway. For it was they who convinced
the engineers of Mikromekanikk in
Umbrellas for 4.99 from the dispensing machines
Vending machines
for umbrellas
Many umbrellas exhibit the property that they are not at hand
when it starts raining. This situation was brought to an end last
autumn, but not (as one might have thought) by an Englishman
it was a Norwegian, Einar Haveland, who solved the problem. He
invented the Rainbuster umbrella vending machine. SICK sen-
sors monitor the provision of umbrellas and provide warnings in
good time, via GPRS, if re-filling is required.
insightLINK
You can obtain further information
on the Internet at:
www.paraply.no
Bergen, the company who developed
the machine together with Haveland,
that opto-electronic sensors and induc-
tive proximity sensors from SICK were
best suited for monitoring the umbrel-
las in the vending machine and keeping
an eye on their numbers. The commis-
sion to manufacture these machines
was given to the Swedish vending ma-
chine producer ParkoPrint.
Follow-up orders look likely
Large follow-up orders are to be ex-
pected considering that Mediterranean
climatic conditions are not likely to be-
come permanent in central and north-
ern Europe in the foreseeable future.
And the vending machine can be used
to provide Sunbuster parasols, sun
glasses and sun lotion in the warmer
regions of the planet. Luckily the sen-
sors are sufficiently immune to sun-
light!
SICK technology makes it possible:
the Rainbuster
SICK insight 1/2003
WL 12L wagon detection in port of Tubaro, Brazil 16 Applications
The WL 12L laser photoelectric
switch ...
>> Vale do Rio Doce is Brazils leading
mining company, with hundreds of
mines scattered throughout the entire
country. Iron ore and other minerals
are transported in railway wagons from
the mines to a variety of ports, such as
Tubaro, where they are unloaded. The
ore is transferred by conveyor belts to
the stockpiles or directly loaded into
ships for transport overseas. This in-
volves wagons being dumped by
enormous discharging equipment
called car-dumpers.
Off target? The WL 12L offers
Ronaldinho-like accuracy!
The process of wagon discharging is
initiated the moment wagons are de-
tected by a so-called car-pusher, and
they are then positioned inside the car
dumper, two wagons at a time. This,
however, has long been a problem: the
sensor previously used for the job had
difficulty coping with the operating con-
ditions. Whether dazzled by ambient
light, misaligned as a result of vibra-
tion, or impaired by unnoticed contami-
nation when the switching signal was
wrong the lifting mechanism grasped
completely off target. This caused a lot
of damage. Now, however, the WL 12L
photoelectric laser switch gives the
plant an accuracy comparable to
Ronaldinhos and is also 95% cheap-
er than the old sensor solution. The
IP 67 enclosure rating of the zinc die-
cast housing and its high level of im-
munity to shocks and vibrations ensure
reliable detection of wagons. Whether
sun, contamination or impacts as
Brazil: Ronaldinho-like sensor
controls unloading of wagons
100% reliability for 95% lower costs the WL 12L photoelectric
laser switch demonstrates its world-class accuracy and tough-
ness, as well as its cost-effectiveness, during the unloading of
mining wagons at the Brazilian port of Tubaro.
... and the reflectors along the tracks
insightLINK
on the Internet at:
www.cvrd.com.br
soon as a wagon wheel interrupts the
light beam between the sensor and the
reflector target mounted opposite it,
parallel to the rails, a start signal is
transferred to the pusher mechanism.
This project was developed by Tubaro
Ports Maintenance Engineering De-
partment.
High accuracy for a low transfer
sum the engineers of Vale do Rio
Doce already have more pitches for
the WL 12L in view.
N
E
W
S
Gas- and steam-proof design
The safety light grids are AL-anodised
instead of painted because of the
clean-room conditions and the mixture
of process gases present. Moreover,
the front windows are injected instead
of glued. INFO 113
SICK insight 1/2003
LMS on palletiser module from Steiff Wafer coating 17 Applications
Cascaded safety
in AL-anodised
housings
>> Cascaded C 2000 units monitor ac-
cess to a wafer coating machine. A
special feature is their housing design
that protects the sensors from the ef-
fects of aggressive process gases with-
in the machine.
The AIX 2400/2600 G3 Planetary
Reactor
from AIXTRON is used for

coating semi-conductor wafers. Two
gloves are integrated in the Plexiglas
front hood in order to be able to work
within the machine. During operation
the interior of the reactor is filled with a
mixture of process gases under light
overpressure.
Unauthorised access prevent-
ed with low mounting costs
If someone puts on the gloves (turned
inside out by the pressure) and ac-
cesses the interior, the hand will be de-
tected by the C 2000 and the machine
switched off. The C 2000 is cascaded
in the AIXTRON reactor to minimise
mounting costs for simultaneous two-
sided monitoring.
>> The supply and palleting module for
commissioning areas consists of two
central elements: a robot with auto-
matic tool-changing and a variety of
gripping techniques, and an LMS laser
measurement system, with which the
position and plane of the packing unit
on the pallet is detected.
High precision allows
reliable gripping
The LMS units are installed above the
commissioning areas and scan the cur-
rent situation of the topmost pallet po-
sition before each gripping process. Ac-
curacy is essential here: within a few
milliseconds the control system is in-
formed about the position of packing
units and the height offset with mil-
limetre accuracy, and from this infor-
mation it determines the gripping co-or-
dinates for the robots. The packing unit
is then gripped and placed on the near-
est free position on a transport pallet,
whose packing unit structure is also
detected by the LMS.
Bar-code scanners provide
further information
If, in addition to the position of the in-
dividual packing units, more informa-
tion is required, a bar-code scanner
can be integrated into the supply and
palleting module. It can be used to
read batch numbers, shelf or service
lives, eat-by dates, or prescription in-
formation, as well as commissioning-
related printing on customer and trans-
port labels.
Pallet commissioning
from all sides
The new supply and palleting module for high-bay entrance zones,
produced by Steiff Frder- und Automatisierungstechnik GmbH in
Giengen, offers flexibility and universal application. LMS 200
laser measurement systems determine the position of packing
units on the pallets and thus ensure reliable gripping by the auto-
matic commissioning robot.
insightLINK
INFO 112
www.steiff-foerdertechnik.de
Safe access to the robot with the LMS 200 laser measurement system
SICK insight 1/2003
Wheel rim identification at Peugeot in France 18 Applications
SICKs OPS omniscanner
the king among Peugeots lions
On Africas plains and savannahs the black and white striped ze-
bras are one of the lions preferred prey. The stripe patterns
(known as bar codes) are just as vital for the Peugeot lions found
at the French production works in Sochaux. So omni-scanner sys-
tems in the wheel assembly area ensure that every wheel is a cer-
tain prey for the process control system.
>> Peugeot, together with Citroen, is
part of the PSA Group Europes sec-
ond-largest automobile manufacturer.
Since serial production began in 1871,
more than 40 million vehicles world-
wide have rolled off the line with the
sign of the lion many of them at
Sochaux in the east of France, the com-
panys largest and most modern pro-
duction site.
Variety of models and bright
prospects
Three series, the 307, the 406 and the
607, are produced here and contribute
towards the variety of Peugeots mod-
els. They also contribute to the compa-
nys bright sales prospects Peugeot
is the second most imported brand in
Germany. However, the variety of mod-
els and bright prospects are a totally
different matter when it comes to iden-
tifying wheels during vehicle assembly.
The shiny steel and aluminium wheel
rims in varying designs and widths, and
with differing diameters, demand so-
phisticated capabilities from bar-code
reading systems that must reliably de-
tect the labels on each wheel.
OPS 290: reading power and
the lions share
Omnidirectional capability, real-time
autofocus, immunity to ambient light,
and error-tolerant decoding all fea-
tures of the OPS omniportal reading
system that contribute towards ensur-
ing that the lions share of wheels are
insightLINK
INFO 114
www.peugeot.com
Leonine power:
the OPS 290
reliably identified. The wheels are inte-
grated directly into the assembly
process according to the model and
type involved. For this purpose, the bar
code on the wheel rim must be read
regardless of its alignment. Thanks to
their real-time autofocus, the OPS sys-
tem scanners (one oscillating mirror
CLV 490 in profile design, per portal)
adjust the ideal depth of focus in a frac-
tion of a second. Reflections from the
steel or aluminium surfaces have no
effect on the reading result, as SMART
decoding reconstructs any missing
parts of the bar code and insert them
into the code information like solving a
puzzle.
Mulhouse is also hunting for
bar codes
Word on the success of the solution im-
plemented in Sochaux a total of eight
OPS systems are in operation has got
around the entire PSA Group. So the
Mulhouse works will also be equipped
with SICK systems for the bar-code
hunt.
SICK insight 1/2003
Sumetzberger tube plant in Austria 19 Applications
At pneumatic tube post system producer Sumetzberger in Vienna,
photoelectric proximity switches specially developed by SICK to
meet the customers requirements detect whether the tubes are
full. And magnetic cylinder sensors of the MZT 1 series, clothed in
blue, ensure that the tube switching points are correctly controlled
and that the tube post cartridges reach their intended destination.
>> Sumetzberger is a leading producer
of pneumatic tube post systems used,
for example, for delivering medicines
within hospitals, whereby the medi-
cines, etc. are transported in black car-
tridges. These find their way to the cor-
rect station via tube switching points
that are automatically set according to
the transport destination.
Difficult cartridge-detection
conditions mastered
SICK developed a customer-specific
compact photoelectric proximity switch
for Sumetzberger to detect the car-
tridges. It looks into the post tubes
from outside and, thanks to sophisti-
cated background suppression, the
insightLINK
INFO 115
www.sumetzberger.at
Precise detection of tube position with the MZT 1
sensor can cut out both the thin layer
of dust that accumulates over time on
the front wall of the tubes, as well as
the entire back wall of the tube includ-
ing any bulge-related interference. This
ensures reliable detection of the weak-
ly reflective cartridges. The sensors
are mounted in tube areas before the
points and in the tube post receiving
stations. For this purpose an attach-
ment platform, that simultaneously
acts as a window for the tube, was de-
veloped by Sumetzberger and SICK to-
gether.
Magnetic cylinder sensors en-
sure correct setting of points
The MZT 1 magnetic cylinder sensor
developed principally for non-contact
detection of piston position in pneu-
matic cylinders detects the tube posi-
tion at every so-called three-finger
point extremely accurately. Activated
by the pneumatic tube post systems
destination controller, an electric drive
moves the tubes above one another.
The MZT 1 reports when the tubes are
exactly congruent and stops the drive
system. After the points have been set,
the route to the destination is free.
The MZT 1 magnetic
cylinder sensor
Keeping nurses posted via the tube
The largest slice
of the cake...
...can quickly lead to argu-
ments in some circles.
>> Though not in the case of cakes
from the automatic cutting machine
that slices the confectionery into ten
equal pieces. And to prevent a fingertip
being lopped off instead of, say, a cher-
ry, the Swiss producer bz Engineering
AG safeguards its automatic machine
with a C 2000 light curtain.
INFO 116
N
E
W
S
SICK insight 1/2003
Cutting machine W2 Series Proximity Switches in the semi-conductor industry 20 Applications
Safeguarding the automatic cutting
machine with the C 2000 light curtain
The WT 2 photoelectric proximity switch: considerably smaller than a human thumb
The WT 2 aligns
wafer boxes
WT 2 proximity switches detect the presence of wafer boxes and
align them in a newly developed handling system for silicon
wafers with a diameter of 300 mm. The WT 2s high level of ac-
curacy, as a result of its laser-like light source, and its sub-minia-
ture design were of decisive importance in choosing the sensor
for use in this area of semi-conductor production.
>> The WT 2 is one of the worlds
smallest series of photoelectric switch-
es. The sub-miniature housing is hardly
larger than the end of a cable. A laser-
like light source and special optics gen-
erate an extremely precise light spot
that meets the users highly demand-
ing requirements for accurate repeata-
bility, and allows reliable detection and
alignment of the wafer boxes. All this
ensures reliable and reproducible han-
dling.
Close-range background
suppression
The WT 2 also offers precise back-
ground suppression for distances of
15 mm or 30 mm. Thus interfering in-
fluences, caused by reflective surfaces
and common in the clean-room environ-
ment, can be reliably cut out of the
background of the handling system.
Furthermore, the wafer boxes can be
reliably detected almost completely in-
dependently of their colour.
insightLINK
INFO 117
SICK insight 1/2003
CargoMover: the autonomous goods wagon 21 Applications
The driverless CargoMover during trials
Numerous measurement systems
monitor the route during the journey
>> CargoMover is a joint venture be-
tween Siemens, the Rhineland-West-
phalian Technical Universitys Institute
for Track Vehicle Technology in Aachen,
and Braunschweig University. The aim
is to offer an economical solution for
transferring consignments of goods
from road to rail.
Divergent traffic trends de-
mand action
The CargoMover is the logical conse-
quence of two conflicting develop-
ments. On the one hand, estimates in-
dicate that the EUs eastwards expan-
sion will bring about an approximately
60% increase in goods transport. On
the other hand, rails share of trans-
port volumes has fallen from 30% to
14% since 1970, i.e. it has more than
halved. If one also considers that
about 80% of all truck traffic is involved
in local and regional goods transport it
becomes clear where the CargoMover
can exploit its advantages.
Successful trial run
Two CargoMovers are currently under-
going trials. Tests have proved so suc-
cessful that the vehicle could con-
tribute towards raising the proportion
of rail-based transport in the foresee-
able future.
Slots itself into timetables and
route occupancy
Electronics makes the autonomous
rail transporter flexible, efficient and
safe, says Franz Mairhofer of
Siemens Transportation Systems. The
vehicle can be integrated into the fu-
ture European Train Control System
(ETCS) and will be ready to roll 24
hours a day. Freight companies can re-
quest the vehicle individually. After def-
inition of the destination, the Cargo-
Mover logs into the ETCS, looks for
gaps in the timetable, checks the oc-
cupancy of rail sections, and finds its
way on the basis of pre-programmed
route maps. In addition to video and
radar sensors, two LMS laser meas-
urement systems (installed horizontal-
ly and vertically) monitor the routes
during journeys and react to hin-
drances. At the destination, the wagon
sensors then approach the unloading
ramp with centimetre accuracy.
insightLINK
INFO 118
www.siemens-cargomover.com
Rushing around at 90 kph driverless
Today a vision, tomorrow perhaps a reality: this is the Cargo-
Mover, a goods wagon that finds its destination station without a
driver and autonomously. While the track-borne transporter is un-
derway at 90 kph, laser measurement systems monitor the vehi-
cles path.
SICK insight 1/2003
ALIS for self-check-in at Frankfurts Rhein-Main Airport 22 Applications
Self-check-in with ALIS:
no access to gate without a code
Business and holiday travellers flying from Frankfurts Rhein-Main
Airport with Lufthansa need no longer queue up at the check-in
counter. They can receive their boarding cards and hand in their
luggage at self-check-in terminals. ALIS flight baggage reading
gates ensure that passengers correctly attach the baggage la-
bels onto their luggage.
>> Those who wish to fly to distant des-
tinations must usually check-in at their
airlines counter. Helpful ladies and
gentlemen arrange seat reservations,
print the boarding cards, and attach
the IATA bar-code labels to the flight
baggage. Then passengers and their
luggage take separate paths to the
flight gates one through the airports
various lounge areas and the other via
conveyor technology.
ALIS prevents delays and
luggage going astray
It is quicker for passengers to check
themselves and their luggage in
autonomously. For this purpose
Lufthansa has set up several self-
check-in stations, involving automatic
rapid check-in machines, at Rhein-Main
Airport in Frankfurt. The check-in
process is initiated by inserting an ATB
ticket, or a valid credit card or Miles &
More card. At the end of the menu-driv-
en dialogue, passengers are asked
whether they would like to hand in any
luggage. If they do want to, IATA flight
baggage labels are printed and the pas-
sengers are requested to attach them
to the luggage. When attachment to
the luggage is confirmed by the pas-
sengers pressing the screen, the bag-
gage is automatically transported to
the baggage-sorting plant. ALIS flight
baggage reading gates now check that
the bar-code label is correctly attached
to the luggage, and then reliably trans-
port the baggage to its immediate des-
tination. This prevents luggage going
astray in the conveyor system and any
need for the baggage to be manually
sorted out which would lead to de-
layed flights.
Cases only reach the plane
with a code
The reading gates are operated as dou-
ble-portal systems. Eight CLV 490 bar-
code readers six of them oscillating
mirror versions are integrated into
each portal. They are aligned in such a
way that they can detect the bar-code
label, if present, in any position and ori-
entation. Only then is the baggage tak-
en over by the conveyor system. If no
code is detected, or it is wrong, it does
not board the flight.
insightLINK
INFO 119
www.lufthansa.com and
www.frankfurt-airport.de
No bar-code labels escape the ALIS flight baggage reading gate
SICK insight 1/2003
Automation and safety technology at Medek & Schrner, Austria 23 Applications
Reliability minimises
service costs
98% are exported the light wave conductor colouring plants of
the Austrian company Medek & Schrner can be found in many
countries of the world. Suitable sensorics, that also function reli-
ably under harsh conditions, are thus particularly important if un-
necessary travelling and service costs are to be avoided.
insightLINK
INFO 120
www.medek.at
Left:
Martin Slama
Manager of Electronic
Development, and Kurt
Descovich Managing
Director (right)
Bottom:
SICK safety interlocks
in use in a light wave
conductor colouring
plant
>> The Viennese company Medek &
Schrner (M&S) is the world leader in
colouring plants for light wave conduc-
tors. The range extends from simple
multi-fibre plants for up to 12 fibres, to
complete coloration plants with speeds
of up to 2,800 m/min. In addition to
coating with UV-hardened colours, the
plants can also add coloured rings for
coding purposes.
Reliability counts
When selecting automation and safety
technology for our machines reliability,
even in the face of heavy contamina-
tion (as is usual when processing with
colours), is the top priority, explains
engineer Martin Slama, Manager of
Electronics Development at M&S. This
is true, for example, of the WS/WE 140
miniature photoelectric switch. Here,
SICK is the only supplier that offers a
compact sensor with a slotted mask
and polarisation filters, and can thus
ensure precise determination of the
position of light wave conductors dur-
ing winding and unwinding, even under
potentially contaminated conditions.
Sensors available worldwide
In addition to the W 140 series, M&S al-
so relies on fibre-optic cable systems,
through-beam photoelectric switches,
proximity switches and safety inter-
locks. If the worst comes to the worst,
SICKs worldwide presence guarantees
the rapid availability of replacement de-
vices almost anywhere in the world,
Martin Slama clarifies not only the func-
tional aspects, but also the availability,
and thus safety, aspects considered
during the selection of these sensors.
SICK insight 1/2003
In Hanover from 7th to 12th April 24 HMI Special
SICK at HMI 2003
Visit us: Hall 9, Stand F 54
insightLINK
Further information on the topic of
SICK in Hanover can be found at
www.sick.de/hmi
Whats new?
This year we are going to Hanover with
lots of new and improved products.
Comprehensibly arranged according to
branch, we will be presenting solutions
for all areas of factory automation.
Sensor solutions for factory
automation
New: encoders and ultrasound sensors
round out SICKs programme. We are
showing the complete SICK sensor pro-
gramme for factory automation at a
glance in order to give you a complete
overview.
Services around sensors
We are presenting our range of Ser-
vices & Training at our Service Point.
As an official partner of Jugend forscht
(a competition to find the best young
researchers) SICK is presenting 12
national champions with their work.
You will be surprised to see how moody
robots, galaxies in the home computer,
or GPS in the childrens room work...
Current developments, new products &
solutions, technological trends we of-
fer first-hand information in short talks.
Register now for the presentations at:
www.sick.de/hmi. Here, you will obtain
a detailed overview of all the talks. Of
course, you can also register at SICKs
Information stand during the trade fair.
Whats going on in
the evening?
On 8th and 10th April we invite you, like
last year, to a party at the SICK stand.
Talks at the HMI
Speaker: Hannes Schleinkofer
Date: 8th April 2003
Time: 11:1511:35
Room: Frankfurt
Topic: Muting is dead long live
blanking! The revolution
with area safeguarding
SICK C 4000 with floating,
self-teaching blanking.
Speaker: Torsten Rapp
Date: 10th April 2003
Time: 13:1513:35
Room: Frankfurt
Topic: A giant step forward in
area guarding: unlimited
possibilities with the
Laser Scanner S 3000
SICK AG Sponsor in South Baden
SICK insight 1/2003
W 9L Laser Photoelectric Switches 25 Products
>> With its new laser photoelectric
switches, SICK is unswervingly continu-
ing its product offensive in the area of
miniature sensors. As a result of their
small design the KT 3 contrast scan-
ner, the CSM colour sensor, and the
LUT-2 luminescence scanner (all in the
same housing as the W 9L) already
solve numerous tasks for which high
performance and low space require-
ment are important.
A complete family
The W 9L family consists of the ad-
justable WT 9L photoelectric proximity
switch with background suppression,
the WL 9L photoelectric reflex switch
with teach-in, and the WS/WE 9L
through-beam photoelectric switch,
which can also be set via the teach but-
ton on the device. All the sensors have
an enclosure rating of IP 67, a robust
ABS housing, and a pulsed laser light
transmitter. This generates a minute
light spot that is not even 0.5 mm in di-
ameter, so that even the smallest of
objects can be reliably detected and
this with a switching frequency of
1 kHz. The temperature-compensated
laser safety electronics ensure that
protection class 2 is reliably main-
tained under all operating conditions.
Gigantic ranges and
user-friendliness
The devices detect over maximum dis-
tances despite their mini-designs: the
scanning distance of the WT 9L is
150 mm, the WL 9L offers a range of
12 m, and the WS/WE 9L through-
beam system is suitable for distances
of up to 50 m. Neither external light
sources (e.g. flashlights) nor strong in-
terfering radiation (e.g. from mobile
telephones) impair reliable device func-
tion. Simple teach-in at the touch of a
button, operation and reception indica-
tors on the device, and a comprehen-
sive range of accessories ensure a
high level of user comfort during instal-
lation and commissioning.
Small design, great performance: the
new W 9L laser photoelectric switch
Mini-housing and mini-light-spot on the object, but long ranges,
high switching frequencies and superior user-friendliness, charac-
terise the new W9L family of laser photoelectric switches. No ad-
ditional protective and safety measures are required as it is in
laser protection class 2. CE, UL and CDRH approvals (the US
laser inspection) open up the whole wide world of automation for
the little sensor.
insightLINK
INFO 121
Small sensors great opportunities: the new W 9L family of laser photoelectric switches sets new standards
SICK insight 1/2003
DME 5000 Laser Distance Measuring Systems 26 Products
DME 5000:
the new kind of distance measurement
>> The device is available in two ver-
sions that are specially optimised for
pallets in automatic small parts stores
and high-bay warehouses. The DME
5000 has been designed for an ambi-
ent temperature range of +55 C to
40 C. Thus this distance measure-
ment device is also suitable for use in
deep-freeze storage systems.
Store-specific versions for
fastest possible positioning
processes
The new DME 5000 offers approach
speeds of up to 10 m/s, and with its
two range-oriented versions (for 70 m
and 150 m) takes the different require-
ments of automatic small parts stores
and high-bay warehouses into account.
The 70 m version is characterised by
highly dynamic characteristics: an up-
dated measurement value is provided
every millisecond. A variety of improve-
ments, including sensor temperature
drift reduced to 0.1 mm/K, ensure an
accuracy of +/2 mm with a repro-
ducibility of 0.5 mm. As a result, ex-
tremely rapid and precise positioning of
storage and retrieval devices at con-
tainer locations can be achieved. In
high-bay warehouses, with their longer
routes for storage and retrieval devices
and larger pallet storage spaces, the
150 m variant of the DME 5000 is the
right choice. It provides a measure-
ment value every 2 ms with an accura-
cy of +/3 mm. Thus particularly rapid
positioning processes are possible
here, too.
Highly accurate and dynamic measurement, two multifunctional
outputs and inputs for Preset, Stand by, Contamination warning,
and other system functions are the main advantages offered by
the new DME 5000 laser distance measurement system. There is
also the device display, that shows all the important information
at a glance, and a particularly user-friendly mounting and align-
ment concept.
The new DME 5000 laser distance
measurement system with illuminated
display
SICK insight 1/2003
VLL 18 Fibre-optic Cable Sensors in M 18 housing 27 Products
insightLINK
INFO 123
M 18 fibre-optic cable
sensors always fit
No space for mounting miniature sensors? Increased require-
ments regarding range, flexibility, chemical resistance, or im-
munity to temperature? The new VLL 18 series with plastic
fibre-optic cables always fits even under harsh conditions.
>> Optics in situ, evaluation wherever
there is the space for it numerous de-
tection tasks in space-critical circum-
stances can be solved using this con-
cept. SICKs VLL 18 series makes use
of the tried-and-tested concept of M 18
cylinder housings in conjunction with
one of a wide range of LL 3 series plas-
tic fibre-optic cables with flexible instal-
lation.
Long ranges, simple handling
As a through-beam system, the VLL 18
offers a scanning distance of 200 mm;
as a scanner the detection distance
can be up to 50 mm. In addition to
these above-average values, the sys-
tem convinces through its simple align-
ment and rapid sensitivity setting by
teach-in. The switching threshold and
hysteresis remain stored in the sensor
even if there is a longer power cut. Sim-
ple mounting allows not just the M 18
housing of the VLL 18, but also the nu-
merous opportunities offered by the
plastic fibre-optic cables, to be exploit-
ed to the full. For example, they can
simply be cut to the right length with
the cutting device with which they are
supplied, and then firmly fixed without
the need for tools. Small bending radii
ensure that the detection site is easily
reached.
Fibre-optic cables with
special options
The wide range of fibre-optic cables al-
so offers numerous options for a vari-
ety of applications. Small or highly
bendable end-collars, reduced bending
radii, Teflon-coated sheaths, special
lengths of up to 10 m, versions with in-
tegrated 90 corner sections, or de-
signs that can withstand temperatures
of up to 180 C these are just a few
of the approximately 50 different alter-
natives available.
Convincing mutuality
As early as the commissioning phase,
as well as in subsequent operation, the
illuminated display of the DME 5000
shows all the important status diagno-
sis functions at a glance. The visible red
light beam, and the horizontally and ver-
tically adjustable alignment mounting
on which the device is firmly fixed with
just three screws, simplify installation.
Large variety of interfaces
SSI and Profibus interfaces are avail-
able for the user. There are also two
multifunctional switching outputs (e.g.
for defined distance values, tempera-
ture warnings or a pre-fault advance
warning message) that can also be pro-
grammed as inputs. It is therefore pos-
sible to use one of the outputs as a
Stand-by input, via which the DME 5000
can be activated by an external signal.
In Stand-by Mode the light transmitter is
only started if required, thus achieving
a longer operational lifetime. The Preset
function is a further system option, with
which (using a sensor as a reference
mark) a more rapid and millimetre-accu-
rate calibration between the target and
actual positions of the storage and re-
trieval device in the aisle can be
achieved during commissioning of the
DME 5000. Alternatively both functions,
Stand by and Preset, can be set up via
the Profibus interface.
Unique: CSA and UL approvals
Finally, the new DME 5000 is the only
device of its type to have been granted
both CSA and UL approvals an advan-
tage that internationally active OEMs
and plant constructors will certainly ap-
preciate.
Always fits the
new VLL 18 series
insightLINK
INFO 122
SICK insight 1/2003
The UM 30 Series of Ultrasound Sensors 28 Products
insightLINK
INFO 124
>> Ultrasound sensors are non-contact
scanners that transmit an ultrasound
impulse and evaluate the time-of-flight
of impulses while taking ambient tem-
peratures, among other factors, into
account. They are particularly suitable
for detecting transparent objects, foils,
liquids, or bulk materials under harsh
environmental conditions.
Analogue and binary for
short and long ranges
The UM 30 series of ultrasound sen-
sors offers five different ranges up to
6,000 mm. Each version is available
with one or two binary outputs (two, for
example, for linking switching points to
min./max. for regulating filling levels),
and with analogue output for continu-
ous detection tasks.
Applications range from A to Z
Whether in automobile construction,
the packaging industry or zone protec-
tion ultrasound sensors cover a wide
area of use spanning many branches.
In addition to measuring filling levels,
these include numerous positioning
tasks, checking presence, monitoring
height and distance for collision pre-
vention, regulating access and dis-
tance, and other applications that in-
volve the detection of objects.
Sensors sought? In principle
SICK has it all!
Sensor-seekers will find all the physical
sensor principles in use at SICK so
there is always a solution. Whether
optoelectronic, inductive, capacitive,
magnetic or ultrasound: there is always
at least one sensor that is suitable for
the detection task in question.
Ultrasound sensors
join SICKs range
To further its ambition to provide customers with the best possi-
ble detection solutions as a single-source supplier, SICK has sup-
plemented its programme of products for automation technology
with ultrasound sensors. A variety of ranges and output versions
offer versatile solutions for analogue and limit value detection.
SICK ultrasound sensors: non-contact scanning with ultrasound impulses
SICK insight 1/2003
CoreTech
Encoders 29 Products
>> CoreTech
is a consistent, compre-
hensive, modular system. Whereas me-
chanical variants and individual line
numbers or resolutions necessitate a
large variety of individual components,
all incremental and absolute CoreTech
encoders make use of the same ASIC-

based core.
Individual impulse resolution
All line numbers between 1 and 8,192
can be supplied with the CoreTech
DRS 60 shaft encoder. In the case of

the CoreTech
ARS 60 absolute en-

coder all step numbers between 2 and
32,768 can be realised. A high level of
interference immunity and signal quali-
ty is achieved through differential scan-
ning by the ASIC scanning element.
Available worldwide
within 48 hours
Adjustment of the core, and assembly
of the other encoder components: the
shaft, flange, circuit board, housing
and plug, can take place in the factory
or in one of the 16 CoreTech
stations
worldwide. It is thus possible to supply
every user in the worlds most impor-
tant industrial markets with each indi-
vidual CoreTech
encoder within 48
hours. This does away with stock-keep-
ing, and considerably reduces the
downtimes of the machines involved.
Zero-impulse allocation: but-
ton prevents frustration
Loosen the screws, twist, compare the
zero point with the control system, and
tighten the screws without displace-
ment for most incremental shaft en-
coders, definition of the zero impulse
involves a lot of work, expense and pa-
tience. CoreTech
encoders put an end

to this frustrating process. The zero im-
pulse is electronically assigned at the
touch of a button. Moreover, with the
ARS 60 absolute encoder the zero can
be set via a control cable. CoreTech
thus offers maximum user-friendliness.

CoreTech
encoders
have the knack
Variants to suit every task, rapid worldwide availability, and com-
fortable zero-impulse allocation at the press of a button, make
the incremental and absolute CoreTech
encoders from SICK-

STEGMANN particularly popular in industrial path and angle de-
termination. Stock-keeping and long delivery times are a thing of
the past thanks to modular device concepts and the possibility of
individual impulse resolution.
insightLINK
INFO 125
Highly valued in industrial path and angle detection: the CoreTech
encoder from
SICK-STEGMANN
The CoreTech
encoders
SICK insight 1/2003
S 3000 Safety Laser Scanners 30 Products
>>The S 3000 laser scanner, succes-
sor to the technological trend-setter
PLS, is used for horizontal and vertical
safeguarding of hazardous points-of-
operation, dangerous areas, and ac-
cess in compliance with Type 3 of
IEC/EN 61496-3. Among the other new
features are its modular concept: the
three system modules (sensor head,
I/O module, and system plug) can be
combined with one another flexibly and
as required, and thus permit the opti-
mum preparation of the sensor for its
tasks.
Safety requests programme
With the selection of the Standard, Ad-
vanced, Professional or Remote I/O
Module, the S 3000 can be ideally con-
figured for the task in hand. As the ba-
sic version, the S 3000 Standard of-
fers one protective and one warning
field. The Advanced version has four
protective and four warning fields, as
well as four digital inputs for protective
field switching. Shaft encoder connec-
tions for speed-dependent protective
field switching have been integrated in
a safety laser scanner for the first time.
This, and the eight protective and eight
warning fields, make the S 3000 Pro-
fessional the right safety system for
mobile applications. If both directions
of motion need monitoring the Remote
I/O Module can be attached to a sec-
ond S 3000 sensor head.
Common features
All versions share features such as the
range (optionally either 5.5 m or 7 m),
switchable response times of 60 ms or
120 ms, the scanning angle of 190,
simultaneous monitoring of second
protective fields, switching outputs
S 3000 safety laser scanners:
the time is ripe for the future
Application expertise gained from many thousand installed PLS
units has been integrated in the new S 3000 safety laser scan-
ners from SICK. Even shorter response times, longer ranges, a va-
riety of functional modules, e.g. the so-called I/O module, for
application-based system design, integrated control and monitor-
ing functions, the possibility of connection to safety-oriented field
buses, and many more advantages make the S 3000 a versatile
and safe investment for the future. Thus begins a new era in safe-
ty technology.
Did you know that
if you added up the protective
field diameters of all the PLS
laser scanners sold, the result
would be longer than more than
2,200 soccer fields?
the total area of the protective
fields of all the PLS units in oper-
ation is larger than that of the
Canary Islands of Fuerteventura
and La Gomera together?
insightLINK
INFO 126
A secured future: the new
S 3000 safety laser scanner
with external relay monitoring, and the
possibility of Bus connection.
Always up-to-date
The modular concept has one more ad-
vantage: the high level of investment
security. Thus new or further developed
modules, simply substituted at the
sensor head, provide upgrading to the
current state-of-the-art at any time.
The S 3000 the time is ripe for
the future!
SICK insight 1/2003
ICS 110 Camera Sensors 31 Products
Contour detection during rotation with
the new ICS 110 camera sensor
Whether merely transported longwise, or also rotating, the new
ICS 110 can precisely detect contours and check for taught-in
features. This allows the two-dimensional testing of parts on
transport and feed plants, for checking assembly, for determining
presence and position, and for inspecting labels and printed
marks.
insightLINK
INFO 127
Precise contour detection, even during
rotation: the new ICS 110
(like that provided by photoelectric
switches) is transferred to the machine
control system. The ICS 100s well-
known extremely high processing
speed is, of course, also provided by
the ICS 110.
Economically a most interest-
ing alternative
In addition to checking contours, the
ICS 110 offers easy-to-set-up opportu-
nities for use for checking shapes,
comparing areas, determining gloss,
and object detection. In many cases
the 2-D sensor from SICK represents
an extremely cost-effective alternative
to PC-based image processing solu-
tions
>> 2-D image capture systems (a
CMOS chip) with 320 x 320 active pix-
els, and integrated high-speed line sig-
nal processors are central components
of the compact ICS 100 and 110 plug
& play sensors.
Simply teach-in objects
Objects are taught in by scanning the
input using a hand-held control device
and a simple teach-in menu, whereby
the camera image provided gives valu-
able support. The necessary device pa-
rameters, such as image resolution
and the required evaluation process,
are defined by the camera itself,
though they can also be entered and
optimised by the user. Values are per-
manently stored in an EEPROM after
successful parameter-setting.
New algorithms have the
knack
The reference patterns and search win-
dows for up to 16 different objects can
be stored in the ICS 110 Intelligent
Camera Sensor. The sensors can
check rotating parts that are not pre-
cisely positioned, as well as those for
which a defined angle of rotation is im-
portant. The ICS 100 generates a bina-
ry image of the contour from the cap-
tured image and this, in turn, is evalu-
ated by the sensors new algorithm. If
the optical examination proves to be in
order, a corresponding switching signal
SICK insight 1/2003
The CDB 400 Switching Module for Bar-code Scanners 32 Products
Simple decision
This decision is pretty straightforward,
however, as the CDB 400 is only half
as large as its predecessor version.
Moreover, with features such as strain-
relief PG screws, IP 65 with standard
scanner cable, a transparent cover pro-
viding a clear view of the LED indicators
and switch settings behind it, the pos-
sibility of mounting it in a closed state,
and plug-in connection to the scanners
service interface, it offers further ad-
vantages important in mounting and
operation.
Box and cloning for almost
all bar-code scanners
All stationary bar-code scanners from
SICK can be connected to the SICK
CAN-Scanner network, to host comput-
ers and PLC units using the new
CDB 400 connection box. The
CMC 400 cloning module also sup-
ports all scanners (except the CLV
410). Customers can easily upgrade,
with the cloning module, reading points
that already have the CDB 400.
New connection module allows cloning
of bar-code scanner parameters
The term mean time between repair (MTBR) is gaining in sig-
nificance in modern production technology. In the case of a de-
fect, components must be replaced quickly and easily, and if
possible by untrained personnel. These demands can be wholly
met in the area of identification technology with SICK bar-code
scanners by using the new CDB 400 connection module and the
optional CMC 400 cloning module.
insightLINK
INFO 128
>> Introduction of the new CDB 400
not only means that a compact, unified
connection module is now available for
all SICK bar-code scanners, but also
that an optional CMC 400 memory
module, that stores all the device pa-
rameters externally, can be inserted in-
to the CDB 400.
Clonable parameter sets
The CMC 400 cloning module carries
the genetic information of its prede-
cessor. New scanners can be cloned
as often as desired by transferring in-
formation back from the CMC 400.
Thus individual scanners can be very
quickly exchanged without the addition-
al bother of parameter-setting. The
write-protection switch prevents unin-
tentional overwriting of the reading-
point-specific bar-code scanner param-
eters. Use of the new CDB 400 con-
nection module, however, into which
the CMC 400 can be inserted, is a pre-
requisite for taking advantage of the
cloning module.
Flexible connectivity with the
CDB 400 connection box
N
E
W
S
SICK insight 1/2003
The OD Hi Displacement Sensor MZT 6 Cylinder Sensor 33 Products
OD Hi: CMOS sensor for
-precise detection
>> The OD Hi is available with four
measurement ranges between 26 mm
and 140 mm, depending on the task in-
volved. Numerous features contribute
towards making the devices powerful
measuring scanners.
CMOS technology:
high precision even with
difficult surfaces
For the first time, a CMOS detection el-
ement is used in the OD Hi. As a result,
unlike other systems, neither object
colour changes, nor fluctuating surface
composition, nor reflective properties,
adversely affect the reliability and accu-
racy of the measurements. Thus a res-
olution of 2 can be achieved, for ex-
ample, with a measurement range of
30 mm +/4 mm and 90% object re-
flectivity!
All functions in a single device
Also unusual compared to other dis-
placement sensors is the fact that the
OD Hi requires no external controller. All
programming, evaluation, and analogue
and digital output functions are inte-
grated in the device. This not only re-
duces engineering and wiring costs, but
also simplifies purchasing and the
keeping of stores.
Scanning and measuring in the -range is the task of displace-
ment sensors. The new OD Hi convinces with special features for
even quicker commissioning, even more flexible opportunities for
use, even greater detection capability, and even higher precision.
insightLINK
INFO 129
Setup on the sensor
Once installed, the OD Hi is quickly
ready for operation: all the necessary
settings can be called up and saved via
the Setup menu.
Flexibility cuts equipping times
The control panel with its five-digit LED
display provides direct information on
the settings saved and the current
measurement value and switching func-
tions. Moreover, it allows rapid in-situ
adaptation of the OD Hi to altered
process requirements, and thus re-
duces equipping times on plants.
A wide range of applications
Displacement sensors such as the
OD Hi are used in the electronics, auto-
mobile and packaging industries, and in
robotics, among other areas. They mon-
itor the presence and position of ob-
jects, measure their profiles, diameters
and thicknesses, and take on other
quality-assessing functions that neces-
sitate -precise detection capability.
The OD Hi displacement sensor scans and measures in the -range
MZT 6 magnetic
cylinder sensors:
reliable mounting
reliable switching
>> The new MZT 6 magnetic cylinder
sensor from SICK offers maximum
user-friendliness, immunity to vibra-
tions, and switching accuracy. It is suit-
able for all common T-slot cylinders.
The newly developed mounting
technology saves time because it is in-
serted from above during mounting on
a pneumatic cylinder, and is pressed
against the floor of the cylinder slot
along its entire length. A standard tool
is enough to provide rapid, solid screw-
ing of the slotted/hexagon socket
screw head in the thread of the metal
socket so that it cannot be pulled out.
Solid as a rock, even with
heavy vibration
Sunken mounting in the slot, immunity
to impact, and vibration resistance
prevent changes in position, and thus
changes in the switching point, during
operation. This ensures reliable switch-
ing characteristics and a high level of
machine availability. It also prevents
the sensor, inserted into the cylinder
slot from above, from being levered out
by its cable tail.
Two versions available
The MZT 6 is suitable for all common T-
slots and thus optimises storage
processes for end-users. The cylinder
sensor is also available as the RZT 6,
an AC/DC 3-wire version with a reed
output contact. INFO 130
N
E
W
S
SICK insight 1/2003
WT 190T The L 4000 Safety Photoelectric Switch System 34 Products
insightLINK
INFO 233
insightLINK
INFO 132
>> The L 4000 system is a Type 4 non-
contact safety device acc. to IEC 61
496. It consists of the UE 401 safety
evaluation unit with an enclosure rating
of IP 20, to which up to four individual
sensor pairs (i.e. transmitter/receiver
combinations) can be connected or, in
a cascading system, up to eight sensor
pairs.
Compact cylinder design en-
sures high mounting flexibility
The L 4000 system is used for safe-
guarding hazardous areas and access
to machines and plant. For the first
time the safety switch optics and signal
processing have been accommodated
in a cylindrical housing with a diameter
of M 18 and M 30, thus ensuring sim-
ple mounting and alignment of the
transmitter and receiver. During opera-
tion, the UE 401 safety evaluation unit
monitors reliable functioning of the
sensors. The system generates a stop
signal if the light beam is interrupted.
Use-friendly through proven
technology
The new L 4000 system, however, not
only provides safety in the highest pos-
sible category, but is also user-friendly
and offers auxiliary integrated func-
tions such as external relay monitoring
and restart interlock. Coloured LEDs
provide in-situ information on the oper-
ating state. Rapid diagnosis is possible
as a result of the visualisation of sta-
tus and error messages on the 7-seg-
ment display of the UE 401 safety eval-
uation unit.
Suitable for individual safe-
guarding solutions
The possibility of connecting four sepa-
rate or eight cascaded sensor pairs,
the L 4000s application-oriented alter-
native range versions, its suitability for
outdoor applications, and the use of
corner mirrors, also allow the solution
of more complex safeguarding tasks.
Category 4 safety, range variants from 0 to 10 m and 0 to 60 m,
integrated functions, and connection of up to eight sensor pairs in
M 18/M 30 cylinder housings this is what the new L 4000 safe-
ty photoelectric switch system has to offer. With an IP 67 enclo-
sure rating and an expanded temperature range of from 20 C to
+55 C it also allows the safeguarding of machines and plant un-
der extreme environmental conditions.
Flexible cylinder-
shaped safety
WT 190T:
high-end scanners
meet challenging
demands
>> A digital display, application-specific
teach-in functions, and a small, fo-
cused light spot make the new
WT 190T the ideal solution for detect-
ing position, inspecting completeness,
or checking presence.
User-friendliness, reliability and
cost-effectiveness are the main re-
quirements for photoelectric proximity
switches. These are fulfilled by the new
WT 190T photoelectric proximity
switch. The device family includes
scanners with foreground or back-
ground suppression. Each design of-
fers a choice between two ranges:
50100 mm for close-range applica-
tions, and 100300 mm for longer-
range applications.
Simple commissioning and
very user-friendly
The digital display and two function in-
dicators, for the switching state and
light reflectivity, show all the current
device settings and functions. A variety
of application-oriented teach-in modes
simplifies the teaching-in of switching
points. A timer function can be activat-
ed, if necessary. The scanner can be
quickly and optimally aligned on the tar-
get object thanks to its transmitting vis-
ible red light. The small, precise light
spot allows reliable detection of the
smallest of objects. The WT 190T is
compact and permits devices to be
used even under difficult environmen-
tal conditions. Rapid installation and
commissioning is further facilitated by
the tried-and-tested mounting and con-
nection technology. INFO 131
SICK insight 1/2003
ATM 60 Multiturn Encoders 35 Products
insightLINK
INFO 133
>> In addition, the SSI and RS-422 pro-
gramming interfaces, and Profibus con-
nectability offer further opportunities
for data transfer.
Rotative measurement system
with maximum immunity to
interference
The ATM 60 is a rotative measurement
system for paths, angles, and posi-
tions. The shaft encoders Multiturn
property allows absolute determination
of rotating axes, e.g. for measuring
length by means of the spindle drives.
Unlike electronic solutions (counters
with battery buffers), the ATM 60 is im-
mune to interfering impulses, mainte-
nance-free, and long-lived.
Electronic adjustment, multi-
ple communication
Electronic adjustment and parameter-
setting via the RS-422 interface pro-
vide individual adaptation, and simple
and rapid commissioning. The SSI in-
terface developed by Stegmann, which
has since become an industrial stan-
dard, transfers the ATM 60s absolute
position signal on four wires. As a re-
sult of the communication protocols for
Profibus, CanOpen and DeviceNet,
standardised transfer of digital data is
possible in the field bus systems most
commonly found in factory automation.
Shockproof, condensation-
proof, and suitable for
outdoor use
The ATM 60 can withstand particularly
harsh conditions. Designs with clamp-
ing flange and servo-flange, as well as
a hollow shaft variant with an enclosure
rating of IP 67, are available for tasks
in which dampness and dirt are to be
expected. Its magnetic functional prin-
ciple not only gives the ATM 60 a high
level of immunity to shocks and vibra-
tions, but also ensures reliable opera-
tional shaft encoder function in the
presence of condensation.
ATM 60: Multiturn shaft
encoder with Multi-Bus interfaces
The ATM 60 Multiturn shaft encoder from SICK-STEGMANN is
now also available with communication protocols for CanOpen
and DeviceNet. As a result, the position measurement system
can transfer its extremely accurate path and angular data in digi-
tal form within the bus systems commonly used in industrial au-
tomation.
Path and angular data the ATM 60 Multiturn encoder from SICK-STEGMANN:
the Bus version above, the slip-on hollow shaft version below
SICK insight 1/2003
LUT Luminescence Scanners: differentiating between originals and fakes 36 Know-how
Luminescence scanners vs. fakes
Numerous products or packages are invisibly labelled with lu-
minophores as a highly forgery-proof, cost-effective and practical
measure for combating copies. LUT series luminescence scan-
ners from SICK provide rapid differentiation between originals and
imitations during production, packaging, distribution, customs in-
spections or automated returns.
>> Imitations are the result of illegal
product and brand piracy. In practice,
both types of forgery commonly occur
simultaneously and are not confined
to luxury articles either.
Turnover of 250 bn. US-Dollar
lost through product and
brand piracy
While product and brand piracy was
largely still restricted to copying con-
sumer articles such as T-shirts, per-
fumes or watches a few years ago, it
has now developed into complex tech-
nological theft of not just CDs and
video cassettes, but also software,
pharmaceutical products, and aero-
plane and car parts. Experts estimate
that the worldwide loss of turnover is
about 250 billion US-Dollar annually. In
Germany alone, product and brand
piracy is responsible for the loss of
70,000 to 80,000 jobs according to
the German Chamber of Industry and
Commerce (DIHK) not to mention the
resultant loss of tax revenue and the
cost to society in policing and lost in-
come. Just about everything has been
faked almost every branch is affect-
ed. Every second video cassette is
counterfeit, 43% of the software on of-
fer is copied and every tenth aero-
plane spare part. Car spare parts
amounting to 1012 bn. US-Dollar in
value, and medications worth 23 bn.
US-Dollar, are also involved.
Product and packaging
labelling as a protection
against fakes
In addition to legal measures and or-
ganisational solutions in purchasing,
sales and distribution logistics, the for-
gery-proof or at least imitation-unfriend-
ly labelling of goods and their packag-
ing offers substantial protection
against product and brand piracy, right
from the start of the product life cycle.
Holograms are also enjoying an up-
surge in popularity as they are difficult
to forge. Colour codes, digital signa-
tures and chemical fingerprints are al-
so used though as a protection
against copying they all suffer from be-
ing highly cost-intensive and not very
practical for dealers, customers or the
customs services. In contrast, labelling
with luminophore materials (that are
normally invisible to the human eye)
has proved forgery-proof, economical,
and practical for certain products, e.g.
spare parts, pharmaceutical packag-
ings, disposable drinks packages or
documents.
Illumination brings
the truth to light
Luminescence scanners make the in-
visible label visible and thus allow au-
thenticity to be checked at production
or processing machines. If no visible lu-
minescence is found when illuminating
an object that, according to producer
definition, has been labelled with a lu-
minophore to prevent copying, then it is
a fake. INFO 134
The LUT for protecting products and brands
Keep ahead of the copiers
with the LUT series
For many products, authenticity la-
belling with luminophores is a techni-
cally and economically practical pro-
tection against product and brand
piracy. The attachment of such mate-
rials is already commonplace in many
industrial processes. SICK offers a
comprehensive series of proven and
robust LUT luminescence scanners
with reliable detection. They meet the
special needs of product and brand
protection. Thus the conditions exist,
as part of a complete strategy for
combating the highly professional
forging of mass-produced articles, to
stay a little bit ahead of the imitators.
SICK insight 1/2003
Futuroscope, France 37 Museum
insightLINK
on the Internet at:
www.futuroscope.fr
330 km south-west of Paris, near Poitiers, there is a very special
kind of park: the Parc du Futuroscope. Visitors are transported in-
to the worlds of fantasy, discovery, pleasure and excitement.
>> For those taking a holiday on the
south-west Atlantic coast, Futuroscope
is on the way. Those visiting Paris can
reach the park in 80 minutes on high-
speed TGV trains.
Fantasy and discovery
Four main themes await the visitor, in-
volving enticing journeys. On the Jour-
ney of Fantasy one can, for example,
experience at close range the flight,
crash and rescue of the French pioneer
of flight Henri Guillaumet in the South
American Andes in 1930. Or one dives
down to Atlantis the legendary city
whose exact location remains a mys-
tery. Impressed by these and other
sensations, the visitors curiosity will
be satisfied during the Journey of Dis-
covery. Whether as an astronaut in
space or as a virtual companion of the
Hubble space telescope through the
Milky Way useful information makes
the journey so interesting that after-
wards one will want to climb Futuro-
scopes rotating observatory without
delay.
Excitement and pleasure
Imagination is called for on the Journey
of Excitement. If the visitor finds the
three-dimensional Cyberworld vaguely
familiar, they could get used to the idea
of living 65 million years ago and daily
fending off the hunting drive of a T-Rex
or other dinosaurs. More comfortable
feelings come to the fore on the Jour-
ney of Pleasure. Wander along on the
trail of pandas, experience Brazils Co-
pacabana, the Amazon and Carnival in
its 360 perspective, or follow butter-
flies on their way from Canada to Mexi-
co on a magic carpet all promise the
visitor moving insights and perspec-
tives.
New worlds are inviting
Futuroscope will also be offering new
attractions again in 2003. The Numer-
ical City revolves around multimedia
and new technologies. Would you be in-
terested in a virtual trip to the Interna-
tional Space Station? Or perhaps a vis-
it to the Mines of Fear? Whatever.
Theres something for everyone at the
Futuroscope. If you dont believe it, you
can check it out for yourself prefer-
ably with an actual visit, or you can
have a preview on the Internet.
It's worth a visit: there's
something for everyone
at Futuroscope!
Futuroscope
travelling in other worlds
SICK insight 1/2003
Interview at SICK-STEGMANN 38 SICK Tour
SICK-STEGMANN: exploiting the
opportunities of the drive technology growt
SICK-STEGMANN after the Hanover Industrial Trade Fair 2003
the company will offer, and further develop, innovative drive and
encoder technology under this name. SICK insight interviewed
Managing Director Friedrich Keglowich, Encoder Dept. Manager
Rolf Wagner, Drives Dept. Manager Elmar Limberger, and Bernd
Appel, Product Manager for motor feedback systems.
SICK insight: What was the aim of
SICK AGs take-over of Max Stegmann
GmbH last year?
Friedrich Keglowich: The acquisition of
Stegmann is part of the strategic ex-
pansion of our portfolio over the last
few years, which has made us a com-
plete, single-source, supplier of indus-
trial sensors for machine construction.
SICK-STEGMANN, a technological leader,
offers a complete product programme
for machine construction and drive
technology. Our aim is to use these ro-
tative sensors and actuators to take
advantage of the market opportunities
arising from the decentralisation of
control systems and drive technology.
SICK insight: What range of products
is behind the name SICK-STEGMANN?
Elmar Limberger: We are at home in
drive technology, in terms of both sen-
sors and actuators. The sensors de-
partment includes encoders for numer-
ous tasks in machine construction, as
well as motor feedback systems for the
digital regulation of servomotors. In the
area of drive technology we offer com-
pact drives with powers of up to 50
Watts, for a variety of possible uses.
The emphasis here is on customer-spe-
cific solutions with a high degree of in-
tegration, where we can bring all our ex-
perience in mechanics, electrics and
electronics to bear. An example of this
is a colour zone drive specially devel-
oped for MAN-Roland with an integrat-
ed control system for precise colour
dosing on printing machines.
SICK insight: A certain amount of
know-how has been amassed in
Donaueschingen ...
Bernd Appel: ... from which in recent
years innovations, patents and market
standards have flowed at regular inter-
vals. Just think about the SSI interface
From left to right: Friedrich Keglowich, Anette Hippach, Bernd Appel, Elmar Limberger, Rolf Wagner
SICK-STEGMANN's
company building in
Donaueschingen
SICK insight 1/2003
39 SICK Tour
h market
patented by Stegmann, which is now al-
most indispensable in circuits for regu-
lating bearings. Or how about the
HIPERFACE
interface, that turns mo-

tor feedback systems into plug & play
information solutions for regulating mo-
tors and drives? We have become the
technological leader in this area, and a
partner of the most important drive
suppliers worldwide. HIPERFACE
has
already become a standard in Europe
and the USA. We can offer our cus-
tomers a wide range of rotative drive
products we are now in the process
of achieving this with linear drives. With
the encoders, our CoreTech
is a sign
of the times, as we can not only indi-
vidually configure almost every cus-
tomer-specific version, but also get it
ready within 48 hours anywhere in the
world. In future, Donaueschingen will
remain a place where you can count on
technological surprises.
SICK insight: What do Sales and Sup-
port look like at SICK-STEGMANN?
Friedrich Keglowich: The customer
groups and contacts supported by
Stegmann, and the application fields
for the rotative sensors, are almost
100% the same as those covered by
SICKs Industrial Sensors Division. It is
thus only logical that encoder sales for
machine construction are carried out
via the Central Sales Office (Germany)
in Dsseldorf, which will start at the
same time as the Hanover fair. We
have also trained our external and in-
ternal service consultants intensively
with the new product range. As is the
case with our other sensors, there is
sometimes a special need for advice
that is more detailed than usual. The
sales organisation makes use of the
expertise of the Product Managers, Ap-
plication Specialists and Developers in
Donaueschingen.
SICK insight: Apropos worldwide the
Hanover Industrial Trade Fair 2003 is
starting soon. What will SICK-
STEGMANN present to the worlds pub-
lic?
Rolf Wagner: To start with we have the
blue line, i.e. the various incremental
and absolute encoders in SICKs famil-
iar corporate colour and with
Stegmanns familiar inner qualities.
One highlight here is a micro-encoder
that provides all the opportunities of-
fered by miniaturisation thanks to our
MiniDisc technology. We already use
this in motor feedback systems, such
as the SinCos
SKS 36 with the HIPER-

FACE
interface that we are showing in

Hanover. There will also be a range of
other motor feedback systems on show
already integrated in servomotors of
various dimensions. The star among
our drives at the HMI will be the HD 70
HIPERDRIVE
a newly developed inte-

gral drive for automatic format adjust-
ment, e.g. in printing or packaging ma-
chines.
insightLINK
INFO 135
In brief
Encoder and actuator producer Stegmann joins
the SICK Group of companies
The Max Stegmann GmbH & Co. KG, with its roughly 600 employees world-
wide, has been part of SICK AG since 1 October 2002. In addition to optical,
inductive, magnetic and capacitive sensors, customers can now order rotative
sensors (encoders) from SICK.
SICK, the leading manufacturer of sensors, safety systems and identifica-
tion solutions for factory automation, and products for process analysis and
environmental measurement, has thus complemented its product portfolio in
the area of factory automation and, at a stroke, achieved a significant market
position in encoders. The main purchasing branches for both the parent com-
pany and for the rotative sensors include the packaging machine industry,
handling and robotics, the automobile industry, warehouse and conveyor tech-
nology, the electronics and semi-conductor industries, and the printing and pa-
per machine industry.
SICK insight: Then we hope that in
Hanover not only will the exhibits re-
volve, but also that a lot of specialist
discussion will revolve around your de-
vices. Thank you very much for this
conversation.
SICK wins the
Grand Prix in
Poland
>> SICK, or more precisely, the C 4000
safety light curtain and the employees
of SICKs Polish subsidiary, have won a
Grand Prix in Poland.
The Ministry of Employment awarded
the Grand Prix for the pole position
achieved by the light curtain in the
safeguarding of machines compliant
with Category 4, on the occasion of the
SAWO safety technology trade fair. The
fair featured a technology competition
accompanied by, among other things, a
series of seminars run by SICK on the
topic of Safety standards in Poland
and the EU. SICK was way ahead of
the competition. No great surprise with
a system like the C 4000. INFO 136
N
E
W
S
SICK insight 1/2003
40 SICK Tour Grand Prix, Poland DeviceNet Safety: SICK/OMRON/Rockwell joint venture
New worldwide
safety network
Rockwell Automation, the OMRON Corporation, and SICK AG are
jointly developing an open protocol for safety-oriented communi-
cation. Based on the existing standard protocol of DeviceNet and
Ethernet/IP, the new expansion of the safety protocol has passed
concept-testing by the TV in Rhineland.
>> The integrated architecture for the
new safety network that the worlds
three leading suppliers of automation
and machine safety technology are de-
veloping will be published by the Open
DeviceNet Vendor Association (ODVA).
Its aim? Smooth communica-
tion between individual safety
components
The new safety protocol is an expan-
sion of the existing standard protocol.
It allows simultaneous operation of
standard and safety devices within the
same network. It will also ensure
smooth communication between indi-
vidual safety components in DeviceNet
and Ethernet/IP networks, without the
need for any additional programming.
Open standard complying with
IEC 61508
The first implementation of the safety
protocol will take place via DeviceNet
and provide reliable, fail-safe communi-
cation between bus participants, e.g.
input and output devices, safety sen-
sors, actuators and safe control sys-
tems. The safety protocol is defined as
an open standard and designed for use
up to SIL 3 according to IEC 61508
(Category 4 according to EN 954). The
safety protocol will allow end-users to
operate a wide range of devices from
differing suppliers together. Further-
more, customers will profit from almost
inconceivable flexibility in network de-
sign, as well as considerably reduced
installation costs.
Administration by ODVA
The TV concept test that has been
passed represents the first milestone
in the development of the safety proto-
col. After completion of this open spec-
ification for the safety protocol, and ac-
ceptance by the TV, administration of
the new standard will be taken over by
the ODVA. The companies next step is
a test template for a system require-
ments specification in order to be able
to implement the safety protocol in De-
viceNet. The companies expect to
present the first DeviceNet Safety solu-
tions in 2004.
Prize-giving during the SAWO
safety trade fair
Certificate and Grand Prix medal
>> Hazardous plants require regular in-
spections to ensure that the plants
protective equipment provides opti-
mum accident prevention during opera-
tion on the basis of directives that are
valid throughout Europe. The measure-
ment of machine overrun is an integral
component in the calculation of the
safety clearance required by the non-
contact safety device (e.g. a light cur-
tain) in a hazardous area of power-driv-
en machinery. A measurement report
for inclusion in the machines docu-
SICK insight 1/2003
Accreditation of SICK as Inspection Centre Training 41 SICK Tour
>> The example of the Safety Systems
Training Department demonstrates how
these events complement one another.
Hand protection or liability
SICKs courses pass on its experience
from almost five decades of safety tech-
nology to constructors, electrical engi-
neers, Safety Managers, Project Man-
agers, operational planners and execu-
tives, among others. And this is
deliberately neutral: speakers are re-
cruited both from SICKs team of spe-
cialists and from experts at the Berufs-
genossenschaft Feinmechanik und
Elektrotechnik (the Trade Association
for Light Engineering and Electrical Engi-
neering), or the Administrative Co-oper-
ation at the EU Market Regulatory
Group for Machines.
Specialist training meets indi-
vidual requirements
SICK not only offers individual semi-
nars, but also means of learning tailor-
made to meet differing requirement pro-
files. This allows knowledge to be sys-
tematically built up to solve individual
tasks. Events such as, for example,
Safety inspections:
accreditation expanded
The DATech (German Accreditation Centre for Technology) has re-
cently expanded SICKs accreditation as a Type C inspection cen-
tre according to DIN EN 45004 to include authorisation to carry
out accredited machine overrun measurements.
Equipping the mind
SICK Training & Education
One never stops learning. Which is why SICK offers practical know-
ledge for efficient solutions in a comprehensive Training & Educa-
tion Programme. The events are intended for a wide variety of
target groups.
specialist training for constructors,
electrical engineers, control system and
automatic control technicians, provide
all the relevant detailed information
needed in their daily work and help
them steer a safe course through the di-
rectives and standards jungle. As a re-
sult, this training programme allows
projects and tasks to be undertaken on
a dependable and responsible basis,
and thus prevents additional costs aris-
ing from subsequent improvements
that may prove necessary. In addition to
the above-mentioned target groups,
there are also specialist courses for
Project Managers, planners and devel-
opers, Safety Managers and others re-
sponsible for safety at work, mainte-
nance and repair technicians, and exec-
utives and technical managers.
Information on call
Further information on the entire fac-
tory automation training and seminar
programme can be downloaded from
the Internet as a PDF-file at
www.sick.de/training or found in the
Training & Education 2003 brochure,
which can be requested directly from
SICK AG. INFO 138
mentation, and an inspection seal,
document proper calculation of the
minimum safety clearance according to
the mathematical principles of specific
machine standards (Type C Standards)
or in compliance with EN 999.
Accredited safety
inspections and not
just for SICK systems
SICK is the first producer of protective
equipment to offer safety inspections
from accredited inspection sites in the
area of non-contact safety devices
such as light grids, light curtains or
laser scanners. Other protective equip-
ment directly connected to safety de-
vices are also inspected, e.g. emer-
gency stop, two-hand switches, en-
abling switches, protective gate
monitoring etc. The SICK Inspection
Seal confirms a positive result during
safety equipment inspections. INFO 137
SICK insight 1/2003
Business rocks!
Quotations for the new business generation
(from pop stars not philosophers)
Cross-media year-round support from SICK
Business rocks! e-mail newsletter 42 Book Corner
A book review by
Ingrid Rathfelder, Editor of the
SICK insight e-mail newsletter
>> Strangely enough, each generation
starts from scratch, knowing nothing.
If one believes this quotation from
Dieter Hildebrand, to be found in Busi-
ness rocks, a collection of quotations,
then the new business generation is al-
so facing this void and must start
afresh. And why not? It is a fact that to-
days management generation commu-
nicates, has meetings and makes pre-
sentations quicker and more frequently
than any that have come before. In the
age of the Internet and modern presen-
tation techniques it would be a shame
The networking of content from individ-
ual communication instruments, such
as printed media, trade fairs, web sites
and e-mail newsletters is exercising the
worlds creative forces. Cross-media is
the word of the moment that is sup-
posed to ensure a uniform market
presence and communication-related
synergistic effects.
You could, of course, say: So what?
If it has to be cross anything, Id rather
watch the next cross-country run or do
a crossword at least Id know what Id
got.
So what do cross-media considera-
tions do for you as a reader of SICK
insight?
Our customer magazine appears
twice a year, in spring for the HMI and
in autumn for SPS Drives. But in the in-
terim period (and also during printing)
there are new products, applications,
training courses, and corporate topics
accumulating that we would like to of-
fer you up-to-date. So just over a year
ago we introduced the monthly SICK in-
sight Online Newsletter, sent to several
thousand interested parties (in Ger-
man or English), to supplement the
printed medium though up to now this
has been without accessories such as
pictures or graphic designs. But be-
cause we couldnt leave well alone,
and actually enjoy messing about with
cross-media, we can now offer you the
choice between an HTML version,
adapted to the design of the customer
magazine as shown in the accompa-
nying picture and a text version with-
out adornments.
So if you are curious about the on-
line crossies, you can register as a
subscriber (free-of charge and without
obligation) at
www.sick.de/newsletter
We wish you lots of fun with SICK as
your cross-media year-round compan-
ion!
Your SICK insight Editors
to spoil the flavour with trite and jaded
quotations. Forget quotes from Caesar,
Seneca, Aristotle and et al. Titbits from
Woodstock, punk, pop and the new
culture curry favour.
Thus an investment adviser could
pep up a presentation by including
these words by Marcel Reich-Ranickis:
Money alone doesnt bring happiness,
but its better to cry in a taxi than on a
tram. Or spice it up with Anyone who
doesnt try to make as much money as
possible must be pretty stupid (Mick
Jagger).
During a meeting, or at a party, the
saving seasoning could be: I give the
impression that Im bored, but thats
not true. I just have an unbelievably
boring face (Charlie Watts).
Anne Stalfort and Sybil Volks have
divided the collection into nine cate-
gories mixing quotations from German-
and English-language sources. They
are mostly concerned with business
matters, though parties, power women
and leisure have their fair share.
An amusing, sometimes even wise,
assistant for the next speech or pres-
entation, and also profitable for our oc-
casionally dull everyday existence.
Make the most of some new condi-
ments!
Business rocks is available
from Financial Times Prentice Hall
ISBN 3-8272-7079-0
(Only available in German)
insightSERVICE
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USA
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Representatives and agencies in
all major industrial nations.
Trade fair dates Imprint Contacts 43 Info
Trade fair dates Germany
Trade fair Location Date 2003
SEMICON Europe Munich 1st 3rd April
Hannover Messe Hanover 7th 12th April
ident.de Wiesbaden 6th 8th May
Motek Sinsheim 23rd 26th September
INTER AIRPORT Europe Munich 7th 10th October
A + A Dsseldorf 27th 30th October
Productronica Munich 11th 14th November
SPS/IPC/DRIVES Nuremberg 25th 27th November
Trade fair dates Europe
HISPACK Barcelona E 31st March 4th April
AMPER Prague CZ 1st 4th April
Automaticon Warsaw PL 1st 4th April
MSV Nitra SL 25th 30th May
DRIVES AND CONTROLS Birmingham UK 3rd 5th June
TOC Europe Genoa I 10th 12th June
PPMA Birmingham UK 23rd 25th September
POST-EXPO Brussels B 7th 9th October
Scanpack Gteborg S 21st 25th October
ITMA Birmingham UK 22th 29th October
Scanautomatic Gteborg S 18th 21st November
Trade fair dates worldwide
SPTC BFEXPO Shengyang China 10th 13th April
IAPA Health&Safety Toronto CAN 14th 16th April
PAC-ex INTERNATIONAL Toronto CAN 6th 8th May
FEIMAFE So Paulo BR 12th 17th May
FISPAL So Paulo BR 10th 13th June
SEMICON West San Francisco USA 14th 16th July
Frontline Solutions Chicago USA 16th 18th September
PACK EXPO Las Vegas USA 13th 15th October
FABTECH international Chicago USA 16th 19th November
Imprint
Publisher: SICK AG Postfach 310 D-79177 Waldkirch Tel. +49 (0)7681 202-0
Fax +49 (0)7681 202-3863 www.sick.com info@sick.de
Co-ordination: Anette Hippach Customer Magazine Project Manager Anette.Hippach@sick.de
Specialist editors: TOP MEDIA Dirk S. Heyden D- 69469 Weinheim
info@topmedia-weinheim.de
Conception/layout: johnson][braun Direktwerbung D- 76133 Karlsruhe jb@johnsonbraun.de
Printing: Druckerei Furtwngler D- 79211 Denzlingen info@druckerei-furtwaengler.de
Individual contributions may be reproduced after prior consent. Please contact us at:
Tel. +49 (0)211 5301 0 Errors excepted Subject to technical change
Central Sales, Germany
SICK AG
Schiess-Strae 56
40549 Dsseldorf
Germany
Phone +49 (0)211 53 01-0
Fax +49 (0)211 53 01-100
E-mail vzdinfo@sick.de
Company Headquarters
SICK AG
Sebastian-Kneipp-Str. 1
79183 Waldkirch
Germany
Phone +49 (0)7681 202-0
Fax +49 (0)7681 202-38 63
E-mail info@sick.de
insight
1/2003
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Safeguard against risks
while maintaining mobility.
The S 3000.
Success is a question of mobility. This also applies to the safeguarding of
machines. The modular concept of the new S 3000 laser scanner allows
safety applications to be solved even more flexibly and comfortably.
The S 3000 not only adapts to your requirements but also to your budget.
So that you are ideally positioned for the future.
www.sick.de/s3000
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Industrial Sensors
7. 12. April 2003
Hall 9, Booth F54
A NEW GENERATI ON
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A secured future

from AIXTRON is used for

encoders make use of the same ASIC-

DRS 60 shaft encoder. In the case of

ARS 60 absolute en-

encoders put an end

thus offers maximum user-friendliness.

encoders from SICK-

interface, that turns mo-

SKS 36 with the HIPER-

interface that we are showing in

a newly developed inte-

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