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insight
Expert interview
UL-certification the
passport to America
Page 22
2003
www.sick.com
2
SICKs customer magazine
The ARS 60 absolute encoder
Visualisation allows
lifting cog control
Page 15
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ICR 850: Data matrix identification
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ICR 850: Data matrix identification
Page 17
Cock of the Walk
Sensors from SICK
Addressing future challenges within the PCB industry.
And succeeding! Adopting SICK Sensor Technology leads
to higher efficiency of manufacturing and quality control
procedures. SICK is a total systems provider, a world
leader in innovation and has acquired a reputation for
reliability, long-term know-how and customer support
worldwide.
For further information visit
www.sick.com
Industrial Safety Systems Auto Ident
M
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SICK AG Sebastian-Kneipp-Str. 1 79183 Waldkirch Germany Phone +49 7681 202-0 Fax +49 7681 202-3609
Industrial Sensors
03 Editorial
insightTELEGRAM
++SICK raises its 25% participation in Swe-
dens IVP Integrated Vision Products AB to
92% - IVP solves special applications in elec-
tronics, the timber industry and robotics with
camera-based products for multi-dimensional
sensorics www.ivp.se++
++The Association of German Engineers (VDI)
offers progress reports on the Internet the
results of top-class scientific engineering re-
search at universities, colleges, major
research establishments and in industry can
be called up with the help of a rapid database
search online orders possible at
www.vdi-nachrichten.com/buchshop++
++5th Group-wide employee share programme
enjoys high participation in 2003 too: almost
1,000 employees in Germany and abroad
bought shares in SICK AG (not listed on the
stock exchange) employees now hold about
4% of SICK shares++
Sweden a highly automated nation
What do Volvo, IKEA, Ericsson, Electrolux, Tetra Pak, Atlas Copco, SKF and STORA
have in common? They are all well-known brands of Swedish origin. Sweden was
at peace throughout the 20th century, giving the country a great advantage. We
were able to create a strong industrial foundation based on the supply of raw and
processed materials such as steel, iron ore, timber and paper. Swedish quality be-
came a catch-phrase.
During the seventies great industrial nations, such as Germany and England,
caught up with Sweden. Despite high costs (primarily work-force related) Swedish
enterprises have remained internationally competitive. This is due to the increas-
ing automation of production processes.
A further important reason for Swedish competitiveness is the countrys heavy de-
pendence on exports. This makes the country sensitive to international needs and
expectations. The export trade generates almost 50% of GNP, and half of all ex-
ports are engineering products. The most important export markets are Germany,
the USA, Norway and the United Kingdom.
The third factor behind Swedens success is the highly trained industrial workforce
and the high level of Swedish engineering, resembling Germany in many ways. As
a Swede employed at SICK one therefore feels very much at ease.
The SICK Group has developed fantastically during the ten years that I have been
managing the Swedish subsidiary. SICK has found a successful concept based on
the development of innovative products and the training of personnel. Moreover,
the SICK Group has made many successful acquisitions, both for specific areas of
business and for the entire Group.
Reason enough for the SICK Group and SICK Sweden to be optimistic about the
future. Find out more on Page 39.
I hope you enjoy reading this autumn issue of SICK insight.
Best wishes
Stig-Olof Bistrm
Managing Director SICK Sweden
UL the passport to America......... 22
Ex-protection: what changes
has ATEX caused? ......................... 24
Hydraulic press standard EN 693... 25
SinCos

SKS/SKM 36: motor


feedback systems in MiDi format ... 26
100 years Deutsches Museum........ 27
Product spotlight ........................... 28
The LMS 400 sets new standards.. 30
ELG the simplest light grid for
standard applications .................... 31
ICR 852/ICR 855 2-D code readers 32
The inductive proximity sensors
of the Triplex series ....................... 33
S 3000: 7 m range offers new
opportunities for use....................... 33
New laser photoelectric switches ... 34
The VMS 400 when its
the volume that counts.................. 35
Application-oriented connection
technology for sensors................... 36
The WLL 190 T sets standards
in the high-end segment ................ 37
The CDM 400 connection module
makes bar-code scanners busable 38
SICK Sweden and SICK Norway
celebrate 10th birthday ................. 39
HMI competition............................ 40
World Skills Competition................ 40
SICK IBEO: time-of-flight systems ... 40
Etiquette for abroad....................... 41
e-mail newsletter ........................... 41
Glossary/Product-Finder/Training 42
Imprint/Service ............................. 43
Trade fairs..................................... 43
SICK insight 2/2003 04 Contents
................................................... 03
Safety for edging robots.................. 06
ICR 850 2-D code reader
shortens cycle rate by 20%.............. 06
Infusion yes, confusion no colour
checks ensure product safety ........ 07
100% sealing ring inspection
with the ICS 100........................... 08
Miele picks Safexpert for CE.......... 09
Pallet measurement:
one turn for three dimensions........ 10
DML positions crane
in waste bunker............................. 11
Ensuring safe loads with the
SMS Safety Muting System ........... 12
The ICS 100 gears up
for reliable running........................ 13
Dubai Airport opts for
SICK scanners .............................. 14
Visualisation allows
lifting cog control ........................... 15
IP 67 light grid resists
disinfectants ................................. 15
Rapid plant
modernisation with AS-i ................ 16
ICR 850: data matrix
identification on circuit boards ....... 17
Automatic container pick-up ........... 18
Robot stops when sliding
door opens.................................... 19
Special scanner mounting prevents
shaky bar codes ............................ 20
SICK ultrasonic sensors control
the automatic filling of silos........... 20
Clever sheathed cable
solution with C 4000 ..................... 21
Book Corner
Technology
Products
SICK Tour
Standards
Info
12
Safe loads with the SMS Safety Muting System
Data matrix identification on circuit boards
(R)evolutionary multi-dimensional object
detection: the LMS 400 sets new standards
17
Ex-protection: what changes
has ATEX caused?
24
30
Museum
Editorial
Internet
Applications
SICK insight 2/2003
05 News in brief
insightBOOK CORNER
H. Fichtinger/G. Sterzenbach
Etiquette manual
for abroad
Should one bow slightly when meeting
people in Japan? Is it true that in the USA
small talk is essential before serious
business negotiations? In which coun-
tries are shoes removed, and when?
These and other questions are asked
by business travellers (among others) be-
fore an up-coming visit abroad. This pock-
et guide provides a lot of important an-
swers. Find out more on Page 41.
Current trade fair information
Two important international specialist trade fairs
one after the other SICK is presenting its prod-
ucts first at the electronics production fair
Productronica 2003 11 to 14 November
in Munich, in Hall A5 Stand 216
Information under: www.global-electronics.net
And then at the trade fair for electrical
automation technology
SPS/IPC/DRIVES 2003 25 to 27 November in
Nuremberg, in Hall 7 Stand 366
Information under: www.mesago.de
Hall plans are included at the back of this issue.
Far away in the Far East, SICK Taiwan is
celebrating the 10th anniversary of its
founding. Whereas the emphasis was
originally on the sale of sensorics to the
textile machine industry, SICK Taiwan is
now the areas expert cross-sector ap-
plication adviser and system integrator
for Automation, Safety and Auto Ident
technology.
SICK Taiwan is a fifty-fifty joint ven-
ture between SICK AG and the Gentry
Trading Co. Ltd. The Managing Director
is James Shih who, after gaining pro-
fessional experience as a service engi-
neer at a company in Germany, has
been at home in the fields of machine
construction, and automation and sen-
sor technology, for over 30 years. Since
1999, SICK Taiwan has been the main
supplier of safety systems to Chin Fong,
the press producer active worldwide. A
sales office for South Taiwan was
opened in Kaohsiung in 2002 to better
provide local customers there with com-
petent on-site support.
It all began with the NT 6 contrast scanner
10 years of SICK Taiwan
Possibilities and limitations
Non-contact distance measurement
What measurement methods are avail-
able? What are the advantages, what
are the limitations? What operating con-
ditions must be taken into account? Are
WTA 24 triangulation photoelectric prox-
imity switches, DS 60 distance sen-
sors, or the laser distance measure-
ment devices of the DME series, the
most suitable for a particular applica-
tion? The comprehensive technological
work "Berhrungslose Entfernungsmes-
sung (Non-contact Distance Measure-
ment) by Martin R. Angelo (Managing
Director SICK Denmark), that can be
called up at www.sick.de, provides an-
swers to these questions.
Subscribers to SICKs e-mail newsletter
were sent the link in the November is-
sue. You havent yet subscribed and
would like to? Then quickly order it on the
Internet at www.sick.de/newsletter or
by e-mail to newsletter@sick.de! INFO 201
Lid on?
Whether milk bottles, or yoghurt or
mustard jars the goods can only be
sold when the lid is on. WT 2 photo-
electric proximity switches check that
the robot arm picks up the lids from the
transport belt by suction, and then
keep their eyes on them until they
have been put on the bottles or jars. Ex-
tremely small and light, easily mounted,
unaffected by the machine background,
and ready to start right away without ad-
justment all advantages that are es-
sential for this application! INFO 202 DME 5000
Safety for edging robots
Around the
corner monitoring
>> The Italian edging robot manufac-
turer Salvagnini monitors the accessi-
ble area around its machines with the
RLS 100 laser scanner. Its large scan-
ning angle of 300, and a trial installa-
tion of a device, convinced Salvagnini
technicians that the RLS should be in-
stalled as standard.
Among other things, finished bent
and folded boxes made of metal sheet
are produced on the fully automatic
edging robot, for later use as switching
cabinets, lockers and housings. Enor-
mous forces are employed to bend,
fold and cut edges. To protect opera-
tors who have to enter the haz-
ardous area, e.g. to remove pallets,
the RLS 100 monitors the accessible
work area around the machine. By link-
ing the safe output contacts of the RLS
in the emergency stop circuit, the load-
ing unit of the edging robot is immedi-
ately powered down when the protec-
tive field is entered.
www.salvagnini.it INFO 203
N
E
W
S
The RLS 100 monitors the accessible
work area around the edging robots
to protect operators
Data matrix code on camshaft
Code reading even with rotating camshaft
camshaft was at a standstill. The time
that was necessary for searching,
alignment and reading has now been
cut drastically. Not only is the cam-
shaft inspected while it is rotating at
600 r.p.m., but the coded serial num-
ber in the data matrix code is also iden-
tified. Both pieces of information are
then laid down in a shared data set in
the quality assurance system.
More rapid inspection cycle
It is the data matrix reading during ro-
tation that has permitted the machine
cycle of 20 seconds to be reduced to
the required cycle time of 15 seconds.
>> With its 80 mm wide scanning line,
its reading frequency of 15 kHz, the
more than 4 m. pixel resolution of the
line CCD image-capture system, inte-
grated laser illumination, and SMART
decoding, the ICR 850 sets new stan-
dards for the automatic reading of 2-D
codes such as data matrix.
Inspection in motion
In the past, the 12 x 12 mm data ma-
trix code could only be read while the
SICK insight 2/2003
Edging robots 2-D code reading on camshaft measurement plant at Muhr and Bender 06 Applications
Rotating data matrix identification
ICR 850 2-D code reader
shortens cycle rate by 20%
insightLINK
You can obtain further information with
the attached card under:
INFO 204
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.mubea.com
The machine cycle of the optical camshaft measurement plant at
Muhr und Bender has been drastically shortened. Instead of time
being wasted searching for the code, the ICR 850 finds it on the
rotating shaft during the inspection process.
Contents are identified on the basis of
the colour of the label
CS colour sensors inspecting labels on the packaging units
SICK insight 2/2003
Label detection at B. Braun Schiwa with CS 3 colour sensors 07 Applications
Infusion yes, confusion no colour
checks ensure product safety
A flushing solution for dialysis systems or an infusion? A salt or
a sugar solution? At B. Braun Schiwa, in Glandorf, Germany, CS
colour sensors reliably check the presence of more than a
dozen similar labels on the packaging units of products.
>> Apart from preventing health risks
for patients, cost factors in the form
of avoidable extra logistical and pro-
cessing costs if labelling is wrong ar-
gue for the highest possible level of la-
belling (and thus product) security in
the packaging of medicines and med-
ical products. SICK distributor, GSS
Schulte-Sutrum, has successfully
solved this task at B. Braun Schiwa
with CS colour sensors.
No confusion over cartons
and canisters
About 11,000 cartons are filled, closed
and labelled every day in the carton
packaging area, where pure batches of
dialysis flushing solutions and infu-
sions (individually packaged in bags)
are consolidated into larger transport
packaging. This is equivalent to a
throughput of approx. 2,750,000 car-
tons or about 50,000 pallets a year.
insightLINK
You can obtain further information with
the attached card under:
INFO 205
or on the Internet at:
www.sick.de/insight/en
More about the customers at:
www.bbraun.de
and
www.gss-industrie-electronic.de
Aim: greater product safety
The label detection project was set up
in order to achieve greater product
safety that could also be documented
and tracked. A variety of aims were
targeted simultaneously, explained
August Mennemann, Project Manager
and responsible for production technol-
ogy at B. Braun Schiwa. Every lot, i.e.
every batch, was to be trackable; logis-
tical costs arising from complaints
about the cartons (that are distributed
worldwide) were to be eliminated as far
as possible; damage to the companys
image caused by erroneous deliveries
was to be prevented; and, finally, cus-
tomers stock-keeping was to be sup-
ported by the presence of external la-
belling on the cartons.
Reliable and user-friendly
CS colour sensors
The task was solved by using CS 3
colour sensors that are capable of reli-
ably differentiating between the more
than a dozen, often similar, colours and
colour tones of the labels and checking
their presence. A second advantage of
the device is the simple in-situ teach-in
of the labels to be detected.
SICK insight 2/2003
Quality inspection with ICS 100 camera sensor at Hansa Metall in Stuttgart 08 Applications
100% sealing ring inspec-
tion with the ICS 100
The German company Hansa Metall, in Stuttgart, uses the
ICS 100 camera sensor to monitor the presence and correct po-
sitioning of O-rings on 1.8 million condenser module head-pieces
for air conditioning systems. 100% inspection of every part, prov-
able quality, and high commercial efficiency are the principal ad-
vantages.
>> Hansa Metall (better known for its
design-oriented and innovative bath-
room and sanitary fittings) has been
producing cooling and acclimatising
components for automobile air-condi-
tioning systems, refrigerators, low-tem-
perature containers and refrigerated
transporters for over 60 years. The
company has achieved a leading mar-
ket position thanks to its high quality
standards. So all production processes
are subject to the best possible, and
documentable, quality monitoring. The
use of the ICS 100 on the new O-ring
plant is an example of this.
CoMo not coma: the ICS 100
Two different head-piece types for the
condenser modules (known as CoMo
for short) are fed into the plant via vi-
bration systems, positioned, and pro-
insightLINK
You can obtain further information with
the attached card under:
INFO 206
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.hansametall.com
The camera sensor inspects the presence and correct sit of the O-rings
Close-up of the O-ring inspection
vided with the right type-specific O-
rings, which are subsequently checked
with the ICS 100 for presence and cor-
rect O-ring sit. The interest factor of the
1.8 million objects per year is not suffi-
cient to prevent a human observer
from quickly falling in a deep, coma-
like, sleep but not the tireless
ICS 100 Intelligent Camera Sensor.
Compact and user-friendly
plug & play solution
The device is an extremely economical
concept for an industry-oriented image
processing sensor. The camera, optics,
illumination and evaluation unit are ac-
commodated in a single compact hous-
ing. The sensor is also designed as a
user-friendly plug & play unit. Up to 16
inspection programmes can be stored.
The ICS 100 operates as a stand-alone
device and switches like a photoelec-
tric switch. Parts that are not in order
are detected and diverted out of the
flow.
The ICS 100 is also used in anoth-
er application at Hansa Metall in-
specting welding seams on metal cas-
ings.
SICK insight 2/2003
Safexpert safety software in production hall at Miele 09 Applications
A view of the production of dishwasher troughs at Miele
Computer-supported safety concept with
Safexpert
Miele picks Safexpert for CE
The home appliance producer Miele successfully introduced
Safexpert safety software and immediately used it to set up a
new production hall.
>> Miele devices can be found in many
households, and for years customers
have been showing how much they ap-
preciate the quality. Quality is the cor-
porate philosophy and has been imple-
mented throughout the company and
in the safety concept for production.
Works-spanning safety
Non-computer-supported processes
for CE-designation of the works plants
were already established. Thomas
Heermann, responsible for this at
Miele, was looking for a solution with
which he could set up a works-span-
ning, computer-supported, CE-designa-
tion safety concept. The possibility of
inter-works teamwork, simple guid-
ance through the requirements of the
machine directive, and the numerous
other ways in which the software made
the work easier were convincing argu-
ments for the introduction of Safex-
pert. Only a single solution that would
simplify work, and which one could
quickly learn to use properly, could
realistically be introduced in the Con-
struction Department, Thomas Heer-
mann commented on the decision.
Thus it was possible to implement the
safety engineering at the new produc-
tion hall in the Bielefeld works with the
help of Safexpert after just a few
weeks experience. Now all projects
have the same structure, and the solu-
tions that we have already worked out
during projects can be exploited by all
participating personnel throughout the
company, obser ved a satisfied
Thomas Heermann.
Broad acceptance
Safexpert has met with broad accept-
ance throughout industr y. Numerous
companies, including Siemens VDO
Automotive, Freudenberg and Conti-
nental, use this structured route to CE-
designation. The software also per-
mits the integration of an assistant
tool to generate operating instructions
parallel to the safety inspection of
machines and plant.
Betriebsanleitungen zu generieren.
insightLINK
You can obtain further information with
the attached card under:
INFO 207
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.miele.de
More about Safexpert at:
www.safexpert.de
SICK insight 2/2003
Automatic pallet measurement with LMS Laser Measurement System at AKL-tec 10 Applications
Pallet measurement:
one turn for three dimensions
Profile detection from a portal crane thanks to APACHE Auto-
matic PAllet CHaracteristic detection from AKL-tec in Alsdorf,
Germany. The system, jointly developed with SIEMPELKAMP Han-
dling Systeme, in Wolfratshausen, scans the pallet below the
crane and detects its height and the angular position of the load
by means of an LMS Laser Measurement System rotated through
180 around its own axis.
>> This solution was first developed for
a company that wanted to detect and
inspect pallets loaded with wooden
panels.
Gripper with eyes
The laser measurement system is di-
rectly integrated into the gripper of the
portal crane. When it arrives above the
pallet it is rotated by a drive through
180 around its own axis. A complete
scan takes place during the movement.
The LMI evaluation module generates a
three-dimensional image of the loaded
pallet from the measurement informa-
tion. If any angular displacement of the
load is detected, outside the grippers
range of tolerance, the pallet is
blocked for further automatic loading.
Furthermore, there is a complete in-
spection of the surface of the stack of
pallets to determine whether further
pallets can be added.
Gripper misalignment is also
detected
The system also offers an opportunity
to detect any angular misalignment of
the gripper equipment by means of a
reference measurement. In this case,
insightLINK
You can obtain further information with
the attached card under:
INFO 208
or on the Internet at:
www.sick.de/insight/en
More about the customers at:
www.apachescan.de
and:
www.shs.siempelkamp.de
The Laser Measurement System is located directly in the gripper of the portal crane
a warning message from the APACHE
system informs maintenance person-
nel about the need for a readjustment.
SICK insight 2/2003
Crane positioning at Vattenfalls waste incineration plant, Sweden 11 Applications
insightLINK
You can obtain further information with
the attached card under:
INFO 209
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.vattenfall.com
Simply reliable
DML positions crane in waste bunker
Vattenfall, one of Europes leading energy supply companies from
Sweden, uses DML laser measurement systems for positioning
cranes at their waste incineration plant in Uppsala.
Bunker cranes with an operating load capacity of 5 tonnes supply the incineration
plant with household waste in Uppsala
The DML laser measurement system
effects of dirt and weather, to keep the
mountain of waste (or the cranes grip-
pers) under control at all times. And
what was most important, the system
had to be reliable and not be affected
by signals from other parts of the crane
system. He was impressed by the
DMLs long range of 300 m and its sim-
ple installation, as the transmitter and
receiver are accommodated in a single
housing. Moreover, the measurement
system (involving the measurement of
the time-of-flight of an emitted laser im-
pulse to a reflector and back) promised
friction-free operation requiring almost
no maintenance. The DML has kept its
promise. Furthermore, the two DMLs
per crane (one for the X-axis and one
for the Y-axis) have proved doubly ef-
fective: they not only ensure precise
positioning of crane and gripper, they
also prevent collisions between the
cranes and the walls of the waste
bunker.
>> Each year 235,000 tonnes of
garbage 10% of Swedens total
household waste is destroyed at
Vattenfalls waste incineration plant in
Uppsala. The incineration plant is fed by
bunker cranes with a load capacity of
4.5 tonnes each. Their automatic posi-
tioning has long been a problem until
Vattenfall engineer Peter Danielsen
came across the DML laser measure-
ment system on the Internet at
www.sick.de.
Far-sighted, waterproof and
doubly effective
He was looking for a system that would
be permanently available despite the
SICK insight 2/2003
Safeguarding horizontal binders at Peter Born AG, Switzerland 12 Applications
indicator lights, offer application-spe-
cific configuration. The MSLZ multi-
beam safety photoelectric switch with
an integrated MSM muting module,
and WL 23 series muting sensors,
were used with the SMS at the brewery
plant. All components can be flexibly
mounted on site on a stable, height-ad-
justable supporting framework and
completely wired up. Time-saving, and
thus cost-cutting installation, adjust-
ment and commissioning is thus possi-
ble. Instead of numerous individual
components from a variety of suppli-
ers, users obtain a muting system, de-
signed to meet their needs, from a sin-
gle source.
Ensuring safe loads with the
SMS Safety Muting System
Before loading, pallets are secured in order to ensure that goods
remain on their pallets during transport e.g. by horizontal
binders from the Swiss company Peter Born AG. The SMS Safety
Muting System and an MSLZ multibeam safety photoelectric
switch with an integrated muting function ensure maximum safe-
ty and smooth integration in automatic transport systems.
insightLINK
You can obtain further information with
the attached card under:
INFO 210
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.bornbinder.com
In order to better illustrate the application, the supplementary mechanical
equipment was removed for this photo
The SMS Safety
Muting System
>> The bornbinder

horizontal binder
only needs a few seconds to fully auto-
matically tie a pallet up. This speed,
and the binding power involved, pose a
risk of serious injury for persons reach-
ing into the plant during running opera-
tion. At the same time, many users
(e.g. in bottle filling) depend on auto-
matic and continuous plant processes.
In order to be able to safeguard a
horizontal binder and simultaneously
integrate it into a stationary conveyor
system it is necessary to set up ac-
cess safeguarding with a muting func-
tion at both the pallet entrance and ex-
it. An SMS Safety Muting System was
used on a plant from Peter Born AG de-
livered to a Belgrade brewery by a fill-
ing machine manufacturer.
Plug & play muting
The SMS mounting components allow
rapid installation and flexible muting.
The Safety Category 2 or 4 optoelec-
tronic muting sensors, and the muting
SICK insight 2/2003
Gear wheel inspection with ICS 100 camera sensor at Magna Steyr, Austria 13 Applications
insightLINK
You can obtain further information with
the attached card under:
INFO 211
A detailed report on this application
is available at:
www.sick.at/news/magna
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.magnasteyr.com
Quality inspection at Magna Steyr
The ICS 100 gears up
for reliable running
Magna Steyr, the Austrian supplier to the automotive industry, us-
es the ICS 100 camera sensor to inspect the surfaces and true
running of the gear wheels for dynamic balancing differential
gears.
>> Magna Steyr, which has long been
known for its successful developments
in 4-wheel drive technology, produces
numerous drive components at its new
works at Ilz in the Steiermark, where
440 dynamic balancing differential
gears are produced every day for
BMWs 3-series. These reduce the vi-
brations of petrol and diesel engines,
thus cutting engine noise leading to
savings in shell stiffening and sound-
proofing, and allowing the use of plas-
tic components on the engine.
The right finish and the right
decision
A principal component of the dynamic
balancing system is the gear shaft, on
which there are several gear wheels.
After an initial visual inspection by the
line foreman, the wheels undergo a
more precise examination of the sur-
face finish and shape in order to en-
sure reliable cyclic running. This guar-
antees that only polished, true-running
gear wheels are included in the nine-
stage assembly process.
Excellent cost/benefit
ratio confirmed
While looking for an automatic quality
inspection system we struck lucky with
the ICS 100, explains Markus Ackerl,
Programming Manager at Magna
Systemtechnik AG, the manufacturer of
the production line. A conventional im-
age processing system would have ex-
ceeded our budget. This 2-D solution
combines the advantages of a powerful
image processor with industry-oriented
sensorics. Thus we could fulfil all the
technical requirements economically
with the ICS 100.
The camera sensor inspects the surfaces and rotation of gear wheels
Gearing up for a tooth inspection ...
with the ICS 100 camera sensor
SICK insight 2/2003
Identification and volume measurement of post bags and packages at Dubai Airport 14 Applications
>> The Omniportal Scanners are used
for identifying both in-coming and out-
going post. Six scanners with real-time
autofocus are integrated into each sys-
tem, and reliably identify the bar-code
labels on the post bags and parcels in
any alignment and at any distance.
The Volume Measurement Systems
are only used for outgoing post.
Rapidly productive,
as planned early
The solution was implemented in col-
laboration with ALS Advanced Logistic
Systems GmbH in Wiesbaden (the gen-
eral contractor for the project), Geb-
hardt Frdertechnik AG, Sinsheim
(who supplied the conveyor systems)
and Aberle Steuerungstechnik GmbH,
Leingarten (for the control system).
The properties of the conveyor tech-
nology and the control inter faces were
agreed between the project partners
and SICK during an early phase of the
project. The plant was then pre-accept-
ed by the user in Germany. Both these
factors made it possible to hand over
an operational plant on-site after just
two days and to carr y out operator
training. Even the subsequent request
by the customer to expand the inter-
faces for further information from the
VMS could be met during commission-
ing.
Availability ensured by
remote access
This all contributed towards the cus-
tomer immediately trusting the sys-
tem. The scanner systems easy han-
dling and diagnostic software ensure
that this remains the case. Moreover,
if there is a problem, remote access to
the entire plant via ISDN can rapidly
find the cause of the trouble and
restart operation of the system.
Dubai Airport opts for SICK scanners
OPS 490 Omniportal Scanner systems and VMS 200 Volume Mea-
surement Systems in the Express and Mail Centre at Dubai Air-
port identify post bags and parcels and determine their volumes,
thus achieving error-free allocation of post to the correct flight,
automatic cargo space optimisation, and the determination of
freight charges.
The Burj Al Arab Hotel Dubais world-famous landmark
insightLINK
You can obtain further information with
the attached card under:
INFO 212
or on the Internet at:
www.sick.de/insight/en
More about the customers at:
www.a-s.de and www.advanced-logistic.de
or www.gebhardt-foerdertechnik.de
OPS 490 Omniportal Scanner systems
now in use in Dubai
N
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Safety assured despite
aggressive media
IP 67 light
grid resists
disinfectants
>> At the washing plant for production
equipment at a French chemical com-
pany, an IP 67 housing with an inte-
grated C 2000 light grid ensures safe
loading and removal of the parts to be
disinfected.
Certain production equipment must
be disinfected with aggressive deter-
gents every two days. For this purpose,
the parts are manually inserted into a
washing plant and subsequently re-
moved again. The opening for loading
and unloading poses a risk for persons
who reach into the plant during running
washing operation. Integrating the
C 2000 within the IP 67 housing was
the solution that avoided all the opera-
tional disadvantages of a protective
fence and offered a long device life-
time. The special housing an acrylic
tube with stainless steel end caps,
pressure equalisation membrane, and
watertight PG thread connections
protects the light grid from the aggres-
sive media and ensures continuous op-
erational safety: any unintentional
reaching into the washing plant reliably
leads to an immediate stop of the
washing process.
INFO 214
SICK insight 2/2003
Encoders in trip cams at Laudenberg Verpackungsmaschinen GmbH Washing plant 15 Applications
>> A further advantage: positional val-
ues can be stored according to the re-
quirements of the individual products
and subsequently activated automati-
cally. Unlike previous processes, for ex-
ample with prefabricated trip cams
from other producers, the ARS 60 also
brings about savings by reducing wiring
and machine operator training costs.
Furthermore, troubleshooting is quick-
er if there are any problems.
ARS 60: almost any increment
numbers can be programmed
The ARS 60 is an absolute encoder for
path and angle determination. The de-
vice has a modular design and permits
adaptation to the most varied of tasks.
For example, any increment number be-
tween 2 and 32,768 can be achieved.
Zero pulse definition on the encoder is
particularly advantageous for Lauden-
berg: it can be carried out either by
pressing a button on the device itself
or directly via a control wire by the ma-
chine control system and visualisation,
as is the case with the packaging ma-
chines.
ARS 60 encoders ensure the right ad-
justment of trip cams
More advantages, lower costs with
the ARS 60 absolute encoder
Visualisation allows
lifting cog control
At Laudenberg Verpackungsmaschinen GmbH in Wipperfrth,
Germany, ARS 60 encoders allow the adjustment of lifting cogs
(trip cams) on the basis of their visualisation.
insightLINK
You can obtain further information with
the attached card under:
INFO 213
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.laudenberg.de
SICK insight 2/2003
Bus technology at packaging producer Kappa Frenade Well, Sweden 16 Applications
insightLINK
You can obtain further information with
the attached card under:
INFO 215
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.kappapackaging.com
Alf-Henrik Petersson of Kappa Frenade Well (left) and Joakim Olofsson of
SICK Sweden (right)
Some of the products in the
AS-i programme
A bus for 248 passengers
In many places, AS-i is the right wiring
technology at the lowest field level of
decentralised control concepts. In-
stead of costly parallel wiring, a large
number of highly varied sensors and
actuators can be connected together
simply, rapidly and economically. Inte-
gration of the AS-i bus in a higher-rank-
ing control system, e.g. a PLC or a
computer, can be achieved without any
problem. Up to 31 slaves can be con-
nected to the two-wire cable, whereby
up to four binar y participants can be
connected to each slave. A total of up
to 248 sensors can thus be supplied
by one bus. These advantages as
well as the possibility of connecting
older components via an external AS-i
module come in ver y handy (and not
just for KFW).
Rapid plant
modernisation with AS-i
Laying cable takes time. AS-i, the actuator-sensor interface, re-
duces this time significantly. At Swedish packaging producer
Kappa Frenade Well (KFW), this bus technology allowed a han-
dling station to be modernised in a single weekend.
>> Instead of individually rewiring each
of the numerous sensors and actua-
tors, SICK sales engineer Joakim
Olofsson recommended the AS-i solu-
tion to KFWs Alf-Henrik Petersson.
And he was thoroughly enthusiastic.
We not only considerably reduced the
entire wiring costs, but were also able
to accelerate its laying down on site. In
the end, only the AS-i cable had to be
led to the new control panel and con-
nected up, says Alf-Henrik Petersson.
SICK insight 2/2003
Circuit board identification with ICR 850 2-D code readers at IPTE Germany GmbH 17 Applications
>> The ICR 850 units are installed on
the feed belt of a multiple panel punch-
er, where many individual small circuit
boards are cut out from the large panel
holding them. By reading the data ma-
trix codes on the multiple panels, IPTE
ensures that the right printed circuit is
lying on the conveyor belt, that the grip-
per in the machine matches the printed
circuit, and that the correct processing
program is active. If a circuit board is
detected that was found to be defec-
tive during an earlier testing process, it
is recognised on the basis of its data
matrix and diverted off the belt.
Industry-oriented connection
module
The compact CDB 420 module was de-
veloped for the connection of station-
ary bar-code scanners and 2-D code-
reading devices from SICK to the SICK
CAN-scanner network, a host computer
Data matrix identification on circuit boards
The ICR 850: multiple benefits
for multiple printed panels
Machine manufacturer IPTE Germany GmbH from Frth detects
alternately arranged data matrix codes on circuit boards in mo-
tion with two ICR 850 devices. The reading devices are connect-
ed to the machine control system via the CDB 420 connection
module. This solutions advantages: time savings and the identi-
fication of mixed 1-D and 2-D codes.
insightLINK
You can obtain further information with
the attached card under:
INFO 216
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.ipte.com
ICR 850 2-D code readers inspect circuit boards
Show your code:
data matrix identification
and a PLC unit. It is not only half the
size of the former version, but also of-
fers features such as PG screw con-
nections with strain relief, IP 65 with
standard scanner cable, a transparent
lid that provides a view of the LED indi-
cators and switch settings beneath it,
mountability in a closed state, and
plug-in connection to the scanners
service interface, among other impor-
tant installation and operational advan-
tages.
SICK insight 2/2003
Position monitoring of container transport with DS 60 distance sensor 18 Applications
Automatic container pick-up
Completely detached?
During automatic hoisting by a crane, DS 60 distance sensors
check that the container can be lifted off the truck without any
difficulties.
>> The DS 60 is a compact robust
sensor that detects the presence
and distance of objects by measuring
the time-of-flight of emitted laser
impulses. It of fers ranges of up to
20 m, is largely immune to ambient
light, and operates reliably regard-
less of the colour or sur face proper-
ties of, for example, a container or a
trucks trailer.
Only the container should
be hoisted
During automatic hoisting by a crane,
two DS 60 units ensure that the con-
tainer gets free of its anchoring on
the trailer without any problems. The
crane is stopped if the distance sen-
sor detects the trailer while the con-
tainer is being hoisted.
insightLINK
You can obtain further information with
the attached card under:
INFO 217
or on the Internet at:
www.sick.de/insight/en
Starting point: anchoring
the container on a truck:
Uncoupling the container
WITHOUT the DS 60 distance sensor:
Uncoupling the container WITH the DS
60 distance sensor:
SICK sensors for ports
In addition to the DS 60, other SICK sensors are used at
numerous international ports and container ports:
p Encoders for drive control and the positioning of rail-borne vehicles
p Photoelectric switches and inductive sensors for a wide variety
of object detection tasks
p Safety photoelectric switches to safeguard access to lashing platforms
p DMT distance measurement scanners and LMS Laser Measurement
Systems for preventing collisions between vehicles and for container
classification, the detection of piled container heights, and crane
positioning at the storage spaces
p DML distance measurement photoelectric switches and Pomux absolute
length measurement systems for positioning a crane along its drive path,
and positioning its gripper equipment.
SICK insight 2/2003
Safeguarding hazardous areas with L 4000 non-contact safety devices 19 Applications
Safe manual loading
Robot stops when sliding door opens
Honegger & Partner GmbH, from Pfffikon in Switzerland, have
created an individual light grid to detect a robot arm with L 4000
single-beam safety photoelectric switch systems at end-user
Eralmetall GmbH & Co. KG.
>> The L 4000 system is a Type 4
non-contact safety device according
to IEC 61 496. It is used to safe-
guard access and the hazardous ar-
eas of machines and plant. A UE 401
safety evaluation device monitors
reliable functioning of the sensors
during operation. The sensors op-
tics and signal pre-processing units
are accommodated in cylindrical
housings with diameters of M18
and M30, ensuring simple installa-
tion and alignment of the transmit-
ter and receiver. This is an impor-
tant advantage for its use at
Eralmetall.
insightLINK
You can obtain further information with
the attached card under:
INFO 218
or on the Internet at:
www.sick.de/insight/en
More about the customers at:
www.honegger-partner.ch
and:
www.eralmetall.de
The robot arm feeds aluminium die-cast parts to the processing stations but only
when the sliding door is closed
Manual loading and automated
removal pose risk of accidents
At the southern German company Eral-
metall, aluminium die cast parts are
produced and processed for the auto-
mobile industr y. Before automatic pro-
cessing in a sawing and deburring sta-
tion, they are manually inserted into a
loading bay and removed from there by
a robot for subsequent transport to
the processing stations. A total of four
L 4000 sensor pairs ensure that the
robot arm can only reach into the bay
when the protective sliding door of the
loading bay is closed. Compared with a
proper light grid, the use of the four
sensor pairs has the advantage that
the beam separations and alignments
could be individually designed for the
particular safeguarding task. A power-
down signal is generated if the light
beam of one of the four L 4000 sensor
pairs is interrupted.
L 4000 maximum safety and
user-friendliness
The new L 4000 system not only offers
safety in the highest possible catego-
r y, but also user-friendliness and sup-
plementar y integrated functions such
as external relay monitoring and
restart interlock. Colour LEDs provide
in-situ information on the operating
state. Rapid diagnosis is possible
through visualisation of status and er-
ror messages on the 7-segment dis-
play of the UE 401 safety evaluation
device.
Reliable identification of
heavy objects
Special scanner
mounting prevents
shaky bar codes
>> Thanks to shock absorber mount-
ings, CLV 450 bar-code scanners al-
ways have a crystal-clear picture of
the bar codes on rolls of paper in the
paper warehouse of Neusiedler AG in
Ulmerfeld-Hausmening, in Austria.
The handling and transport of ob-
jects that are weighed in tons, e.g. rolls
of paper, often involves heavy vibra-
tions on fork-lift trucks. At the same
time, however, increasing numbers of
vehicles are equipped with fixed bar-
code scanners to relieve drivers from
having to use hand-held readers for
scanning, and to permit ergonomic
work processes.
Special mounting absorbs im-
pacts and vibrations
It has proved possible to absorb im-
pacts and vibrations with a specially
developed oscillation damper. This is
advantageous for reading reliability and
the scanners lifetime. A total of six
fork-lift vehicles have been equipped in
this way at Neusiedler. The paper roll is
automatically identified on lifting. As
there are now no more shaky bar
codes, clear read information is, in
effect, available from the first scan and
is then transferred to the control level
via radio data transmission online.
www.neusiedler.com INFO 219
N
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SICK insight 2/2003
Paper store Conveyor system control with UM 30 ultrasonic sensors 20 Applications
Fork-lift vehicle transports paper roll
SICK ultrasonic sensors
control the automatic
filling of silos
Ackerbau GbR Falkenhain has automated the pouring process in
grain stores. SICK ultrasonic sensors control the conveyor sys-
tem in such a way that an even distribution and filling height is
achieved in the silos.
>> Dust, heat, stuffy air ultrasonic
sensors now work where in the past an
employee with a breathing apparatus
had to control the conveyor manually.
The solution was realised by Kppchen
Elektro GmbH in Wurzen, Germany.
While one device on a transverse con-
veyor intermittently determines the fill-
ing height in the silo, four other sen-
sors on a longitudinal conveyor control
the transverse conveyor appropriately
during automatic pouring. Special ad-
justment and alignment prevent detec-
tion of the transverse bracings in the
storage silo itself.
SICK ultrasonic sensors with
five ranges
The UM 30 series offers ultrasound
sensors with five different ranges up to
6,000 mm. Each version is available
with one or two binary outputs and an
analogue output for continuous detec-
tion tasks.
Good for personnel
and process
The ultrasonic sensors offer advan-
tages for the personnel and the
process. There is no longer any need
for an operator for monitoring and man-
ual control under these extremely diffi-
cult conditions, and the grain is opti-
mally stored for staying dry across its
entire surface area thanks to the even
quantity distribution.
Mounting an ultrasonic sensor on the
conveyor system in a grain store
insightLINK
You can obtain further information with
the attached card under:
INFO 220
or on the Internet at:
www.sick.de/insight/en
SICK insight 2/2003
Safety technology at DaimlerChryslers welding plants in Sindelfingen 21 Applications
The C 4000 Safety Light Curtain safeguards with mobile blanking
>> Spot welding of car bodies is car-
ried out manually at a processing sta-
tion in the shell construction area. Em-
ployees use welding guns that are pow-
ered via a sheathed flexible cable. Up
to now, this has compromised safe-
guarding of the workplace and handling
of the welding guns. Reliable blanking
within the monitored field of a light
screen was hitherto impossible. Thus
the guns were always hung up further
away from the car body, behind the op-
erators.
Mobile blanking provides the
solution
An ergonomic and time-saving solution
has been achieved with the mobile
blanking function of the C 4000 Safety
Light Curtain. Regardless of how the
guns sheathed cable juts into the
monitored field the area is always reli-
ably cut out, without impairing the mon-
itoring function. Now the welding guns
are ready for action near the car body
instead of behind the operators, mak-
ing the work process considerably
more comfortable and efficient. Mobile
blanking with object detection also en-
sures that resolution is not unneces-
sarily larger, as the plant is kept shut-
down if the sheathed cable is not in the
protective field. So there are no unnec-
essary gaps in the field.
Only its own sheathed cable
is monitored thanks to beam
coding
All manual welding stations in this
plant area are now equipped with the
new safety solution. The unique beam
coding of the individual C 4000 units
prevents systems at different stations
from mutually interfering with one an-
other. Thus each light screen only has
eyes for its own sheathed cable.
insightLINK
You can obtain further information with
the attached card under:
INFO 221
or on the Internet at:
www.sick.de/insight/en
More about the customer at:
www.daimlerchrysler.com
Clever sheathed cable
solution with C 4000
Its showdown time at DaimlerChryslers welding plant in
Sindelfingen, Germany: thanks to new safety technology, workers
can now draw their welding guns quicker and win the duel against
machine cycles.
SICK insight 2/2003
Interview with the testing organisation UL International Germany GmbH 22 Standards
UL the passport to America
SICK insight: Can you tell us some-
thing about the history of Underwriters
Laboratories?
Mirko Bautz: Underwriters Laborato-
ries, the insurance companies' testing
labs, were founded in 1894. The back-
ground was the demand by American
fire insurers to inspect electrically pow-
ered devices for their fire risk, as elec-
tricity was becoming more widespread.
The first UL standard was agreed in
1903. UL gained its first German cus-
tomers, for whom factory inspections
were carried out, in 1954. UL Deutsch-
land (founded in late 1999) currently
employs about 85 staff in Neu-Isen-
burg and Munich and completed about
1,500 projects in 2002. And UL is now
one of the world's leading organisa-
tions for testing and certifying product
safety.
SICK insight: How do you check that
fire prevention regulations are ob-
served? Who awards the labels?
Mirko Bautz: Electrical devices were,
and still are, inspected with regard to
electrical and mechanical hazards as
well as the risk of fire. Fire prevention
tests for sensors, for example, depend
on the housing material. Metal is safe,
but the use of plastic as a basic com-
ponent, or in the form of a finished
product, must be tested. Incidentally,
in this regard UL 94 has become es-
tablished as a standard in Europe.
Those who take it into account during
development can sometimes save
themselves a lot of expense later. On
the subject of development: I would al-
so like to mention that UL offers sup-
port, if desired, from the first draft to
the prototype, and right up to the pur-
chase of the product, by awarding the
U
L
or U test symbol.
SICK insight: What is the difference
between the U
L
and the U symbols?
Dirk R. F. Mller: U
L
(the L stands for
listed) labels devices with individual
certification without restrictions on
their use when employed for their in-
tended purpose. Household devices or
computer equipment are classic exam-
ples. U (the mirror image of the R
stands for recognised) confirms the
testing of products or components that
will later be used in UL-certified end-
products, machines or plant. Examples
of these include switches or plastic
frames. The use of U devices, howev-
er, is always restricted as specified in
the certification documentation. Final-
ly, there is also a grey area of devices
for which decisions must be made on a
case-by-case basis on whether a U
L
or
U label can be awarded. Thus a relay
is not simply a relay: a terminal relay
From left to right: Davorin Jaksic of SICK, Dirk R. F. Mller and Mirko Bautz of UL Deutschland in Neu-Isenburg
International companies rely on national approvals when selling
their products, and those wishing to export to North America can-
not get around UL certification. During an interview with Mirko
Bautz and engineer Dirk R. F. Mller of UL Deutschland, SICK in-
sight found out what is behind the Underwriters Laboratories test-
ing organisation, what the difference is between the U
L
listing
symbol and the U recognition symbol, and why companies should
collaborate with UL Deutschland.
R
R
R
R
R
R
SICK insight 2/2003
23 Standards
insightLINK
See UL on the Internet at:
www.ul-europe.com
or at:
www.ul.com
Mirko Bautz
as a finished product for use by an end-
user receives the U
L
label; while a print
relay that can only be used as a com-
ponent, e.g. for a control system, re-
ceives the U test label.
SICK insight: How can one ensure that
not just the test-piece but all the later
serial devices correspond to U
L
or U ?
Dirk R. F. Mller: This is guaranteed by
works inspections. These take place
every three months, are unannounced,
and check whether the general condi-
tions concerning certification are being
maintained.
SICK insight: Is UL legally required if
one wants to export to the USA?
Mirko Bautz: First let me say that basi-
cally there is no law in the USA enforc-
ing any UL certification. Anyone want-
ing to export to the USA must conform
to the currently valid version of the NEC
(National Electrical Code), which repre-
sents the minimum requirement. This
is where the problems can start, how-
ever, because on the one hand, there
is a gradient regarding how up-to-date
the currently valid version is in the vari-
ous federal states. On the other hand,
there are individual supplements in var-
ious states that are connected with, for
example, the state's geographical loca-
tion and its special climatic demands,
and which can thus increase the re-
quirements of the NEC. Take the case
of, say, the major seasonal tempera-
ture fluctuations in the mid-west, or the
hurricane threat in Florida. In these sit-
uations, certification by the Underwrit-
ers Laboratories becomes interesting
as it prevents importers in the USA or
producers in Europe running any risk of
failing to be accepted by the authori-
ties. Thus the slogan: UL the pass-
port to America. By the way, this ap-
plies for Canada too, where UL is also
accredited and accepted.
SICK insight: What other benefits does
UL offer?
Dirk R. F. Mller: UL also offers bene-
fits for the practical things in life. This
starts with the customers in Germany
and the users in the USA, for whom the
UL test symbol is synonymous with
simplified acceptance by the authori-
ties. The next aspect is the insurance
premium. Those with the UL label pay
considerably lower premiums. Further-
more, UL is also a marketing argu-
ment, as the regular factory inspec-
tions represent independent evidence
of quality. Finally, UL not only awards
its own test symbols, but also nu-
merous other international standard
symbols. This then goes hand-in-hand
with the UL inspection, saving time.
SICK insight: And what particular ad-
vantages are there if the customer col-
laborates with UL Deutschland instead
of the American parent company?
Dirk R. F. Mller: Here, too, daily prac-
tice counts. Whether the certification
engineer who inspects the product for
the UL standards, or the reviewing en-
gineer who counterchecks this inspec-
tion according to the four-eye principle
at UL Deutschland they are all at
home in the VDE world [Association of
German Electricians] and at ease with
their philosophy. They know where to
look for any traps, as they are capable
of correctly interpreting the standards
on the basis of the particular basic
concept involved. Then, of course, we
speak the same language, and during
approximately the same working hours,
because there's no time shift between
Flensburg, Friedrichshafen and Neu-
Isenburg! Ultimately, being in the vicini-
ty is a major advantage despite wide-
spread use of the Internet and e-mail,
because sometimes there's only one
thing that helps: to meet, put all the
problems on the table, and then find
solutions to each of them in turn.
SICK insight: The close vicinity is also
helpful if one can have interviews as in-
teresting as today's. So thank you very
much for this conversation.
Facts and figures on the UL testing organisation
UL: on location worldwide with assured success
p More than 6,000 employees worldwide
p Turnover, 2002: EUR 463 million
p 127 UL test centres in 65 countries
p 17 billion UL test symbols applied in 2002
p Certification carried out at approx. 67,000 producers in 96 countries
p 106,942 product certifications carried out, complying to a total of
886 UL standards
p In addition to U
L
and U , UL carries out other types of certification,
including GS, CE, ISO 9000, ISO 14000; QS 9000, TL900, VDA 6.1
R
R
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SICK insight 2/2003
Important information on the new ATEX directive 24 Standards
Ex-protection: what
changes has ATEX caused?
>> The aim of the new directive is to en-
sure the free movement of these prod-
ucts within the European Union. Taking
the differing international conditions in-
to account has led to numerous amend-
ments, the most important of which are
described below.
Clear delineation of
responsibility
The allocation of products to categories
is new. This has clearly separated the
sphere of responsibility of the customer
(whose application must be assigned to
a zone) and that of the device producer
(whose product must meet the require-
ments of the particular category). Cus-
tomers define their potentially explosive
area (e.g. Zone 1) and then select a de-
vice from the corresponding category
(2G in this case).
Customer must be more
specific about dust
Customers will be particularly surprised
about the effect of the new directive re-
garding dust. After a detailed exami-
nation, some applications will now have
to be assigned to Zone 22. For cus-
tomers, this means that the standard
devices used up to now may no longer
be employed. Furthermore, in Zone 22
it is necessary to determine whether
the application involves conductive dust
(e.g. metallic dust: Category 2D devices
required) or non-conductive dust (e.g.
grain: Category 3D devices required).
Regular Exi-audits in
production areas
In addition to the EU type examination
certificate for devices, certification of
the Production quality assurance sys-
tem is now necessary for the produc-
tion of Category 1 and 2 devices as a
supplement to ISO 9001. For cus-
tomers this guarantees consistently
high product quality, and continuous
back-tracing of products from the cus-
tomer, through production and back to
the suppliers.
Since 1 July 2003, only goods that comply with the new
94/9/EG (ATEX) directive, and the other relevant standards, can
be marketed for potentially explosive areas. This has brought
about a variety of changes for producers and customers.
Category
Suitable for use
in zone (gas)
Also suitable for
use in zone (gas)
Suitable for use
in zone (dust)
Also suitable for
use in zone (dust)
Definition (94/9/EG).
Potentially explosive
atmosphere exists:
Certifiable
through
Producers
responsibility
Customers responsibility
1G/1D
0
(0)
1 and 2
20
(10)
21 and 22
Permanently or long-
term or frequently
Notified
bodies
2G/2D
1
(1)
2
21
(11)
Zone 22
conductive dust
22 Occasionally
Notified
bodies
3G/3D
2
(2)

22
non-conductive
dust
(no comparable zone)

Rarely and
short-term
Producer
or notified
bodies
G = gas, D = dust; ( ) = old designation in brackets
Complies with the standard for potentially explosive areas
according to the new ATEX directive: the WLL 24 (right)
Objections in Britain: the EN 693 safety standards for hydraulic presses 25 Standards
Categories 3D and 3G require
special devices
The 94/9/EG (ATEX) directive no
longer permits the use of standard
devices with producer declarations
for Zone 2 and Temperature Class
T4. Categor y 3G/3D devices, that
can be used in Zones 2 and 22, must
conform to the new requirements.
Their protective measures are no
longer based on intrinsic safety, but
on the waterproofing and impact
immunity of the housing. This me-
chanical protection must be proved
by means of impact assessments
and bumping tests, among other
measures.
Category
Photoelectric
switches
Inductive
proximity sensors
Magnetic
proximity sensors
Magnetic
cylinder sensors
Safety light curtains
Safety Systems Industrial Sensors
1G
1D
2G W 24Exi
IM 08 IM 012
IM 18 IM 30
MM 12 MM 18
MZR 2 MZZ 1
MZP 3 MZP 4

3G
W 27-2
(special)
MZT 6
C 4000 Standard/Advanced,
Entry/Exit (selected types)
3D
W 27-2
(special)
MZT 6
C 4000 Standard/Advanced,
Entry/Exit (selected types)
>> In Britain (where about 50,000
presses are currently in operation) ex-
perts, among others from press manu-
facturer PJ Hare, believe that two-hand-
ed control systems alone provide insuf-
ficient protection at hydraulic presses.
The actual operator may indeed be pro-
tected by use of the two-handed con-
trol, but not third parties who remain
exposed during the hazardous phase of
the press cycle.
Productivity considerations
strengthen the status of non-
contact safety devices
Not just safety, but also process effi-
ciency and economics, support the use
of safety light curtains or other non-
contact safety devices, confirms
Hydraulic press standard EN 693 under discussion
Curtain up for safety and
efficiency
Michael Hare of PJ Hare. A light
screen triggers the press cycle quicker
than a two-hand control. And the opera-
tor has both hands free for other activi-
ties while the press is operating. A light
screen quickly pays for itself if one
takes this, and other aspects, into ac-
count. This was confirmed by Hugh
Duffy regarding safety technology the
machine construction company advis-
es: In numerous cases light screens
lead to significant increases in produc-
tivity of up to 60%.
Whatever the results of British ob-
jections to EN 693 apart from com-
prehensive safety; ergonomic, econom-
ic, and competitive arguments also
support the use of non-contact safety
devices on hydraulic presses.
Ambiguity and design differences have prompted the United
Kingdom to raise a formal objection to the EN 693 safety stan-
dard for hydraulic presses.
Objection! The UK is against the
EN 693 safety standard
2D
Accessories: EN2Ex isolating switch amplifier: the intrinsically safe electric circuits of the isolating switch amplifier are suitable for Zones 0, 1,
2, 20, 21 and 22. The device itself may not be installed in Zones 0, 1, 2, 20, 21 and 22.
SICK insight 2/2003
Overview of ATEX sensorics from SICK
SICK insight 2/2003
Motor feedback systems from SICK-STEGMANN 26 Technology
SinCos

SKS/SKM 36:
motor feedback systems in MiDi format
The maximum range of functions with minimum size manufac-
turers of small and micro-motors, in particular, are most appre-
ciative of the advantages of the SinCos

SKS 36 (single turn) and


SKM 36 (multiturn) motor feedback systems from SICK-
STEGMANN. Thanks to mini-disc technology (MiDi) they offer a
unique level of compactness and the integrated HIPERFACE

in-
terface makes it a plug & play information system for regulating
motors and drives.
>> It terms of its functional principle,
the SinCos

motor feedback system is


a combination of incremental and ab-
solute encoders. Its absolute values al-
low commutation and position detec-
tion when a drive is switched on.
Thereafter counting takes place incre-
mentally via sine/cosine signals. The
multiturn drive provides information on
which turn the drive is in. HIPERFACE

(for high performance interface), with


eight cables, allows bi-directional com-
munication between the drives regula-
tory system and the motor feedback
system and has established itself as a
standard on the market.
Mini-disc technology allows
minimum size
With the SKS /SKM 36, a new genera-
tion of optical encoders has been de-
veloped whose considerably smaller
sizes are the direct result of a funda-
mentally different system structure.
Housing diameter is just 36 mm, and
its length of approx. 40 mm (including
the shaft) is extremely small. Thus the
MiDi motor feedback systems, weigh-
ing only 60 g, are the most compact
devices of their type, without being
merely a smaller version of the usual
single or multiturn encoder. Its special
feature is the very small code disk, lo-
cated at the centre of the axis of rota-
tion, that permits a high operating
rotational rate of 12,000 r.p.m. and
a maximum angular acceleration of
5 x 10
5
rad/s
2
. There are 128 bars on
the code disk that are scanned holisti-
cally by a specially developed opto-
ASIC, with which sine signals are creat-
ed with a high level of linearity and in-
terpolatability. Furthermore, previously
unimaginable levels of shock and vibra-
tion immunity have been made possi-
ble by the devices compactness.
Compact motor feedback
systems for multiturn
applications too
The small size of the SinCos

SKS/
SKM 36 is particularly appreciated by
producers of small and micro-motors,
at last allowing them to construct even
more compact drive systems. Thanks
to its micro-mechanical drive, a real
multiturn motor feedback system in a
36 mm housing is available, with which
absolute detection with up to 4,096 ro-
tations can also be achieved in this
motor segment.
Multiturn SKM 36 gears
insightLINK
Further info direct from
SICK-STEGMANN
SinCos

motor feedback systems are not


yet sold through SICKs Central Sales
Department in Dsseldorf. More
information is thus available from
SICK-STEGMANN in Donaueschingen.
Your contacts for application advice:
Bernd Appel, Tel. +49 771 807-121
e-mail: Bernd.Appel@stegmann.de
Stefan Brenner, Tel. +49 771 807-211
e-mail : Stefan.Brenner@stegmann.de
SICK insight 2/2003
The Deutsche Museum in Munich 27 Museum
An impressive century of
museum history
>> When judged according to the criteria
of exhibition space, the number and im-
portance of the individual objects and
collections, the range of topics and
tasks covered, and the spectrum of spe-
cial museum programmes and activi-
ties, it is one of the worlds leading sci-
ence and technology museums.
A varied history
For 100 years the task of the Deutsche
Museum has been to combine scholarli-
ness with clarity, and impart basic
knowledge on scientific and technologi-
cal interactions in a stimulating and
popular manner. The museum was cre-
ated by the then internationally recog-
nised electrical engineer Oskar von
Miller, who founded it in 1903 to ac-
commodate the collection of the Associ-
ation of German Engineers. Miller took a
different path to that of the technical
museums in Paris and London: he se-
lected fully functional originals, replicas
and models of machines, as well as
live technical and scientific demon-
strations. His aim was to entertain and
educate in a way that was accessible to
the general public. After being located in
a number of temporary quarters in Mu-
nich, the exhibitions moved to the Isar
island in Munich where, on 7 May 1925
(Oskar von Millers 70th birthday) the
Deutsche Museum was opened. The Li-
brary and Congress Hall followed in later
As part of technical museums worldwide series, we would like
to present the internationally recognised Deutsche Museum in
this issue an overview of one hundred years of impressive
museum history.
years. After destruction during the Sec-
ond World War, the museum was quickly
re-opened in October 1947 with the
special show 50 years of Diesel En-
gines. New exhibit areas of current in-
terest have continuous-
ly been added, among
them the Aerospace
Hall (added in 1984),
and the gene technolo-
gy or new media ex-
hibits. In addition to the
site on Munichs Isar is-
land (where space is
limited) further sites
have been opened at the airport of
Schleissheim, the traffic centre on
Theresienhhe, and the Deutsche Mu-
seum in Bonn. There are now about
80,000 displays presenting comprehen-
sible hands-on science and technology
in a total of 70,000 m
2
of exhibition
space. One wonders whether Oskar von
Miller would have dared imagine this
100 years ago?
insightLINK
Visit the Deutsche Museum on
the Internet at:
www.deutschesmuseum.de
Current special exhibitions
p 9 October 2003 to 31 January 2004:
Meat extract and silvered mirrors
200 years of Justus von Liebig
p 13 Nov. 2003 to 14 Nov. 2004:
The Wright brothers
the birth of powered flight
Famous exhibits
The Deutsche Museum accommodates
world-famous exhibits temporarily or per-
manently. Among these are the U1 U-
boat, the Dornier Wal flying boat and a
range of other ships, aircraft and loco-
motives. Freely accessible ships decks,
mines and laboratories provide insights
into a world that is now, as in the past,
out of the ordinary for most people. In
August 1969 the Apollo 8 space cap-
sule, in which three astronauts first or-
bited the moon the previous year, visited
Munich. The Deutsche Museum has re-
peatedly succeeded in obtaining inter-
esting objects on loan for the current to-
tal of 45 departments for temporary ex-
hibitions, and has organised many
special events on topics whose rele-
vance extends into present times.
SICK insight 2/2003
+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlig 28 Products
S
P
O
T
L
I
G
H
T
New inductive proximity sensors
Automation with IQ
Tamperproof, economical, with maximum availabili-
ty and low installation costs this is how users pre-
fer their safety equipment. This wish is granted
with the C 4000 Entry/Exit Safety Light Curtain.
The C 4000 Entry/Exit can be used wherever material is auto-
matically transported into the hazardous area of a machine
and, simultaneously, the access of persons must be reliably
prevented. Instead of using supplementary muting sensorics,
the permanently active safety light curtain uses self-taught-in
distance monitoring data for reliable differentiation between
persons and material. INFO 222
Active light curtain differentiates between persons and material
A revolution in access safeguarding
Whether the five-fold rotatable sensor area of the
IQ 40 or the versatile mounting possibilities of the
IQ 80 automation with IQ opens up new oppor-
tunities.
The IQ 40s new long design conforms to the recently intro-
duced market standard. The device is characterised by
switching distances of between 15 mm and 20 mm, its high
enclosure rating of IP 68, and the sensor area that can be ro-
tated in five directions. Object detection over distances of up
to 50 mm; flush, non-flush and sinkable installation options;
integrated snap-in mounting profile; and considerably simpli-
fied device connection are the highlights of the IQ 80. The
sensor is not just used for classic position polling a ma-
jor automobile manufacturer has also qualified the IQ 80 as
a muting sensor for safety systems. INFO 223
The C 4000 Entry/Exit is the latest
member of a large family. Once
again we have developed a solution
for our customers that combines
safety and economy. SICKs
application experience and our
customers constructive comments
have produced another trend-setter.
Hannes Schleinkofer
Product Manager
Industrial Safety Systems
The IQ 40 inductive
proximity sensor
SICK insight 2/2003
ght+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spotlight+++Spot- 29
S
P
O
T
L
I
G
H
T
Interlock for protective equipment
Reliable interlocking with the i200 lock
Three freely selectable actuator directions, a ro-
bust stainless steel actuator, and a retention
power of 2,000 N make the i200 lock a reliable
safety interlock for movable protective equip-
ment with high mechanical demands.
The i200 lock can be used wherever access to mechanically
screened protected areas must be monitored. Numerous
features (see box opposite) have been designed specifically
to cope with harsh conditions. INFO 225
Facelift for MZT 1/RZT 1
magnetic cylinder sensors
The high-strength housing material and the new
housing facelift are important facets of the re-
design of the MZT 1 magnetic cylinder sensor
and its reed-switch version, the RZT 1. The
technical specifications, type designations, or-
der numbers and the many mounting and oper-
ating advantages provided by the sensors
remain unchanged.
The thread could be considerably strengthened as a result of
the substantially tougher housing material now used. The at-
tachment screw can now be tightened with two-and-a-half
times as much torque as before. Thus the sensor sits even
more firmly in the T-slot. The sensor can now be identified
while still in the slot: from the devices design, and as a result
of labelling with the type designation, order number, etc.
INFO 224
The MZT 1 magnetic
cylinder sensor
The i200 Lock
safety interlock
Features
p Housing made of glass-fibre reinforced thermoplastic
p Actuator entry area made of stainless steel
p Retention power: 2000 N
p Auxiliary unlocking on three sides
p Versions with 3 captive NC contacts / 2 NO contacts,
or 4 captive NC contacts /1 NO contact
p 3 actuator directions
p LED indicator
p Flexible use, straight locking bar
SICK insight 2/2003
The LMS 400 laser measurement system 30 Products
(R)evolutionary multi-dimensional object detection
The LMS 400 sets new standards
Reporting the presence of objects, classifying objects, checking
contours, and controlling gripper equipment the range of au-
tomation uses of the new LMS 400 Laser Measurement System,
to be introduced at the SPS/IPC/Drives 2003 trade fair, knows
no limits.
insightLINK
You can obtain further information with
the attached card under:
INFO 226
or on the Internet at:
www.sick.de/insight/en
>> Decreased space requirement, in-
creased power and performance the
new LMS 400 sets new standards,
compared to its predecessor the
LMS 200. The angular resolution that
has been increased to just 0.1 allows
even more precise object detection.
The finest of structures can be recog-
nised, objects can be detected in two
and three dimensions and classified.
The reliable inspection of shells and
containers on conveyor systems is now
possible at undreamed of speeds be-
cause, with a scanning frequency of
500 Hz, the new LMS can capture dis-
tance data more than six times faster
than its predecessor. The finer angular
grid and improved distance resolutions
now allow even demanding pick &
place applications to be solved, e.g.
during automatic palletising and depal-
letising, or during reliable gripping from
a mixture of objects transported with
random orientation.
With interface flexibility too
The new LMS 400 is as flexible in
terms of connection to external evalua-
tion systems as it is in terms of appli-
cations. Ethernet, RS 422, RS 232,
CANbus, and digital inputs and outputs
are available for todays technologies.
The LMS 400 sets new standards
wherever industry-oriented, rapid, reli-
able and precise detection of objects is
necessary some trial participants are
even saying that it could bring about a
small revolution.
NEW: the LMS 400
laser measurement system
SICK insight 2/2003
The ELG light grid 31 Products
ELG the simplest light grid for
standard applications
A single-beam sensor is often not sufficient to provide the neces-
sary level of object detection when checking pallets for projec-
tions, monitoring automatic doors or gates, or counting in a
sorting plant. The ELG light grid, with its up to 128 optical ele-
ments is the reliable, economical and installation-friendly solution
for such applications.
insightLINK
You can obtain further information with
the attached card under:
INFO 227
or on the Internet at:
www.sick.de/insight/en
installation of numerous individual pho-
toelectric switches. Those who are al-
ready detecting objects in this way,
however, can also rapidly and easily
convert to the ELG, as it has full elec-
trical compatibility with standard photo-
electric switches.
Suitable for indoor and
outdoor use
The rigidity of the ELG, in its robust de-
formation-free aluminium housing, is
matched by the flexibility it offers
users. Ranges of 02 m or 112 m are
available, with monitoring heights of
901,410 mm or 4503,300 mm. In
outdoor applications, equippers of
door and gate systems or vehicle-sep-
aration solutions at toll booths, in par-
ticular, profit from the ELGs optimum
size/per formance relationship, its
robust housing, its high enclosure rat-
ing, and its extreme immunity to con-
stant light of up to 150,000 lx. More-
over, standard plugs or cable lengths
of up to 15 m solve all connection
tasks. In material flow technology, on
packaging machines, and in other in-
door applications, the optical synchro-
nisation of transmitter and receiver
modules, and the typical industrial
connection systems offer economical
installation. Wiring is considerably sim-
plified allowing easy integration in
plant and control systems, and rapid
commissioning.
>> The ELG consists of two profiles in
which transmitters and receivers can
be integrated at 30 or 60 mm intervals,
and the electrical evaluation accommo-
dated. This creates a light grid that
would otherwise require the complex
Improved control: the ELG offers highly reliable object detection
The light grids ELG long range and ELG short range
SICK insight 2/2003
ICR 852 and ICR 855 data matrix readers 32 Products
>> Miniaturisation of assemblies
means miniaturisation of their la-
belling. Ink-jet codes on circuit boards,
and laser-etched 2-D codes on housing
parts or vehicle components, can be
detected with the new ICR 852, even
with cell sizes of just 0.1 mm
2
. Com-
pared to CCD readers, the ICR 852
offers another major advantage: its
40-mm-wide scanning line. No precise
positioning of codes in the reading win-
dow is necessary every code that
passes the scanning line is detected
regardless of its position on the object.
45,000 scans per second
The ICR 855 is specially designed
for automated document handling.
Whether bank statements, mobile tele-
phone bills or letters from insurance
companies it is the printed data ma-
trix codes that make these mass mail-
ings economical to mass-produce, in-
sert into envelopes and send. High-per-
formance post processing plants that
can quickly handle several million let-
ters require reading systems that oper-
ate as rapidly as possible. Thanks to
its scanning frequency of 45,000 Hz,
the ICR 855 is capable of reliably iden-
tifying data matrix codes even at feed
speeds of up to 4 m/s.
ICR 852 and ICR 855 2-D code readers
Optimised for mini-codes
and maxi-speed
The two new code readers of
the ICR series allow the identi-
fication of rapidly moving
miniaturised or etched 2-D
codes.
insightLINK
You can obtain further information with
the attached card under:
INFO 228
or on the Internet at:
www.sick.de/insight/en
during the detection of rapidly moving 2-D codes
The ICR 855 demonstrates its strengths
N
E
W
S
SICK insight 2/2003
Triplex the new series of inductive proximity sensors S 3000 laser scanner 33 Products
>> The three-fold switching distance
3 mm with quasi-flush installation of
the M8 version and 40 mm with non-
flush installation of the M30 design
permits larger installation distances,
and thus the protected mounting of
sensors in machines or conveyor sys-
tems. At the same time, the larger po-
sitioning tolerances for metallic objects
ensures their reliable detection. And
the sensors provide optimum results
even with objects that are more diffi-
cult to detect, e.g. small or thin parts,
wires or bright metals.
Many variants, high reliability
In addition to the numerous designs,
allowing range- and position-optimised
sensor selection, there are also de-
vices available for differing installation
insightLINK
You can obtain further information with
the attached card under:
INFO 229
or on the Internet at:
www.sick.de/insight/en
situations. And there are versions with
NO contact and NC contact functions,
with NPN or PNP switching outputs, and
with cable or plug connection. An en-
closure rating of IP 67, and high sensor
immunity towards shock, vibration, in-
creased ambient temperatures, and
electromagnetic interference ensure
maximum reliability.
Now available
S 3000: 7 m range
offers new oppor-
tunities for use
>> Large machines or rapidly moving
autonomous vehicles are the benefici-
aries of the 7-metre-deep protective
field of the new S 3000 Safety Laser
Scanner.
Progress in a variety of technolo-
gies since the first PLS laser scanner
was commissioned, about 10 years
ago, is largely responsible for many of
the improvements in performance
achieved with the S 3000. This can be
seen most clearly with the range. Par-
ticularly short pulses can be generated
thanks to optimised laser diode con-
trol. This has allowed the permitted
protective field radius to be increased
from 4 m to 7 m (while maintaining
Laser Protection Class 1) resulting in
the opening up of completely new op-
portunities for use.
Measurement accuracy also
improved
At the same time, more rapid proces-
sors have allowed improved evaluation
of the reflected light impulses, and
thus an enormous increase in meas-
urement accuracy. A resolution of
70 mm is possible at the maximum
range of 7 m. This means that a per-
sons leg can be reliably detected,
even from this distance, and the haz-
ardous machine movement brought to
a halt.
www.sick.de/s3000 INFO 230
The S 3000 laser scanner with
a range of 7 m
Triplex, the new series of inductive proximity sensors in a cylin-
drical design, sets the new standard regarding range. It offers the
largest switching distances on steel currently available on the
market.
The inductive proximity sensors
of the Triplex series
Three-fold switching
distance improves
plant availability
SICK insight 2/2003
The V 18 L family of laser photoelectric switches 34 Products
insightLINK
You can obtain further information with
the attached card under:
INFO 233
or on the Internet at:
www.sick.de/insight
insightLINK
You can obtain further information with
the attached card under:
INFO 231
or on the Internet at:
www.sick.de/insight/en
>> The devices of the V 18 L series
complement the standard inductive,
capacitive and magnetic sensors also
available from SICK. As a result of their
mechanical and electrical compatibility
they offer users every opportunity for
optimum device selection.
Complete series
The V 18 L is a complete series whose
devices offer large functional reserves
for standard applications. And because
of their precise switching points, small
light spots, and low hysteresis they are
also highly suitable for special tasks.
They all have switching modes that can
be freely selected via the control wire,
designs with NPN or PNP switching out-
puts, a four-pin M12 connection plug,
and LEDs for the optical indication of
status and function.
Long ranges
The VS/VE 18 L through-beam photo-
electric switch achieves an extreme
range of 60 m, while the VL 18 L pho-
toelectric reflex switch reaches 35 m.
The VTE 18 L energetic proximity
switch offers a range of 400 mm.
Detect small and speedy
objects
But despite extreme distances, users
can still exploit the small light spot typ-
ical of lasers: a diameter of 0.7 mm
with the photoelectric reflex switch,
and just 0.5 mm with the through-beam
system, allow reliable detection of
large and small parts. Furthermore,
high switching frequencies of up to
1000 Hz permit the detection of rapidly
moving objects.
Unusually long ranges of up to 60 m, short response times, the
detection of small parts, and laser Protection Class 1, are the
main features of the new V 18 L family of laser photoelectric
switches. The through-beam and reflex systems, and the cylindri-
cally shaped scanner, offer all the advantages of laser technology
with the same handling as conventional V 18 units.
The new V 18 L family of laser photoelectric switches
Powerful laser cylinders
Long ranges, together with the
detection of smaller parts and
short response times, are the
main advantages of the V 18 L
family of laser photoelectric
switches
SICK insight 2/2003
The new VMS 400 Volume Measurement System 35 Products
insightLINK
You can obtain further information with
the attached card under:
INFO 232
or on the Internet at:
www.sick.de/insight/en
>> In the transport business, weight
and size determine how many pack-
ages or pallets can be loaded onto a
truck. With the new VMS 400 Volume
Measurement System it is now possi-
ble to measure the real volume, or cal-
culate the exact box volume in the form
of a space-occupied volume.
System solutions with one or
two measurement heads
In addition to the application software
for object measurement, the VMS sys-
tem consists of one (VMS 410) or two
sensor heads (VMS 420), depending
on the task involved, installed above
the conveyor system. The VMS 410
measures cubic objects, and the
VMS 420 both cubic and non-cubic ob-
jects, with great precision at transport
speeds of up to 2 m/s. Accurate to
within 0.5 cm, the time-of-flight of the
laser pulses emitted by the sensor
head(s) is evaluated and the box vol-
ume (VMS 410), or the real volume
(VMS 420), calculated. Together with
the value provided by a weighing device
and the read information from bar-code
scanners, all transport-relevant infor-
mation on the most varied of objects
can now be determined as actual data.
Any supplementary costs accruing to
the sender arising as a result of this
measurement can, in extreme cases,
lead to amortisation of the VMS within
a few days.
Legal-for-trade complete
system expected in spring
Volume measurement is so accurate
that a certified, legal-for-trade com-
plete solution is now possible. Thus
the VMS 520 the legal-for-trade ver-
sion of the VMS 420 is currently un-
dergoing testing by the OIML (Interna-
tional Organisation for Legal Metrology)
complying with recommendation 129
for multi-dimensional measurement
instruments. Certification is expected
in spring 2004.
For logistics, and freight and package despatch
The VMS 400 when its
the volume that counts
Low weight = small package size or small pallet loads. This equa-
tion is frequently false for transport service providers. Real
volumes can now be reliably measured with the VMS 400 Volume
Measurement System and, if necessary, realistic supplemental
fees charged.
What else fits in? Reliable measurement of real volumes
with the VMS 400 Volume Measurement System
SICK insight 2/2003
Plug connectors and connecting cables 36 Products
Application-oriented connection technology for sensors
SICK has the best connections
With plug connectors and connecting cables designed to meet
sector requirements, SICK ensures that objects are not just
reliably detected, but also that switching signals are consistent-
ly transferred to the machine control system.
>> The well-known orange PVC connec-
tion and interconnection cables set the
standard for many applications, e.g. in
storage and conveyor technology. Stan-
dard connection cable lengths of 2 m,
5 m and 10 m and interconnection ca-
ble lengths of 0.6 m and 2 m are avail-
able. Suitable M8 or M12 plug connec-
tors in straight and angled shapes, and
with a variety of pin numbers, meet al-
most every situation found during in-
stallation and cable laying.
Halogen-free PU not just
pure black
Halogen- and silicon-free, polyurethane-
coated sensor cables are suitable for
more difficult and harsh operating con-
ditions. They are also particularly re-
sistant to coolants and lubricants,
highly suitable for drag chains, and re-
sistant to torsion. These halogen-free
PU cables are found in car assembly,
on machine tool and processing
machines, or on robots. M8 and M12
device plugs with various pin numbers,
straight and angled cable ingress, and
a variety of cable lengths for connec-
tion and interconnection also cover
almost all installation conditions.
Cleaning processes in the food
industry make high demands
In the food industry, particularly in fill-
ing plants, or in the chemical and phar-
maceutical sectors, plant cleaning
processes make high demands of the
connection technology. Here SICK of-
fers special PVC cables in combination
with stainless steel (V4A) with an en-
closure rating of IP 69k. These special
cables for the food and luxury goods
sector and the chemicals industry are
permanently resistant to acids, alkalis,
detergents, high pressures and hosing
with steam.
Plug connectors and connection cables
elemental connections for sensors
insightLINK
You can obtain further information with
the attached card under:
INFO 233
or on the Internet at:
www.sick.de/insight/en
SICK insight 2/2003
The WLL 190 T photoelectric fibre-optic switches 37 Products
The WLL 190 T is a new series of intelligent space-saving photo-
electric fibre-optic switches in the high-end segment. Interactive
control display, bus-enabled hardware, integrated power monitor-
ing and three times the range these four central features set a
new standard in this device class.
>> In operation, the WLL 190 T con-
vinces through its extremely stable and
reliable switching behaviour even with
high-resolution switching thresholds.
Features that are worth noting
The bus-enabled hardware of the
WLL 190 T cuts wiring costs enormous-
ly and, compared to other systems, al-
so offers eight-fold anti-interference
through internal synchronisation. This
means that up to eight WLL 190 T in-
stalled in close proximity to one another
are protected from mutual interference.
It is also possible to subtract one value
from another. Automatic Power Control
(APC) integrated power monitoring en-
sures constant switching thresholds by
compensating for the effects of ageing,
and temperature and power fluctua-
tions. Finally, the WLL 190 T opens up
new application opportunities with its
three-fold range increase compared to
the predecessor series.
Ease-of-handling through inter-
active control display
The interactive control display consists
of a three-digit and a four-digit display,
simplifying and comprehensibly show-
ing the teach-in programming of the
switching threshold, response time
and release delay. This simplifies first
commissioning, as well as subsequent
adjustments carried out during running
operation.
Through-beam or scanner
system designs
The WLL 190 T, to which the LL3 series
fibre-optic cables from SICK can be
connected, is available as a through-
beam photoelectric switch with a range
of 1,300 mm and as a photoelectric
proximity switch with a scanning dis-
tance of 300 mm. Red-light LEDs emit
visible light. With the optional green-
light LED, the proximity switch is ideal-
ly suited for detecting printed marks.
Seven types of switching threshold are
available for teach-in.
One like all
All WLL 190 are adjusted to standard-
ised values during production. Whether
sensitivity, type of switching output,
time delay and hysteresis all devices
leave the works with identical basic
functions.
The intelligent solution the WLL 190 T sets new high-end standards
The WLL 190 T fibre-optic
photoelectric switch
New photoelectric fibre-optic switch offers
a wide variety of supplementary advantages
The WLL 190 T sets standards
in the high-end segment
insightLINK
You can obtain further information with
the attached card under:
INFO 234
or on the Internet at:
www.sick.de/insight/en
SICK insight 2/2003
Busability via CDM 400 connection module 38 Products
The CDM 400 connection module
makes bar-code scanners busable
The expandable CDM 400
connection module is extreme-
ly flexible and enabled for a vari-
ety of field buses. Thus all
1-D and 2-D bar-code reading
devices from SICK, and the
LMS 400 Laser Measurement
System, can easily be net-
worked with Profibus and
DeviceNet.
>> Moreover, connection can be made
to SICKs CAN-scanner network, host
computers and PLC units. And beyond
the connection opportunities, users of
the CDM 400 have numerous other op-
tions.
32 plug-in configuration
options
As a basis device, the CDM 400 offers
three sockets for optional field-bus
modules and one socket each for a pa-
rameter memory, a display with a foil
keyboard, and a switchable power sup-
ply. As a result of this flexibility, users
can put together the optimum applica-
tion-specific configuration to meet their
needs. This ensures that only those
functions that are actually required
need be purchased. There is also the
option of equipping the CDM basis de-
vice for bus-enabled functionality. The
plug-in field bus gateways allow con-
nection of all 1-D and 2-D reading de-
vices to Profibus or DeviceNet, thereby
potentially disposing of the need to
maintain stocks of field-bus-specific
scanner types.
Users deciding to employ the op-
tional CMC 400 parameter memory
can rely on the simplest possible de-
vice replacement, as the memory mod-
ule stores all the operating parameters
of the replaced devices and automati-
cally transfers them to the new unit. If
users integrate the optional power sup-
ply module in the CDM 400 they save
by not having to provide a 24 V cable
all the way to the reading device.
Easy in-situ diagnosis
The optional four-line illuminated dis-
play with integrated foil keyboard offers
a particularly high level of user comfort
especially for scanners that are diffi-
cult to access. Without the connection
of an external PC, it displays read re-
sults and a variety of diagnostic infor-
mation on the connected reading de-
vice (called up via the keyboard). The
CDM 400s transparent lid allows all
commissioning, operating and diagnos-
tic messages, as well as configuration
switch settings, to be seen at a glance.
Thanks to its enclosure rating of
IP 65, the CDM 400 is also suitable for
connection of bar-code scanners under
industrial conditions. In combination
with a CLV 480 or CLV/X 490 bar-code
scanner with integrated heating, the
CDM 490 can also be used for deep-
freeze applications down to 35 C.
Numerous configuration possibilities make the CDM 400 particularly flexible
insightLINK
You can obtain further information with
the attached card under:
INFO 235
or on the Internet at:
www.sick.de/insight/en
SICK insight 2/2003
10 years of SICK Sweden and SICK Norway 39 SICK Tour
Top:
Employees at SICK Norway
Bottom:
Underway at SICK Sweden
At a glance: Sweden Norway
Capital: Stockholm Oslo
Population: Approx. 8.9 m inhabitants Approx. 4.5 m inhabitants
Size: 449,964 km
2
324,000 km
2
Important industries: Metal, timber, textiles, electronics Oil, paper
Main nations D (11.1 %), GB (9.1 %), GB (18.2 %), NL (10.6 %),
receiving exports: N (8.8 %), USA (8.8 %) D (10.1 %)
Main supplier nations: D (18.9 %), GB (10.2 %), NL (8.2 %) S (15.1 %), D (12.9 %), GB (9.2 %)
SICK Sweden and SICK Norway
celebrate 10th birthday
SICK has been present in Sweden and Norway with its own sub-
sidiaries for 10 years now. On their 10th birthday they look back
on a successful decade.
>> The most important industrial sec-
tors in Sweden and Norway are convey-
or, warehouse and handling technolo-
gy; the packaging industry; the primary
material industry for automobile manu-
facturers; and mechanical engineering
in general. As classic SICK target
groups it was thus logical to offer
these branches direct support to take
their importance into account.
It began in Sweden
SICK Sweden was founded in Stock-
holm on 17 March 1993. The first em-
ployee was Stig Bistrm now Manag-
ing Director. Building upon the existing
level of SICK brand recognition, within
a short time SICK Sweden became the
market leader in automation and safety
systems and an important supplier of
Auto Ident technology. This market suc-
cess can be demonstrated in figures.
Sales rose from EUR 3.3 m in the
year of its founding to an estimated
EUR 10.5 m in 2003. And there are no
longer just seven employees as was
the case in 1993: SICK Sweden now
employs more than 30 personnel.
Norway soon followed
Just two months later, on 14 May
1993, the current Managing Director,
Geir Austefjord, founded SICKs sec-
ond Scandinavian subsidiary near Oslo
with two colleagues. Automation tech-
nology is highly rated among Norwe-
gians. During the last ten years it has
made a considerable contribution to
the five-fold increase in sales from
NKr 4 m to approx. NKr 20 m (about
EUR 2.4 m) today. SICK Norways nine
personnel also expect interest in safe-
ty and Auto Ident technology to in-
crease in the near future and that the
success story will therefore continue.
Sources: www.auswaertiges-amt.de, Homepage Spiegel/Lnderlexikon
HMI competition
Happy with the
DigiCam
>> We asked about the New class of
Iaser scanners. Lots of visitors cor-
rectly answered with The S 3000.
Five of you were lucky enough to win
the digital cameras offered as prizes
including Michael Reinhard from Bosch
Rexroth, and the student Sven Meyer.
Michael Reinhard from Erbach is a
Product Manager in the Control System
Technology section of the Motion-Con-
trol and PLC Dept. His favourite photo
motifs, that he will now be able to seek
on his hikes and bicycle tours, are ani-
mals, plants and natural events. Sven
Meyer from Loxstedt was busy working
on his thesis at least he was when
the winners of the competition were
drawn. He was naturally particularly
happy when the digital camera arrived
by post as, according to his own state-
ment, I have never yet won anything
big. So he is now also snapping pho-
tos of friends and parties, as well as
the odd nature shot, during the breaks
from working on his thesis.
Congratulations to the winners, and
we hope that they enjoy their digital
photography.
N
E
W
S
SICK insight 2/2003
40 SICK Tour DigiCam competition International World Skills Competition SICK IBEO GmbH
Among the leaders at
the World Skills Competition
Congratulations from
the Chancellor
Gerhard Schrder insisted on congratulating the team representing
Germany for their excellent results at this years World Skills Com-
petition in St. Gallen, Switzerland. For the first time, three trainees
from SICK succeeded in different disciplines in the national heats
absolutely unique for this competition.
>> Industrial mechanic Daniel Volk,
technical artist Andreas Kuri, and in-
dustrial electronics engineer Boris
Szerbakowski were three of the roughly
750 participants from 37 nations seek-
ing to become world champions in 44
careers. Even if they didnt take gold,
silver or bronze, all three of them suc-
ceeded in coming in directly behind the
medal-winners.
Gerhard Schrder (in his capacity as
patron of the German team) could be
well satisfied with the performance of
his team. The 33 German participants
returned from Switzerland with three
gold medals, four silver, a bronze and
19 good performance certificates.
Find out more at: www.berufs-wm.com
The lucky winners:
Michael Reinhard from Bosch Rexroth
(top) and student Sven Meyer
>> SICK has gathered to-
gether technological expert-
ise in single-beam and laser
scanning measurement sys-
tems in the newly found-
ed Time-of-Flight Systems
Business Unit (TOF).
In addition to SICK AG
products such as the LMS
series, it also includes the
products and systems of
SICK IBEO GmbH in Ham-
burg. The new TOF Business Unit, with
its expanded product range of single-
and multi-beam laser measurement
systems is focused on the target mar-
kets of ports, the steel industry, bulk
materials, agriculture, vehicle naviga-
tion, robotics, traffic, and building se-
curity.
Time-of-flight systems under one roof
Focused technology and
sector-oriented
>> Just imagine, your boss calls you in
to see him and informs you that you
have to fly to China. Negotiations with
business partners there are proving dif-
ficult. Personal discussions are now
necessary. And soon. Your plane
leaves tomorrow.
Well, OK, you are well acquainted
with the subject matter, that is not a
problem. But China...
You need concise and reliable infor-
mation. Just a moment, didnt one of
your colleagues just buy an etiquette
manual for abroad? Yes, there it is, on
his desk. Its got a great format for a
start: small and light. It even calls it-
self a pocket guide. It is, however, only
available in German.
So whats in it?
The first section points out the typical
problems of individual- and group-ori-
ented cultures, reports on visible and
subconscious characteristics in cultur-
al behaviour, hierarchical differences
and non-verbal communication. The
SICK insight 2/2003
Etiquette for abroad Online survey 41 Book Corner
> Usefulness of information: 2.4
> Interest in topics offered: prod-
ucts/new developments (93%), appli-
cations (61.1%) and new technolo-
gies (81.4%), with company news,
services and trade fair information
also receiving average to good as-
sessments
Extracts from personal comments:
> One of the few good to very good
sources of information from producers
for users
Etiquette for abroad by H. Fichtinger/G. Sterzenbach
Business trips abroad
a pain or a pleasure?
Results of our major online survey
A newsletter that really informs
> Very good work please keep it up
> One of the few newsletters that I
would like to continue receiving
> Your newsletter is one of the best in
the branch
> Compact lucid informative keep
it up
If this has made you curious
www.sick.de/newsletter
Again, we are grateful to all those who
participated, and THANK YOU for your
motivating comments!
reader is given valuable tips on how to
side-step stumbling blocks and avoid
faux pas. It goes on to look at dealing
with foreign business partners in more
detail. Discussions, doing business,
and how to behave during business
meals are the most important sub-sec-
tions.
A second section, in alphabetical
order, is devoted to looking at 32 coun-
tries and regions worldwide. A special
section on Asia is also included. Super,
China is also in Asia!
The pages covering individual coun-
tries provide important information on
appearance and communication, eat-
ing, drinking, and making invitations,
finishing up with a list of dos and
donts. So in addition to other impor-
tant rules of etiquette for example, one
should never make a direct criticism in
China as this leads to loss of face. And
one should never give knives, umbrel-
las or watches as presents, for whatev-
er reason. On further leafing through
the book the traveller finds out where
the left hand is considered unclean or
it is impolite to show the soles of ones
feet, as well as the acceptability of
smoking in public buildings and on the
street. Valuable tips and experiences
are passed on here.
The third section of the pocket
guide offers a quiz. One can test ones
intercultural knowledge with
right/wrong questions. Readers are fi-
nally questioned on their own commu-
nication behaviour, how time is treated,
and the influence of group behaviour.
In summary: an easy-to-understand
little book that offers rapid orientation
for all those who do not have the time
to inform themselves in detail about
foreign cultures, or who would simply
like to freshen up their knowledge.
Your negotiations in China are
saved success is assured!
Book Corner by
Ingrid Rathfelder, Editor
SICK insight e-mail newsletter
>> These and other pleasant positive
statements were the result of the sur-
vey on our e-mail newsletter carried out
in May 2003. We asked about clarity,
scope, the usefulness of information,
main topics and total assessment.
Here is an extract from the results
(graded 16, where 1 is excellent and
6 is dreadful):
> Total assessment: 1.9
> Clarity: 2.01
> Scope: 84.8% just right
Rudolf Haufe Verlag, ISBN 3-448-05551-4
Only available in German
SICK insight 2/2002 SICK insight 2/2003
> Internet glossary
> The for fast results
Glossary Product-Finder Training 42 Internet
You want to increase or broaden your knowledge in the vari-
ous specialist areas in industry?
You can do this with our Training & Education pro-
gramme. Whether practical training in using our products or
specialist seminars on safety-related technical topics with
our ability and experience we will provide you with the nec-
essary framework for greater safety and success. We are al-
so pleased to carry out training at your premises. We will
make you an offer on request.
We describe our training courses and seminars in detail
at www.sick.de/schulungen. The complete programme is
available as a download. On the web site we also inform you
about current events and the dates available. You can simply
book online.
You will also find an overview of the training and seminar
dates for 2004 there. All information on new topics such as
our practical seminars on risk analysis and risk assessment,
or user training for the new S 3000 laser scanner, are al-
ready available.
> Knowledge is power
What does muting or blanking mean? How can one explain
background suppression comprehensively? There are lots of
specialist terms (arranged in alphabetical order) covering the
entire area of industrial sensorics at www.sick.de/glossar.
If you cannot find a particular term you can send us an e-mail
straight away, directly from the glossary, letting us know
about it. We always look forward to comments and new
ideas! Also available soon in English.
For some years now, SICK has offered an extensive range of
products and solutions on the Internet. In order to simplify
your search for the right sensor for your application we have
now developed an online catalogue for a large number of de-
vices, offering selection aids such as the Product-Finder. You
will thus find support for your daily work at the www.sick.de
portal regardless of your location or the time. Are you look-
ing for application solutions for your tasks? Pre-selection of
particular parameters such as range, power supply, switch-
ing output, etc. simplify research. A few mouse-clicks will
take you to the right products, comprehensibly shown in da-
ta sheets, and more detailed documentation (e.g. connec-
tion plans and dimensional drawings). lf desired, you can ob-
tain an offer straight away, make personal contact, or regis-
ter for a product introduction course at our Training Centre.
insightSERVICE
Subsidiaries
Australia
Tel. +61 3 9497 4100
+1800 3 3480 2 toll free
sales@sick.com.au
Austria
Tel. +43 22 36 62 28 8-0
office@sick.at
Belgium/Luxembourg
Tel. +32 2 466 55 66
info@sick.be
Brasil
Tel. +55 11 5091 4900
sac@sick.com.br
China
Tel. +85 2 2763 6966
ghk@sick.com.hk
Czech Republic
Tel. +420 2 57 91 18 50
sick@sick.cz
Denmark
Tel. +45 45 82 64 00
sick@sick.dk
Finland
Tel. +358 9-25 15 800
sick@sick.fi
France
Tel. +33 1 64 62 35 00
info@sick.fr
Great Britain
Tel. +44 17 27-83 11 21
info@sick.co.uk
Italy
Tel. +39 02 27 40 93 19
ced@sick.it
Japan
Tel. +81 3 3358 1341
info@sick.jp
Korea
Tel. +82 2 786 6321/4
kang@sickkorea.net
Netherlands
Tel. +31 30 229 25 44
info@sick.nl
Norway
Tel. +47 67 81 50 00
austefjord@sick.no
Poland
Tel. +48 22 837 40 50
info@sick.pl
Singapore
Tel. +65 6744 3732
admin@sicksgp.com.sg
Spain
Tel. +34 93 4 80 31 00
info@sick.es
Sweden
Tel. +46 8-680 64 50
info@sick.se
Switzerland
Tel. +41 41 619 29 39
contact@sick.ch
Taiwan
Tel. +886 2 2365 6292
sickgrc@ms6.hinet.net
USA
Tel. +1 (952) 941 6780
info@sickusa.com
Representatives and agencies in
all major industrial nations.
Trade fair dates Imprint Contacts 43 Info
Trade fair dates Germany
Trade fair Location Date 2003/2004
Productronica Munich 11.11.14.11.2003
SPS/IPC/DRIVES Nuremberg 25.11.27.11.2003
HANNOVER MESSE Hanover 19.04.24.04.2004
SEMICON Europe Munich 20.04.22.04.2004
Trade fair dates Europe
Trade fair Location Date 2003/2004
INTEGRALE VEILIGHEID Utrecht, NL 11.11.13.11.2003
inspex Birmingham, UK 11.11.13.11.2003
Scanautomatic Gteborg, S 18.11.21.11.2003
MOCON Den Bosch, NL 26.11.27.11.2003
Elektro Vakbeurs Hardenberg, NL 09.12.11.12.2003
Teknik & Data Odense, DK 03.02.05.02.2004
IMHX Birmingham, UK 02.03.04.03.2004
CFIA Rennes, F 09.03.11.03.2004
MECANELEM-MECATRONIC Paris, F 22.03.26.03.2004
Total Processing and Packaging* Birmingham, UK 29.03.01.04.2004
Intertraffic Amsterdam, NL 30.03.02.04.2004
AMPER Prague, CZ 30.03.02.04.2004
EL 2004 Odense, DK 11.05.14.05.2004
BIEMH Bilbao, E 07.06.12.06.2004
Trade fair dates worldwide
Trade fair Location Date 2003/2004
FABTECH International Chicago, IL, USA 16.11.19.11.2003
ISA Show South America So Paulo, BR 18.11.20.11.2003
MD&M West Anaheim, CA, USA 06.01.08.01.2004
NA 2004 Cleveland, OH, USA 29.03.01.04.2004
METALFORM Louisville, KY, USA 30.03.01.04.2004
* incorporating PPMA und PAKEX
Imprint
Publisher: SICK AG Postfach 310 D-79177 Waldkirch Tel. +49 7681 202-0
Fax +49 7681 202-3863 www.sick.com info@sick.de
Co-ordination: Anette Hippach customer magazine Project Manager, SICK AG
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
Pictures: SICK AG, Deutsches Museum, Salvagnini, Miele, AKL-tec
Individual contributions may be reproduced after prior consent. Please contact us at:
Tel. +49 211 5301 0 Errors excepted Subject to technical change
Central Sales, Germany
SICK AG
Schiess-Strae 56
40549 Dsseldorf
Germany
Phone +49 211 53 01-0
Fax +49 211 53 01-100
E-mail vzdinfo@sick.de
Company Headquarters
SICK AG
Sebastian-Kneipp-Str. 1
79183 Waldkirch
Germany
Telefon +49 7681 202-0
Fax +49 7681 202-38 63
E-mail info@sick.de
When maximum accuracy
counts: the LMS 400.
Quicker, more reliable, better: whether pick-and-place,
robotics or material handling, at close ranges of up to 3m,
in particular, the demands on the measurement system
grow with the tasks. Anyone wanting to keep up needs
a system that sets technological standards. The new
LMS 400 positioning and handling scanner from SICK
offers you the precision you need for success.
More information at:
www.sick.com
Industrial Safety Systems Auto Ident
M
,

R

&

H

F
r
e
i
b
u
r
g
SICK AG Auto Ident Nimburger Str. 11 79276 Reute, Germany Phone +49 7641 469- 0 Fax +49 7641 469-1201
Industrial Sensors
insight
2/2003
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