S I C K ’ S
C U S T O M E R
M A G A Z I N E
2014
: FOCUS SCANNER AND VISION
SEEING
DETECTING
UNDERSTANDING
HARNESSING SCANNERS AND
VISION TECHNOLOGY FOR INDUSTRY
Visit us online:
www.sickinsight.com
08
>> Industrial applications have high expectations of laser measurement technology and Machine Vision. Whether they’re being used to
ensure flawless quality assurance, in production automation or for
controlling processes, sensors must be able to gather information
about their environment, analyze data instantly, and produce results
that allow clear-cut decisions to be made. All that, and they also have
to perform reliably even under the toughest industrial conditions.
That’s why efficient data processing is a must. For a sensor manufacturer like SICK, this comes down to the ability to record, comprehend, and interpret a variety of object properties simultaneously,
directly in the sensor. This goes far beyond simply processing received signals or camera images in the normal way.
SICK’s innovative sensors are so rugged that they can withstand the
harsh requirements of industrial contexts effortlessly. This ability
to be used in industrial applications has always been an essential
feature of camera-based sensor technology as well as laser-based
detection and ranging solutions – developments such as the first
safety laser scanner based on the time-of-flight of pulses principle,
or the world’s first CMOS sensor to be compatible with industrial
environments, are proof of exactly that.
20
Vision systems
The end-to-end solution in focus:
Interview with Dr. Peter Pokrandt.
Today, therefore, we offer our customers a wide-ranging portfolio of
both laser-based and camera-based sensors and systems for efficient control and optimization of automated processes. In this issue
of our customer magazine, we hope to give you an overview of the
areas of laser and vision technology in which SICK specializes.
I hope you enjoy reading.
ServaPark
“We park for you!” Simple idea,
huge challenge, solved by intelligent
sensors from SICK.
Dr. Mats Gökstorp
Executive Board Member Sales & Service of SICK AG
2
: FOCUS SCANNER AND VISION
CONTENT
IDpro
Scanners, cameras and RFID
in cooperation ......................................04
Vision technology
Inspection and quality assurance .......08
Vision
State-of-the-art camera technology
helps to increase quality and throughput
in production and logistics.
Vision portfolio
More than 25 years of experience ......10
Food and beverages
Safe, but also sustainable ...................12
Femeg
Checking QR codes with Lector®62x .....14
Adbro Controlls
Quality assurance for baked goods ....16
BMW
Automatic crack detection
at wheel housings ................................17
Vision systems
The end-to-end solution in focus .........18
Interview
Vision systems means less effort .......20
24
Lector®65x
Scanner
Evolutionary developments
and recognized expertise.
Nonstop code reading flexibility ..........22
Ataturk airport
Keeping track of baggage ....................23
Scanner technology
Scanner technology harnessed
for industrial use ...................................24
Imprint
Publisher:
SICK AG · Postfach 310
79177 Waldkirch · Germany
Phone +49 7681 202-0 · Fax +49 7681 202-3863
www.sick.com · [email protected]
Managing Editor:
Andreas Esslinger
Editors:
Tobias Maillard · Ingrid Rathfelder
30
Layout:
ad:johnson Kommunikation · www.adjohnson.de
Scanner portfolio
Innovations in laser measurement
technology ............................................26
Serva Transport Systems
Controlling dynamic movement
sequences on automated vehicles .....30
RWE
Measuring volume flow with Bulkscan® 34
Inside the tunnel
Pictures:
SICK AG, Serva Transport Systems
Danger of fire averted ..........................36
Reproduction of individual contributions
is permissible with prior consent.
Subject to change without notice.
Collision prevention
Increased safety for people
and investments...................................38
3
FOR THE OPTIMAL COST/BENEFIT RATIO
FINDING THE IDEAL
SOLUTION WITH SICK
From laser-based bar code scanners and high-end solutions with 2D cameras to RFID
technology: SICK is synonymous with years of know-how and experience in all automatic identification technologies. This means that SICK is also able to provide comprehensive consulting services to help customers choose the right technology at the
earliest possible stage – implementing the ideal solution to meet all requirements
and achieve the optimal cost/benefit ratio.
>> Over the past few decades, the fields
of trade and production logistics, e.g. in
the automotive industry, were among the
pioneers in the development and implementation of new labeling and identification methods. Time and time again, this
4
process showed that, depending on the
informational and application-related requirements of the particular industry, 1D
bar codes, 2D codes and RFID transponders can have specific advantages or disqualifying criteria in different applications.
Aspects such as the amount of data,
transport speeds, scanning range or reading distance, field of view, and ambient
conditions can play a critical role depending on the specific application in question.
On the way to an ideal solution
Top consulting services can only come
from a company that has extensive experience in all three technologies. Industrial durability, high read performance,
quick and easy diagnostics, and security for the future all play a critical role
on the path to finding the ideal solution.
,GHQWLÀFDWLRQ
: FOCUS SCANNER AND VISION
IDpro FROM SICK: THREE TECHNOLOGIES – ONE INTEGRATION CONCEPT
RFID
Reads and writes data
Group capture (multiple identification)
No optical contrast necessary
CAMERA
SCANNER
Identifies 1D and 2D codes
Flexible reading distance
Omni-directional 360° identification
Large reading field width
Increased data security through
image processing
Not dependent on lighting conditions
One supplier for all technologies: SICK offers a wide portfolio and broad expertise.
It is not uncommon for one company to
require the use of multiple identification
technologies across different processes
as a result of varying conditions. Also,
process optimizations or changing requirements often necessitate the use of
multiple identification technologies or,
if necessary, even a subsequent technology modification. From an economic
standpoint, however, a modification
only makes sense if the identification
systems are based on a single platform
and if the devices have the same performance and connectivity:
Featuring a scanner, camera and RFID,
the IDpro showcases SICK‘s expertise in
all three automatic identification technologies. All IDpro devices are characterized by uniform connectivity, an identical
user interface and a consistent accessory concept.
Flexibility thanks to single device platform
The single device platform provides increased flexibility. Investments in a specific identification solution are not necessary until after the requirements have
been fully established. If the identification
devices – whether RFID, laser-based bar
code scanners or image-based code readers – all have the same interfaces and
speak the same “language,” then the actual decision can wait until very last step.
Even switching from one identification solution to another is simple, thanks to the
single platform. Here, a uniform interface
design makes converting the data from
bar code to RFID easy.
More information:
www.sick-idpro.com
5
: FOCUS SCANNER AND VISION
,GHQWLÀFDWLRQ
ALIS hybrid track and trace system identifying pieces of luggage
Perfect interaction:
Hybrid systems from SICK
In order to achieve an extremely high
read rate despite difficult application
requirements, a combination of technologies may also be necessary, such
as in self-service bag drop systems at
airports. In this case, the simultaneous
use of both RFID and bar code technology is often the best solution for satisfying the diverse requirements. Hybrid systems from SICK are built around proven
individual components and, as scalable
solutions, can be accurately adapted
to meet the specific requirements of
the application.
The Airport Luggage Identification
System (ALIS) uses both scanners for
the identification of 1D codes and UHF
6
RFID antennas. Particularly when it occurs in baggage sorting processes at
airports, unread labels lead to extremely costly delays or errors. Increasing
the read rate by just a few percentage
points is enough to help minimize baggage sorting costs.
Hybrid systems consisting of scanners and line-scan cameras are often
used in the courier, express and parcel
(CEP) sector. If information is available
about how the bar code labels are affixed to the parcels (e.g. 98% of the
labels on top), then the ICR890 can be
used to achieve extremely high read
performance in these situations. In order to cover the other five sides of the
package, which may contain the label
in 2% of the cases, omni-directional la-
ser scanner systems can be used as a
more affordable solution that still offers
proven performance.
In line with the nature of the hybrid
approach, it is also possible to integrate
other functions into systems in addition to a “pure” identification capability. For example, in the CEP, airport and
retail sectors, it is common to measure
additional object attributes, such as
dimensions and weight, as part of the
identification process. The Dimensioning Weighing Scanning (DWS) systems
from SICK utilize various different functions. These systems make it possible to
reliably perform the above tasks in both
static and dynamic environments and
at virtually any transport speed encountered in the logistics sector.
TAKE CORNERS AT HIGH SPEED.
Limited installation space, tiny objects, or strict requirements in terms of sensing range, temperature stability,
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to very short response times of 16 μs. Suitable for sensing ranges up to 20 m, immune to electromagnetic
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VISION TECHNOLOGY FOR INSPECTION AND QUALITY ASSURANCE
RELIABLE ERROR RECOGNITION
Vision sensors and cameras give machines and systems the capability to “see,”
“read,” and interact with each other. State-of-the-art camera technology replaces
or supplements human inspection and helps to increase quality and throughput in
production and logistics because errors are recognized and avoided.
8
Vision technology
Cameras for industrial use
A vision camera for industrial use consists of a lens, image sensor, processing
unit, and communication interface – all
safely contained within a reliable housing. Different types of vision camera will
Laser triangulation – the third dimension
e action
Tak
im
Take age
Analyze
>> Vision sensors and cameras are
used in the industrial sector for code
reading and image processing in
order to control and inspect production and logistics processes.
In order to recognize errors and
to introduce the correct countermeasures, vision sensors and
cameras work at four process
levels in the industrial sector:
after pure image capture the
image is analyzed. The result of
this analysis is emitted, triggering
an action: a poor quality object is
discharged, a robot arm takes hold, a
further process step is initiated, or the
data is simply saved for traceability.
All errors in the process, on the tool,
or during production are immediately
recognized.
Send
r e s ult
s
be required depending on the application and the integration environment.
From the independent sensor, which can
be easily configured on the belt, through
to programmable systems with appropriate software support.
Height profile
Fields of Application
Typical fields of application for vision sensors and cameras include positioning,
inspection and quality assurance, and measuring and reading information:
Objects are located during positioning. The camera provides information on
the object coordinates, e.g., for robot control.
During inspection, product quality can be monitored as the camera analyzes
the object to check for correct shape, completeness, or other defects.
Object dimensions such as length, width, weight, area, or volume
are determined during measurement.
A vision sensor is also equipped to identify 1D, 2D, or stacked codes,
and even read text.
: FOCUS SCANNER AND VISION
As in traditional photography, there are
some basic requirements for good image results. For example, the right
light and accurate focus are crucial.
The resolution is also important,
as well as the required field of
vision and the distance from the
object. SICK has a wide range of
vision sensors and cameras, as
well as accessories for lighting
and mounting, for a huge range
of requirements: from code reading to positioning, inspection and
quality control through to measuring
of dimensions.
“Seeing” in up to three dimensions
Simple line scan cameras record one
line after the other in a one-dimensional manner. This enables an image
of a bar code to be produced and read
by moving the object. Vision sensors
record an area in two dimensions in
a snapshot, even without movement
of the object. The sensors generate
a snapshot in 2D. The image result is
prepared and then read or analyzed.
3D image
It is also possible, however, to record
and process images with a third dimension, either with snapshots taken using
f.ex. stereoscopy or with the aid of laser
triangulation.
Laser triangulation is a quick scanning technology which provides precise
3D data for the reliable analysis of real
size features such as height, cross-sectional area, and volume. This 3D image
recording technology produces height
profiles with the aid of a laser line and a
camera. The recording of these height
profiles creates the complete 3D image
of a moved object.
9
Inspector PIM60
EASY POSITIONING, INSPECTION AND MEASUREMENT
MACHINE VISION AT SICK
MORE THAN 25 YEARS
OF EXPERIENCE IN VISION
The machine vision specialist, IVP AB, was founded more than 25 years ago in the
university city of Linköping in southern Sweden as an offshoot of the university there.
Since then, the company has been working with machine vision, thereby creating the
foundation for SICK AG’s current Vision range.
>> The first partnership between SICK
and the Swedish vision specialists came
about as early as 1999. IVP has been
a part of the SICK Group since 2003.
SICK can therefore also benefit from
more than 25 years of experience in the
area of vision sensors and machine vision. During SICK’s early years, the first
CMOS sensor for industrial use was
brought to the market, which combined
a pixel matrix, analogue–digital converter, and a graphics processor in a single
chip. The most recent generation of this
image sensor, the M12 Imager with patented technology, guarantees the high
performance of the SICK 3D cameras.
The first 3D vision product Ranger was
launched in 1996. Today, SICK has a
well-rounded portfolio, which ranges
from vision sensors for code reading
and quality assurance, through programmable image processing cameras,
to high-end cameras for quick 3D image
processing in tough industrial environments. But SICK does not only provide
customers around the world with vision
sensors and cameras. On the basis of
many years of experience, intelligent vision systems have been created which
provide solutions for very specific applications such as robot control or package sorting.
Foundation of the Machine Vision
Specialist IVP as a Spin-off from
Linköping University in Sweden
>> The Inspector PIM60 vision sensor
provides high-speed positioning, inspection and measurement. Its multi-functional vision toolbox solves a wide range
of quality control applications and improves production efficiency. The PIM60
combines smart camera functionality
with the ease of use of a vision sensor.
Its powerful toolbox solves inspection,
robot guidance and measurement tasks.
Thanks to the vision sensor’s excellent
calibration support, it provides easy-touse mm data, simplifying guidance and
measurement.
More information:
www.sick.com/InspectorPIM60
Ranger: the first
3D vision camera
COMPETENCE
IN
VISION
SINCE 1985
World’s first commercial
CMOS sensor
10
M12 Imager – A new generation
patented core technology
Vision portfolio
: FOCUS SCANNER AND VISION
LECTOR®65x
ScanningRuler
ColorRanger
NONSTOP CODE
READING FLEXIBILITY
3D VISION FOR
ROBOTICS APPLICATIONS
HIGH-SPEED 3D AND
COLOR IN ONE CAMERA
>> The LECTOR®65x image-based code
reader from SICK provides maximum
performance and optimum throughput
in logistics and factory automation. With
a frame repetition rate of 40 Hz and realtime decoding, the LECTOR®65x can reliably identify 1D, 2D and directly marked
codes at the highest possible speed.
The 2 or 4 megapixel image resolution
offers a large field of view. Combined
with dynamic focus, maximum flexibility
in code positioning, object height and
transport speed is achieved.
More information:
www.sick.com/Lector65x
IVC-3D – Word’s first
3D Smart Camera
>> The ScanningRuler is the perfect tool
for 3D imaging in robot picking applications. It provides accurate and reliable 3D
measurements of stationary objects. The
data that is acquired can be used to locate
parts in random bin picking applications
and to calculate the best robot gripping
position. The camera has a built-in laser
light source and provides 3D point cloud
measurements in millimeters of the entire scene. These features, in combination
with the camera’s immunity to ambient
light and its simple configuration, make
the ScanningRuler very easy to integrate
and use. In addition to 3D images, the
ScanningRuler also provides a 2D image
of the scene to simplify part identification.
More information:
www.sick.com/ScanningRuler
First Inspector vision sensor
launched
ICR89x: Solution for
identification of parcels
>> ColorRanger E extends the standard
Ranger family by providing high-resolution
color measurements. It offers full resolution RGB-color with on-chip color channel
white balancing and spatial correction for
high-quality color images. It is the ideal
choice for applications where both 3D
shape and color texture matters. ColorRanger E uses laser triangulation to extract the true 3D shape of objects regardless of the objects’ contrast or color. Using MultiScan technology, it can measure
a multitude of other object features, such
as contrast, laser scatter, and color at the
same time. This allows for reliable inspections and cost-efficient solutions since it
only takes one ColorRanger E to see it all!
More information:
www.sick.com/ColorRangerE
Lector®62x – compact,
camera-based code reader
Color Ranger E: the world’s first
high-speed 3D camera with highperformance color measurements
Lector®65x – flexible code
reader with 2 or 4 megapixel
image resolution
Vision systems
PLB and PLR
11
SAFE, BUT ALSO SUSTAINABLE
GLOBAL CHALLENGES IN THE
FOOD AND BEVERAGE INDUSTRY
Food producers and sellers need to ensure that products are fit for use by consumers and do not pose any health risks. The meat adulteration scandal in Europe, in
which foods advertised as beef products were found to contain horse meat, was not
the first time that consumers were alarmed. Certainty about the origin and quality
of products that end up in shopping carts is an important issue. But consumers
are also increasing demands for sustainable production methods that waste less
energy and resources.
12
>> SICK scanners and vision sensors are
used throughout the entire production
and delivery process to help control the
quality and origin of food and beverages
and improve production efficiency.
the product, or that the right product
has been packed in the right packaging
Seal inspection: Ensuring that lids
and caps are properly positioned and
closed
Food safety and tracing
Tracing and food safety are tantamount
to full transparency about the food‘s
origin and its path through the entire
supply chain, from the producer to the
consumer. This includes processing, filling and packing. SICK vision sensors can
be found in an incredibly wide range of
applications:
Code validation: Ensuring that all
codes on packaging are readable, or
that the correct code was printed on
the product
Label and packaging validation: Ensuring that the proper label is affixed to
Quality control
In the global market, product quality is
an increasingly important key to success. Quality problems damage the image of food and beverage producers. Today, this can be largely avoided by using
the right technology:
Monitoring of shape, size and color:
Ensuring a global supply of consistent
quality at all times
Level monitoring: Vision sensors monitor crates, boxes, cartons and other
forms of packaging and ensure that
they contain the proper number of
pieces or the right filling quantity
Label checking: Ensures that the labels
were affixed correctly
Sustainability and efficiency
Less is more: A reliable inline quality control system implemented over different
process steps translates into fewer rejects, less packaging and reduced energy
consumption. Inline quality control systems are playing an increasingly important role, particularly in situations where
more product needs to be manufactured
in shorter and shorter amounts of time.
For example, slight product deviations in
shape and size during the manufacturing of chocolate bars or meat products
are enough to significantly impact medium-term production costs. A reliable inline quality control system therefore not
only improves product quality, it also cuts
down the number of rejects.
Food and beverages
: FOCUS SCANNER AND VISION
Top: IVC-3D smart camera in action in a
quality control and contour checking system
for cookies
Bottom: LECTOR®620 OCR image-based
code reader performing optical character
recognition
Knowing what‘s inside: Inspector
vision sensor ensures food safety
Over the past few years, the number of
people suffering from food allergies has
risen significantly. The Inspector vision
sensor ensures that each and every unit
of packaging truly contains nothing but
what the food labeling indicates. For example, the Belgian frozen food manufacturer Crop‘s uses the sensor to visually
check every product that comes off the
line. This enables the company to guarantee that consumers with particular
food allergies will always have accurate
information.
More information:
www.sickinsight.com
LECTOR®620 OCR: The best choice
for optical character recognition
The new LECTOR®620 OCR image-based
code reader can identify all common 1D
and 2D code types. Featuring optical
character recognition (OCR) and optical
character verification (OCV), this code
reader is perfect for use in the food and
pharmaceutical industries, as well as on
packaging machines.
More information:
www.sick.com/lector
Quality control and contour
checking for cookies
When cookies enter the packing line, they
pass by the IVC-3D smart camera. This
camera captures the 3D contour (correct
diameters, heights and volumes) at high
speed and verifies that the cookies have
no dents, all while the baked cookies are
moved past the device on the conveyor
belt. Inferior cookies are rejected, and
the measured values are communicated
to a control system in order to fine-tune
the process and assist with statistical
evaluation.
More information:
www.mysick.com/applications
13
LECTOR®620 CHECKS QR CODES FOR TRACK AND TRACE
ENJOYING FISH OF
THE FINEST QUALITY
Frozen fish specialties are a solid alternative to fresh fish. The wide range of available
choices is the main reason why connoisseurs and innovators are turning to these
culinary delicacies. But where was the fish caught? And how? Now more than ever,
consumers are looking for a sensible solution in the search for a modern approach to
using natural resources. Femeg, a German producer of frozen fish specialties, has the
answer: QR codes on frozen food packaging allow food enthusiasts to access extensive information about the fish they’d like to buy. In order to ensure that the QR code
is also readable, the LECTOR®620 Professional image-based code reader checks it
during the packing process.
>> Femeg was founded in Bargteheide
(near Hamburg) as a family business in
1989 and has steadily grown into one
of today‘s leading specialists for frozen
fish and seafood. The name Femeg is
synonymous with uncompromising quality and innovative ideas in the area of
frozen fish specialties. Femeg specializes in the production of current international fish trends and the classics of
fish cuisine – both with top frozen food
quality. These delicacies can be found in
the product lineups of well-known supermarket chains.
14
Track and trace via QR code
Since the traceability and sustainability
of its different fish species are so important to Femeg, the company also prints
QR codes on its packaging in addition to
other information. These codes link to the
company website, which contains extensive background information on the fish
itself, as well as the catching methods
used. There, seafood lovers can also find
out if steps have been taken to ensure the
sustainability of the population of the particular fish or seafood. Femeg also offers
product-specific recipes. And all this is
available to consumers via smart phone
before they reach the checkout counter
at the supermarket. “Printing all of the
information on the labels is a huge step
towards greater transparency and a customer-oriented approach,” says technical
manager Tim Grunewald.
Only perfectly readable QR codes
Femeg has high standards for the process it uses to pack its product. That‘s
why the company uses the LECTOR®620
Professional image-based code reader
to check the QR codes in the packing
facility. At this facility, Femeg‘s frozen
fish, seafood and ready-made meals
are packed in immediate packaging with
QR codes. If a code is not readable, the
LECTOR®620 transmits an output signal,
which causes the packaging to be rejected. This ensures that only perfectly readable QR codes make it to market.
The LECTOR®620 Professional receives high marks from Femeg for its
simple installation and commissioning.
,GHQWLÀFDWLRQ
: FOCUS SCANNER AND VISION
The LECTOR®620 Professional accepts nothing less than
perfectly readable QR codes at German frozen fish producer Femeg
Thanks to the swivel connector, mounting
is easy in even the most constricted spaces. Two laser points indicate the exact position of the reading field, making the sensor a cinch to align. With its Auto Setup
feature, the LECTOR®620 can be set up
automatically to provide reliable QR code
recognition. The sensor is also capable of
reading 1D and data matrix codes. Femeg
uses a sensor with an enclosure rating
of IP 65, but the device is also available
with an IP 67 enclosure rating. The sensor supports modern fieldbusses directly
via the integrated Ethernet interface or
through a suitable gateway.
Different packaging types
are no problem
The facility handles multiple packaging
sizes and different packaging colors,
which requires a highly flexible code
reader. The LECTOR®620 Professional
offers the solution, with multicolored
LEDs in either red or blue light. When
used together, they produce white light.
This allows the sensor to recognize a
wide range of different packaging types
and QR codes.
It is not always possible to hear an
acoustic signal during the packing operation, since the process is very loud. However, the green feedback light provides
continuous information about whether
or not a read operation was successfully
completed.
Universal micro SD card
If the code is unreadable, the camera
generates “no-read images,” which can
be saved on the micro SD card. This card
can also be used universally. Because it
can store parameters, the card enables
the quick and trouble-free exchange of
reader devices. Simply load the card on
the new device; after just a few minutes,
the new sensor is ready for use and the
system stoppage is over.
Another reason why Femeg chooses
the LECTOR®620 is because SICK offers a
variant with optical character recognition:
the LECTOR®620 OCR. Featuring identical connectivity, this variant can be easily
integrated into the existing system. This
means that Femeg will be able to convert
to an optical character recognition operation at a later date with little trouble.
Professional support from SICK
SICK‘s LifeTime Services provide assistance with system installation, commissioning and upgrades. Services range
from product-independent consulting to
traditional product services. Thanks to
the company‘s comprehensive industry
knowledge and over sixty years of practical experience, SICK‘s unparalleled
range of solutions expertise truly sets it
apart from the competition.
Further applications:
www.mysick.com/applications
More about the customer:
www.femeg.de
15
FOOD MEASURING IN 3D AND COLOR
QUALITY CONTROL
FOR BAKED GOODS
In the production of baked goods, it is necessary to reject inferior items, which lack the
proper shape or color, before they are packed. Here, the ColorRanger E high-end camera
monitors the quality of the baked goods.
>> Higher brand awareness and customer satisfaction are an increasingly
important factor for the manufacturers of baked goods. That‘s why these
manufacturers are looking to make detailed improvements to the pre-packing
quality control process for goods such
as bread, cookies and donuts. Together
with additional demands for cost efficiency, this means that optical quality
control must be automated and performed at high speed.
High-grade goods,
qualitatively speaking
These improvements have to take a
wide range of quality aspects into consideration, such as product shape,
thickness, and color. Additionally, the
presence and amount of topping, as
well as the presence and quality of imprinted patterns and logos, must also
be monitored. The level of completion
of the baked goods and any foreign objects they may contain both need to be
identified. In order to take all these attributes into account, the control system
must have the capability to measure
16
both 3D and color attributes at a high
resolution. Moreover, the system needs
to analyze the measurements and make
the correct grading or sorting decision
within a limited window of time. The
sorting station also needs to include a
device for rejecting inferior items.
The need for high speed
System integrator Adbro Controls Ltd.
discovered the solution to this challenge
in the form of a high-speed rejection system that handles quality control in the
food industry. It works with conveyor systems and is designed for easy integration
into existing production lines. The application is built around the ColorRanger E
3D camera from SICK, which provides
simultaneous 3D and color images at
high speed. It also features two light
sources: one white light source for color
recognition and one line-projecting laser
for 3D measurements according to the
laser triangulation method. The camera offers a high degree of flexibility,
which means that the measuring speed,
resolution, and field of view size can all
be adjusted.
Image data from the camera is sent to
a PC (host), where proprietary software
performs image analysis and compares
the scanned data with a preprogrammed
range of ideal data in order to either
feed the item to the next process step or
reject it. HALCON‘s camera support enables quick software development in the
machine vision library.
The system tracks the exact position of goods on a conveyor belt and
sends the grading decision to an array
of pneumatic nozzles mounted in slots
above the belts. The nozzles then use
compressed air to blow the inferior item
off the belt.
Further applications:
www.mysick.com/applications
More about the customer:
www.adbro.co.uk
INTEGRATED LIGHTING, IMAGE EVALUATION
AND ETHERNET INTERFACE
AUTOMATIC CRACK DETECTION
WITH INSPECTOR I40
Every error detected too late costs money. At BMW in Munich, until now defective
wheel housings were recognized only at the outfeed of the press line. Now Inspector
I40 vision sensors from SICK already check every component for cracks after the first
drawing process in the lead press.
>> More than 400 different pressed
parts form the basis of the body-inwhite of a BMW 3 Series. For this purpose, at the Munich Presswerk II of the
BMW Group every day about 600 tons of
sheet steel are processed, for more than
130,000 body components on eight
press lines. In light of this volume, it is
essential to detect and sort out defective components as early as possible. In
the area of the pressing plant, previously
the quality of the wheel housings for the
BMW 3 Series was checked manually by
an employee only at the exit point of the
press line – which means after the steel
sheets had been drawn, bent, punched,
and trimmed to size. Consequently, the
car manufacturer’s request involved detecting cracks in the metal sheets immediately after the first processing step.
To this end, SICK developed a solution that was just as simple as it was cost
effective. Its core is the Inspector I40
vision sensor with integrated lighting,
image evaluation, and Ethernet interface. Independent of the components,
crack inspection already takes place at
the body panel deposit of the orientation
station, which serves as an intermediate
storage space. A so-called feeder deposits the metal sheets, deep-drawn in
the lead press, into this station. Exerting
a press force of 1,800 tons, this press
has already performed the major forming of the part. The subsequent presses
take on additional cutting and forming
processes, resulting step by step in the
: FOCUS SCANNER AND VISION
creation of a precisely shaped complex
component.
Mounted above the orientation station is the Inspector I40 vision sensor
from SICK. The ICL300 external illumination unit illuminates the metal sheets
from the outside. The sensor is actuated
in such a way that it works as a pixel
counter in the dark. Components that are
OK remain completely in the dark. Only in
case of cracks, the light passes through,
appearing as light pixels. When the sensor detects a crack in this way, the facility is stopped, with the corresponding
error message issued. Error-free drawn
components are transported to the next
press by means of another feeder.
Employing this simple solution
makes it possible to do without an additional PC for image evaluation. The
sensor is integrated directly into the
press controller via its input and output
subassembly. “It is possible to integrate
Fo : BMW
Foto
BMW AG, Werk
k Münc
ünch
ncc en
Monitoring and controlling
The Inspector I40 vision sensor is mounted
above the orientation station. The ICL300
external illumination unit illuminates the
metal sheets from the outside
Phot
Photo:
hoto: BMW
BMW
WA
AG,
G Werk
G,
erk Muni
Mun
unicch
h
this type of crack inspection without major effort into any existing facility and to
use it for any formed parts,” says one
employee at BMW Maintenance. Initial
trials in production operations yielded
extremely high accuracy in detecting torn
components. So far, the crack inspection
in this form has been used at the Munich
Presswerk for two different components.
“However, we do not rule out deployment
for additional parts in the future.”
Further applications:
www.mysick.com/applications
More about the customer:
www.bmw.com
17
VISION SYSTEMS FROM SICK
THE END-TO-END SOLUTION IN FOCUS
Innovation based on proven solutions: SICK’s vision systems are underpinned by
proven components that are in widespread use in the field of factory automation,
extensive industry know-how, and globally available support and services. The focus
always lies in developing practical, scalable solutions. And close collaboration with
customers means that SICK is always a step ahead in the conceptual process.
>> During the manufacturing process, a
number of different markers are applied
to tires for quality control purposes. In
addition, the markers indicate the correct orientation of the tire for mounting
on the wheel rim. With its quality control
system for markers, SICK has developed
a scalable, forward-looking solution to
meet the demands of tire manufacturers
now and in the future.
18
The challenge: Detection and validation
of extremely diverse markers
Colored markers are applied as early as
the tire manufacturing stage. These indicate the external side of the tire and
must be clearly visible and unmistakable
in nature in order to ensure that the tire
is mounted correctly on the wheel rim.
These colored markers may be damaged
while the tire is being processed in the
curing press. It is therefore vital for tire
manufacturers to be able to perform
quality control during final tire inspection.
Another type of marker used during
tire manufacture consists of glued markers. These indicate the heavy spot of the
tire and are applied after the production
process has been completed. The glued
markers make it possible to mount the
tire on the wheel rim in such a way that
the valve compensates for the imbalance of the tire. When the tires are transported along roller conveyors, the glued
markers may be partially damaged or
even destroyed and this may give rise to
customer complaints.
Vision systems
High quality and safety demands
Tire manufacture is a complex process
that imposes exacting demands in terms
of quality and safety. In order to ensure
high quality during production, SICK can
provide an end-to-end solution for the
quality control of markers on tires. Alongside outstanding performance, factors
such as excellent economic efficiency
and ease of commissioning are also crucial since they contribute decisively to
widespread acceptance and implementation of the system in globally active
enterprises.
The end-to-end solution
from SICK: Simple integration
with minimum downtime
The quality control system consists of
two identical modules that are mounted
above and below the conveyor assembly.
All the components of these modules, including the cameras, lasers, illumination
and mirrors are supplied precalibrated.
No additional adaptations by a vision
system specialist are required.
At the heart of the system lies the
ColorRanger E high-end camera. This
combines the functions of a 3D camera
and a color line camera: The 3D function delivers reliable information about
the position and shape of the tire – independently of the characteristics of
the background of the inspected object.
The so-called “region of interest”, in
which markers are searched for, is calculated on the basis of this information.
This ensures that only markers that are
actually located on the tire are evaluated. Markers that have come loose
and are located on the conveyor belt
are ignored. The color component of the
ColorRanger E reliably identifies the color of the markers even in the presence
of reflected light or dirt on the surface
of the tire.
: FOCUS SCANNER AND VISION
Success through pooled expertise
Thanks to the close collaboration between industry experts and SICK’s product specialists, a wide range of requirements relating to system design and
maintenance were taken into account
right from the outset. The modular concept permits rapid installation, commissioning and maintenance. The individual
components are precalibrated and can
be replaced quickly and easily. The system also possesses an integrated autodiagnostic function. SICK additionally
provides a remote maintenance concept
as an option.
Tire Inspection-Marker:
developed for the detection and
validation of markers on tires
LED line light
Deflection mirror
Laser bar
Camera’s field of view
Illumination
Camera
Laser line
Tire on conveyor belt
Laser bar
Camera
Deflection mirror
LED line light
19
AN INTERVIEW WITH DR. PETER POKRANDT
VISION SYSTEMS MEAN LESS EFFORT
With automation systems such as PLR and PLB, SICK supplies tailor-made solutions
for use in the vision field. SICKinsight talked with Dr. Peter Pokrandt, Manager Solutions Engineering at SICK.
SICKinsight: Dr. Pokrandt, SICK is deliberately moving forward in the area of
Solutions Engineering. What are the benefits to the customer and what trends is
SICK following?
Dr. Pokrandt: At present, operators and
integrators of production equipment are
faced with an ever growing choice of sensors and system components which they
can use to implement their automation
solutions. However, the task of assembling all the component-specific expertise is a long and expensive one.
We supply our customers with sensor systems that are tailor-made for their
applications and make all the complex
technology required accessible over a
user-friendly interface. This greatly re-
20
duces the effort that customers have to
expend on sensor integration and also
minimizes the risks in terms of scheduling and costs.
By packaging the various elements
together in this way, we enable system
integrators working, for example, in the
robotics field or the packaging industry to
deploy complex vision systems efficiently
and profitably even if they do not possess
in-depth knowledge of image processing.
SICKinsight: Focusing on the issue of
complexity: What are the greatest concerns when implementing a vision system and how do you counter these?
Dr. Pokrandt: Without a doubt, the greatest concerns relate to how to control
these image processing systems during everyday operation, that is to say at
times when the developer of the production equipment or the system integrator is not immediately available. What
do you do if your production equipment
stops due to an image processing error
and no-one knows how to track down the
problem and get the system up and running again?
And that is precisely the focus of
our system solutions. In our sensors, we
implement a comprehensive, forwardlooking diagnostic functionality that informs the operator in good time that the
system is dirty, misaligned or simply aging or worn and that now – before any
potential failure – is the time to clean it,
adjust it or replace any defective parts.
With this feature alone, we manage to
prevent many failures during operation.
However, if the system should ever
fail despite all this, then our replacement and spare parts concept makes it
Vision systems
possible to get the system working again
quickly and without any special visionrelated know-how. If you like, it’s our version of “plug-and-play”.
SICKinsight: For what industries and applications does SICK provide system solutions?
Dr. Pokrandt: For the packaging industry, for example, we supply solutions
that permit the automated, supervised format adjustment of more than
100 points in the corresponding production equipment (Rapid Changeover).
We also provide systems that monitor
the manual packaging of furniture parts
(Content Verification). In the robotics
field, customers use our systems to
localize parts which the robot then removes with the utmost precision from
the corresponding rack or stack (PLR)
or from a box (PLB). Our portfolio also
includes quality control systems for use
in the tire manufacturing industry, the
placement of components on PCBs, filling drinks containers and many other
applications.
: FOCUS SCANNER AND VISION
PLR: Determining the position of parts in racks
The PLR system was developed for the
automated removal of stamped vehicle
body parts from racks. This stand-alone
system contains the parts localization
software as well as other tools for simplified integration in the robot. The PLR
system from SICK is the ideal solution for
the cost-effective, automated handling of
parts stored in racks
PLB: Parts localization in boxes for automated parts handling
The PLB system is used for the precise
localization of randomly oriented parts
in bins and boxes. The system consists
of a 3D camera, parts localization software and other tools for simple integration and communication.
OD Mini: COMPACT, LIGHTWEIGHT SENSOR FOR PRECISE MEASUREMENT.
The OD Mini short range distance sensor is the simple, precise, and economical way of carrying out measurement tasks – irrespective of
the color and brightness of the surface material to be detected. Precise thanks to the latest CMOS technology, packaged in a compact
aluminum or stainless steel housing, available with a male connector or with a cable and male connector. Economical thanks to its low
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IRXUVWDWXV/('V3UHFLVHPHDVXUHPHQWIRUTXDOLW\FRQWUROFODVVLÀFDWLRQRUVRUWLQJ:LWK2'0LQL:LWKHDVH:HWKLQNWKDW¶VLQWHOOLJHQW
www.sick.com/en/OD_Mini
LECTOR®65X IMAGE-BASED CODE READER
NONSTOP CODE READING
FLEXIBILITY
Maximum versatility, flexibility, integratability and availability are the requirements of
modern logistics automation. In practice, varying object heights and reading distances,
large fields of view, randomly aligned codes, and high transport speeds can all be found
in a single application. These are typical constraints that present too great a challenge
for many code readers.
>> The LECTOR®65x image-based code
reader – available in the “Dynamic Focus” and “Flex” focus variants – offers
the features necessary to tackle the following different tasks:
Manual parcel sorting
The LECTOR®65x from SICK makes it
possible to turn manual parcel sorting
into a semi-automated process and is
designed for use in small to medium sizes hubs. Thanks to rapid identification,
manual sorting capacities of more than
1,000 objects per hour are possible in
under 100°milliseconds. The handler
can also keep both hands free during
the parcel sorting process. This further
increases efficiency and improves ergonomics. The lighting on the LECTOR®65x
operates flicker-free, so that the handler is not bothered by flashes of light
coming from the camera. Another advantage is the integrated laser targeting
assistant and the highly visible green
feedback LED (green = “code read successful”). These visual signals boost
sorting capacity, especially under loud
conditions.
Manual parcel sorting
22
Code reading for varying parcel sizes
on a conveyor or sorting belt
The LECTOR®65x Dynamic Focus represents an innovation in the image-based
code reader market: It can adapt its reading distance to the current object height
in just fractions of a second. Using height
information, e.g. from an automation light
grid or laser scanner, the code reader
can adjust the focal position to optimally
fit each object, thereby maximizing the
read rate. In addition to code reading,
the optimal focal position and accompanying image sharpness can also be used
to assess the code quality. For example,
this means that if a faulty label printer is
responsible for a rising no-read rate, the
cause is very easy to localize, making it
simple to optimize the overall process.
Automatic identification of
tires and wheels
Varying tire widths and diameters, variable orientations of the codes and different tire/wheel positions on the conveyor
belt represent the challenges posed by
this type of code reading. Image-based
solutions like the LECTOR®65x provide
Code reading for varying parcel sizes
on a conveyor or sorting belt
code recognition in many different alignments, even for codes with low bar
heights. With two focus variants, the
LECTOR®65x is perfectly equipped for
a wide range of different applications.
The “Flex” variant boasts individually
selectable lighting and lenses and is
perfect for the efficient identification of
car tires. If tire height and diameter vary
more significantly, e.g. when identifying
truck tires, then the “Dynamic Focus”
variant is the right choice. Because it
can be flexibly adapted to the desired
belt width, the LECTOR®65x offers even
greater modularity and flexibility for designing reading gates. Depending on the
desired field of view, the system can be
expanded to include the necessary number of cameras. With just one cable per
device, the system is still easy to integrate and extremely cost-efficient. Even
as a multi-head system, the control uses
only one interface for communication,
thereby simplifying integration.
Track and trace in pharmaceutical
packing facilities
Accurate identification, localization and
tracing are the top-priority requirements
in the pharmaceutical industry, even
where code quality varies widely. The
high-resolution LECTOR®654 features a
large field of view and a camera resolution of four megapixels. As a resu lt, just
one image is enough to verify whether
a bundle contains a complete set of
all secondary packaging materials and
whether the proper serial numbers have
been printed.
More information:
www.sick-idpro.com
www.sick.com/lector65x
Automatic identification of tires and wheels
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: FOCUS SCANNER AND VISION
ISTANBUL ATATURK AIRPORT RELIES ON TECHNOLOGY FROM SICK
KEEPING TRACK OF BAGGAGE
For identification of inbound pieces of baggage, Istanbul’s Ataturk Airport relies on
automatic track and trace systems from SICK. In this way, it was possible to improve
transparency and traceability of passenger baggage in particular.
>> Istanbul Ataturk Airport is Turkey’s
biggest airport, currently ranked in 20th
place of the world’s largest airports. It is
operated by TAV Airports Holding which
is among the leading airport operators
in the world. TAV Airports operates in
all areas of airport operations such as
duty-free, food and beverage services,
ground services, IT, security and operations services. In 2012 the number of
passengers at Instanbul Ataturk Airport
increased about 20 percent.
Today, only a relatively small number
of airports worldwide are capable of providing reliable and detailed data about
inbound baggage and of making this information available to passengers and
airlines. Generally, the number of incoming pieces of baggage is recorded at best,
without any clear matching with individual
passenger taking place. The airport in Istanbul has now changed this situation,
using innovative track and trace systems
from SICK for this purpose.
INCREASE OF TRANSPARENCY
Today, eleven track and trace systems
ALIS overall ensure a significant increase
of transparency in the inbound area of
Ataturk Airport. The passenger baggage
is transported by the ground crew to the
terminal and then fed into the airport’s
baggage handling system. SICK’s read-
ing stations were installed in those segments of the system located ahead of the
baggage return area accessible to passengers, specifically on to the conveyor
lines leading to the arrival carousels.
Here, the suitcases marked with one-dimensional bar code labels pass through
the automatic reading gates. Special
diagnostic and visualization software
provides statistics concerning the monitoring of the reading systems as well as
system performance. In addition, this
step sees processing of numerous other
data used for evaluation reports. There
is also the option of taking an image of
the piece of luggage at each reading station and of archiving it together with the
corresponding suitcase ID.
have landed about the exact place and
time of baggage return.” On top of that,
however, the data provided by SICK’s
systems can also make an important
contribution to the lost-and-found process. If a passenger reports a suitcase
“lost” to the airline, the carrier is now
able to check whether this suitcase was
still transported to the baggage carousel
and went missing only afterwards. This
facilitates and accelerates the search for
missing items of baggage.
Further applications:
www.mysick.com/applications
More about the customer:
www.ataturkairport.com
www.tavhavalimanlari.com.tr
CONTRIBUTION TO THE
LOST-AND-FOUND PROCESS
“With the newly installed reading stations, transparency at the inbound area
of Ataturk Airport has increased significantly,” says Bergman Gulsun, responsible for the project on behalf of SICK.
“For example, today it is possible without
any problems to inform passengers who
Ideal for traceability of baggage:
the ALIS track and trace system
23
A NEW DIMENSION IN PRODUCTIVITY AND SAFETY
SCANNER TECHNOLOGY HARNESSED FOR INDUSTRIAL USE
When SICK introduced the first 2D laser scanner to the world years ago, it started a
revolution in laser measurement technology. The detection and ranging solutions allowed customers who came from vastly different industries and had a huge range of
different requirements to tap into a totally new dimension of productivity and safety.
Thanks to countless evolutionary developments and globally recognized expertise as
a manufacturer and provider of system solutions, the name SICK is now synonymous
throughout the world with laser scanners and laser detectors.
24
Scanner technology
>> Laser scanners and laser detectors
are perfect for scanning ranges from a
few meters to several hundred meters.
Laser measurement technology differentiates between two time-of-flight measuring methods: the pulse time method and
phase time method.
Pulse time method
The measurement of the time interval
between a transmitted laser pulse and
received pulse is used to calculate the
distance between the sensor and an
object. The signal received also provides information about the remission
of the detected object. Interfering factors such as rain, fog, snow or dust
can affect measurement by the sensor.
: FOCUS SCANNER AND VISION
The new generation of outdoor 2D laser scanners from SICK receives multiple echoes (multi-echo technology)
per transmitted laser pulse, instead of
just one reflexion echo. This allows the
sensors to function with high precision
and reliability, even in the worst weather
conditions.
Phase time method
A sine wave is modulated onto a visible
laser beam. Distance and remission are
measured based on the differences in
phase time between the outgoing wave
and the wave reflected by the object.
SICK uses the phase and amplification
conditions in a closed resonant circuit to
optimize the phase time method.
Multi-pulse time method (multi-echo technology) illustrated using the LMS5xx
Advantages of laser measurement technology
Suitable for object measurement and positioning, area monitoring,
and collision prevention
Scanning area from 70° to 360°
For both indoor and outdoor use
Measurement objects do not require any special remission properties
Objects require no reflectors or marking
Target object can be in any position
Measured data available in real time
Mounting locations outside of collision area
Reliable building and object surveillance thanks to flexible design
of monitoring fields
Mounting possible in any position
Large monitored areas keep installation costs low
Consistent development of proven
technology: HDDM™ from SICK
One-of-a-kind measuring certainty and
precision: That‘s what SICK‘s HDDM™
time-of-flight method (High Definition
Distance Measurement) offers with its
statistical pulse time measurement. In
applications where interfering influences
can be expected in the form of ambient
light or reflections, the HDDM™ time-offlight method has demonstrated incredible reliability in all sensor types. This
minimizes downtime while enabling the
monitoring of large indoor and outdoor
areas – all with sensors that are smaller
than ever before.
This technique involves the simultaneous transmission of multiple laser
pulses and uses the remission values
to calculate an average. HDDM™ turns
laser scanners and distance sensors
into an optimal combination of measurement performance and efficiency. This
method is based on the transmission of
laser pulses. Unlike other time-of-flight
methods, multiple reflected laser pulses
are measured and used to calculate an
average measured value. As a result,
there are no gaps during scanning, and
measurement remains extremely stable
even when affected by ambient light or
other optical systems.
HDDM™: Low energy use
This innovative measuring method
does more than guarantee precise results in any measuring range; it also ensures maximum outdoor measurement
availability and reliability – even if dirt,
dust, dazzling, and humidity are present. A further advantage of the HDDM™
technology is its low energy use: For example, the TiM551 is one of the most
energy-efficient 2D laser scanners on
the market with a power consumption
of just three watts. This is an important
factor with respect to sustainability.
Laser scanners are also used as part of
SICK‘s systems, e.g. to capture traffic
data or for collision avoidance.
25
TiM5xx 2D laser scanner
MORE THAN JUST
OBJECT DETECTION
INNOVATIONS IN LASER
MEASUREMENT TECHNOLOGY
ALWAYS ONE STEP
AHEAD WITH SICK
SICK has been working in the field of laser scanners for nearly 40 years. Early on,
the company recognized that using laser beams to perform monitoring and measuring tasks leads to enormous productivity gains. That’s why SICK has invested significant amounts in laser measurement technology, in both new technologies and
product innovations alike.
>> Whether it‘s the Watchman, Optotrap
OTD or PLS – SICK represents innovation in laser scanner development. The
use of the pulse time method in industrial sensor technology marked the start of
the high point for the LMS2xx in 1996.
The device used light reflected onto the
sensor from the object, no longer requiring a reflector. Designed for indoor and
Watchman:
“Forefather” of the PLS
safety laser scanner
outdoor applications (day and night use,
rain and snow filter), it formed the basis
for the scanner systems that are in use
today in traffic systems, ports and the
field of geomapping. The development
of the LMC in 2011 as the first VdS-certified laser detector for object protection was a logical step in the direction of
building safety and security.
First industrial use of pulse
delay method for distancemeasuring sensor technology
>> As a pure measuring sensor, the
TiM5xx enables the precise capturing
and measurement of distances and objects – no matter what shape, color or
surface texture. This small sensor is also
energy efficient. Measurement remains
extremely stable, even when affected by
ambient light or other optical systems.
More information:
www.sick.com/tim5xx
PLS: The first safety laser
scanner based on the pulse
delay method
THE
DEVELOPMENT
OF
LASER SCANNERS
SINCE 1968
OPTOTRAP: Use of polygonal mirror
wheels and laser diodes
26
Use of distance-measuring sensor
technology on autonomously
moving vehicles
LMS2xx: Laser scanners with pulse
delay method for general indoor
and outdoor industrial applications
Scanner portfolio
: FOCUS SCANNER AND VISION
TiM351 2D laser scanner
NAV navigation scanner
LMS5xx 2D laser scanner
OUTSTANDING SIZE
AND PERFORMANCE
TOP NAVIGATION
PERFORMANCE FOR AGS
COMPACT SIZE FOR THE
BIGGEST TASKS
>> The TiM351 is an extremely compact
laser scanner with an enclosure rating of
IP 67. It operates within a temperature
range of –25 °C to +50 °C and provides
reliable outdoor detection for virtually
any desired object shape. Use options
range from mobile to stationary applications: from forklifts and port cranes to
object protection on and in buildings.
More information:
www.mysick.com/en/tim35x
S3000 safety laser scanner:
Extremely powerful and
reliable – remains a milestone to this day
>> In 1991, the use of distance-measuring sensors to navigate autonomously
moving transport vehicles was already a
hot topic. The result was the navigation
scanners in the NAV product family. They
provide the highest level of performance
for the navigation of automated guided
systems (AGS). The autonomous location of spatial positions occurs using reflector marks and provides the AGS with
maximum flexibility by virtually altering
its route in the vehicle computer.
More information:
www.mysick.com/en/nav
LMS5xx: Sampling
method for high outdoor
measuring capacity
LMS1xx: Use of multi-echo
technology
>> With numerous innovative functions,
the LMS5xx increases the productivity of
existing applications and opens up entirely new application possibilities. The new,
ultra-fast multi-echo technology makes laser measurement applications less sensitive to weather conditions and increases
the reliability of captured data. LMS5xx
boasts the best price/performance ratio
on the market in this sensor class.
More information:
www.sick.com/lms5xx
TIC1xx: First system for traffic
counting based on the LMS1xx
LMC: First certified laser detector
for object protection
TiM3xx: Use of HDDM™
technology
27
Outdoor scanners
Bulkscan laser volume flowmeter
RELIABLE UNDER TOUGH
CONDITIONS
NON-CONTACT MEASUREMENT OF VOLUME FLOW
>> Laser scanners used in outdoor applications should not be sensitive to climatic influences. The new generation
of outdoor 2D laser scanners from SICK
receives multiple echoes per transmitted
laser pulse, instead of just one reflexion
echo. This allows the sensors to function
with high precision and reliability, even in
the worst weather conditions.
>> The Bulkscan® LMS511 uses timeof-flight laser technology to provide
non-contact volume flow measurements
on conveyor belts. No matter what kind
of bulk materials are involved or how
bad weather conditions are, the multiecho technology allows the Bulkscan®
LMS511 to generate a reliable volume
flow signal using the laser‘s time of flight
and the belt speed.
More information:
www.sick.de/bulkscanlms511
More information:
www.sick.de/outdoor
THE LARGEST PORTFOLIO FOR DIFFERENT APPLICATIONS:
AREA
DIMENSION AND
CONTOUR (2D AND 3D)
VOLUME
PATTERN
RECOGNITION
Bar code scanners/hand-held
scanners
x
x
2D laser scanners (indoor/outdoor)
x
x
3D laser scanners
x
28
x
x
x
x
/DVHUYROXPHÁRZPHWHUV
Track and trace systems
SAFETY/PERSONAL
PROTECTION
x
Safety laser scanners
Navigation scanners
OBJECT
PROTECTION
x
x
x
Scanner portfolio
: FOCUS SCANNER AND VISION
Safety laser scanners
ADVANTAGES OF THE
SCANNER TECHNOLOGY
SAFETY LASER SCANNERS FROM SICK:
SAFE BY EXPERIENCE
>> With the PLS from SICK, safety laser
scanners for stationary and mobile machine protection have enjoyed unimaginable success for over 20 years. Thanks
to over two decades of experience, SICK
can look back at countless successful
application solutions involving the use of
safety laser scanners.
Whether mobile or stationary, area
protection or access surveillance, SICK‘s
extensive portfolio of safety laser scanners offers an economical package for
any requirement or task – making them
a safe investment that will add value for
years to come.
Modularly designed safety portfolio
for greater application versatility
Thanks to the modular layout of the SICK
safety portfolio, the right solution can be
constructed to fit each specific application – using as many components as
needed and as few as possible. The range
of applications stretches from a simple
alternative to pressure mats, e.g. in machine-loading stations, and protection for
forward and backward movements on
transfer carriages to the comprehensive
protection of highly complex, independently navigating automated vehicles.
If a single scanner is enough to handle
protection duties, the choices include
the S3000, S300 and S300 Mini product
families. Here, the S3000 impresses with
a unique safe scanning range of 7 m. The
S300 and S300 Mini shine thanks to their
combination of a compact design and a
sensing range of 3 m.
If protection needs call for more than
one safety laser scanner, the scanners
can be intelligently linked to one another
and to the Flexi Soft safety controller.
Central configuration and diagnostics,
little wiring, and an expanded range
of functions offer clear advantages for
commissioning and operation.
Vertical protection during final assembly
Mobile protection on an AGS
No special system preparation necessary
Easy mounting and alignment
Sender and receiver in a single device
Freely configurable protection and
warning fields
Rapid adjustment to different ambient
conditions
Adaptation to hazardous situations
during operation
Flexible choice of installation location
Simple integration
More information:
www.sick.com/scanner-plus
Hazardous area protection at a tire-curing press
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Automated parking system
: FOCUS SCANNER AND VISION
“We park for you!” That’s how easy it is to sum up the concept developed by Serva
Transport Systems for parking in the future. But even though this simple idea presents
huge challenges in terms of the design and operation of transport systems, intelligent
sensors can be used to solve the problem.
>> Cars are made for driving. In reality,
however, automobiles only travel slightly
less than 40 km per day and remain motionless for more than 23 hours, either
on private property or in public spaces.
Over the past few years, various concepts for automated and semi-automated parking have been developed with
the goal of improving the organization of
“stationary traffic.”
Drivers are familiar with winding
around annoying curves in the parking
garage until finally sighting an open spot.
If the driver has a plane or train to catch,
this can be especially unpleasant. This
problem led Serva Transport Systems, a
German company based in Grabenstätt
on Lake Chiemsee, to develop a special
application that parks, sorts and picks
up cars autonomously. This particularly
innovative technology, which features
software from the field of pallet logistics,
factors both area utilization rate and time
into its calculations. The system from
Serva Transport Systems arranges cars
in the most space-efficient manner possible. The automobiles are taken to a specific spot in the garage, from which they
are then later returned. Drivers no longer
need to search for a parking spot, since
the system takes care of it for them.
“In existing parking garages, we can
improve space utilization by up to 40
percent, and by up to 60 percent in new
structures,” says Rupert Koch, Director
of Sales at Serva Transport Systems.
This should be clear: The cars can be
packed in tightly, since there is no need
for people to get in or out of the car inside the parking garage.
If the Serva concept is applied, the
only thing the driver needs to do is park
the car in the transfer station and get out!
This station is similar to a car wash. A
parking robot measures the car and lifts
it up. The car is then autonomously taken
to the designated spot, where it is parked.
If the driver wishes to retrieve the
car, he/she can have it parked out of
the space using a smart phone app or
the ticket itself. What happens if a car
is sandwiched between a mass of other
cars? In this case, the system simply
clears the other cars out of the way using the parking robot, re-parks them, and
remembers the new locations.
Parking robot with sensor intelligence
The central element of the system is the
parking robot, which is an automated
guided vehicle (AGV). This robot is a type
of forklift for cars and features four fully
movable and independently powered
wheels. The parking robot lifts the car
up, moves it to the designated spot and
also brings it back again. It is the key to
the “parking revolution” conceived by
Serva Transport Systems. However, the
robot would not be complete without a
few sensor-related capabilities.
31
The transfer station takes three-dimensional measurements of the car and
determines the distances between the
wheels as well as the wheel diameters,
both of which are critical for the parking process. The parking robot receives
this data and uses wire draw encoders
from SICK to adjust to the optimal size
for the specific vehicle. A tiny little Smart
car has a different wheelbase and different dimensions than an SUV. LMS
2D laser scanners determine the right
lifting point, and the parking robot carefully raises the car. To do this, the AGV’s
rails, which are equipped with rubber
rollers, laterally move under each of the
car’s wheels.
It is vital that the parking robot remains safe whenever it moves, which
means that both the vehicle it transports and any people in the vicinity
must be reliably protected. It also needs
to be capable of autonomous navigation, in order to find the correct path
to the parking spot. In doing so, it executes maneuvers in the smallest of
spaces, performing movements that no
32
“Comprehensive advising and expert experience
are critical for us. SICK accompanied us from
the prototype all the way to the finished system.”
Rupert Koch, Managing Director at Serva Transport Systems
car can. This demands a lot from the
sensors, and also from the experts in
the SICK sales team, who must select
the right products to meet these strict
requirements.
Serva Transport Systems decided to
go with SICK not only because SICK can
deliver all of the sensors from a single
source, but also because SICK provides
comprehensive advising. From the prototype to the finished system, SICK accompanied the development process at
Serva Transport Systems and supported
it with countless improvements and optimizations.
Measuring and identifying with LMS
Multiple LMS100 laser scanners from
SICK measure the car that is to be
parked and then send the captured data
to the system’s software. This data is
used to identify and classify the car and
its dimensions, and also to measure its
wheelbases and wheel diameters. This
allows the parking robot to know to automatically adapt to the particular car. Incredibly precise data is required so that
the system can identify the right car, and
so that it can park it in the most spaceefficient manner possible. In addition,
a laser scanner performs monitoring to
Automated parking system
: FOCUS SCANNER AND VISION
Parking from the future: A parking robot
picks up a car from the transfer station
and brings it to the designated spot –
autonomously.
Well-connected sensors
All of the parking robot’s sensors are optimally connected and coordinated with
one another via controllers. Here, integrated safety is provided by two Flexi Soft
safety controllers, which directly communicate with the laser scanners via a safe
bus connection to protect all paths of moment. The control principle can be considered the core of the parking robot’s sensor equipment. SICK was actively involved
in the development process from the very
beginning. The basic design was conceived together with the Fraunhofer IML in
the prototype stage. As the design was put
into practice, the SICK sales team’s application specialists and project management implemented numerous expansions
and optimizations with Serva Transport
Systems, such as integrating the Flexi Soft
safety controllers with EtherCAT gateways
and coupling the controllers together.
make sure there are no protruding parts,
which could otherwise be damaged.
Knowing the right path
The robot, which moves autonomously across the parking area, uses the
NAV350 navigation scanner for orientation. The navigation scanner leads the
AGV along the guide track and localizes
its exact position. The scanner provides
precise spatial contour and reflector data, which are outputted via an Ethernet
interface. A specially developed navigation control system has the capability
to accurately position the parking robot
within a few millimeters. In order to save
as much space and time as possible, the
parking robot can even rotate in position.
These are complex movement sequences to which the sensors must adapt.
Protection with safety laser scanners
The S3000 Expert and S300 Mini Remote safety laser scanners ensure that
the parking robot is truly safe. The necessary protective fields surrounding the
parking robot are monitored to avoid
collisions and protect pedestrians. This
is an incredibly demanding task for the
sensor. Not only do the protective fields
need to be adapted to the changing, carspecific dimensions of the parking robot,
they must also dynamically adjust to altered movement directions and speeds,
since the robot can move in all directions. This results in an extremely high
number of possible evaluation cases.
Outlook
Several test runs have already been successfully completed. At the Düsseldorf
airport, a parking garage featuring autonomous parking robots will soon begin
operation.
More about the customer:
www.serva-ts.com
Research meets industry – Intelligent sensors for the logistics of the future
There has long been close cooperation between the Fraunhofer Institute for
Material Flow and Logistics (IML) in Dortmund and SICK AG for the purpose
of developing logistics concepts for the future. But since the start of 2013, this
solid partnership has taken on a new quality thanks to the SICK EnterpriseLab.
A cooperation agreement has cemented the partnership at different research
laboratories with the objective of turning projects into reality as a team.
Examples include cellular transport vehicles, market-specific shuttle solutions,
and the automatic parking system from Serva Transport Systems. As part of
this cooperation, SICK sends employees to the IML in order to work on specific
solutions on-site.
33
MEASURING VOLUME FLOW WITH BULKSCAN® LMS511 AT RWE POWER IN INDEN
BROWN COAL EXTRACTION, OPTIMIZED
Inden is the third strip mining site in the Rhineland brown coal mining district after
Garzweiler and Hambach. The mining field is approximately 4,500 hectares in size. Its
coal seams are up to 45 m thick and lie as far as 230 m beneath the earth’s surface.
The Bulkscan® LMS511 laser volume flowmeter measures the bulk materials on the
conveyor belts and is thus able to control the bucket-wheel excavator’s output.
34
>> Yard by yard, bucket-wheel excavator
255 cuts its way through the earth with
its swinging boom. The bucket wheel
moves the excavated earth onto a belt
located on the boom, where it is then
Measuring
: FOCUS SCANNER AND VISION
to the millisecond. “This value is used
in the bucket-wheel excavator control in
order to vary the slew speed, and therefore the output, so that the most uniform
volume flow possible is ensured. The resulting avoidance of peak loads also reduces system wear,” says RWE Power’s
Bernd Steyer.
Laser measuring enables driverless
operation of tripper cars
The proper alignment and positioning
of the tripper car (TC), e.g. in front of
stacker 737, is ensured with the help of
laser scanners. These scanners are attached to the structure of the TC in such
a way that a vertical scan of the overland
conveyor’s belt frames takes place in
both the front and rear areas. “The laser
scanners on the tripper car ensure the
exact positioning of the TC relative to the
overland conveyor system. An additional
function is the accurate control of the TC
ramp section height relative to the overland conveyor,” says RWE Power’s Manfredo Cammaleri.
Next-generation technology in testing
Currently, the predecessors of the
LMS511 are still in use on the tripper
cars. However, because they can only
be repaired to a limited extent due to
a lack of obtainable components, the
LMS511 devices are being tested on
both the tripper cars and bucket-wheel
excavator booms. It remains to be seen
whether the new devices will be in use
by the scheduled closing of the Inden
strip mine in 2030. After the closing, the
mining field itself will be recultivated into
arable land and converted into a nature
preserve and recreational area with a
4.25 square mile (11 km²) lake.
transported to an overland conveyor
system at the rear of the bucket-wheel
excavator. RWE Power has installed a
Bulkscan® LMS511 above the first belt
on the boom – with an integrated heater,
and without added weather protection.
The volume flow sensor quickly and accurately measures the profile of the bulk
materials and, using the belt speed, calculates the current volume flow down
Further applications:
www.mysick.com/applications
More about the customer:
www.rwe.com
35
INSIDE THE TUNNEL: DANGER AVERTED!
NO ENTRY FOR OVERHEATED VEHICLES
Plenty of people underestimate the danger of a fire spreading through a tunnel.
Smoke and heat have no way to escape, and they spread at rapid speeds. The short
amount of time needed for hot axles or cracked brake rotors on trucks or motor coaches to cause a fire is also well established. Despite all this, there is a way to identify
overheating parts on a vehicle before it enters a tunnel and to pull that vehicle out of
traffic: the VHD Pro vehicle hot spot detector from SICK.
36
>> The advantages of this system have
already been utilized by Austrian autobahn operator ASFINAG and by FEDRO,
the Swiss Federal Roads Office. The
VHD Pro system monitors the 8 km
Karawanks tunnel in Austria and the
Monitoring and controlling
: FOCUS SCANNER AND VISION
1. The graphic representation of the alarms
in the user interface allows the user to
quickly assess the situation and take any
necessary action.
2. In this case, the hot axis on the trailer has
triggered the alarm, while the two “cold”
wheels show cracked brake rotors.
Gotthard tunnel in Switzerland, which
at a length of 17 km is the world’s thirdlongest road tunnel.
A VHD Pro system combines the
measured data from thermal imaging
cameras and laser scanners to catch
overheating vehicles before they enter a
tunnel. Thanks to the special overhead
and side positioning of the LMS511
Traffic laser scanners from SICK, it is
possible to measure vehicles in freeflowing traffic both lengthwise and in
profile, and also to detect wheels and
various other vehicle components. Be
it in the cab area, near the exhaust
pipe or on the wheels, dangerous outer
temperatures at the vehicle’s exterior
envelope are measured by the VHD Pro
thermal imaging camera and matched
to the corresponding vehicle segments
on the 3D Model.
Localizing, identifying and evaluating
Every vehicle – even if it accelerates or
brakes as it passes by the VHD Pro system – is captured by the LMS511 Traffic, regardless of the weather conditions.
The Vehicle Hot Spot Detector software
evaluates the 3D data together with the
measured temperature values. In this
way, potentially dangerous outside vehicle temperatures are accurately localized, identified and displayed on the 3D
model of the vehicle.
The operating temperature of a
wheel indicates a possible technical
anomaly as soon as it reaches a value in
excess of 60 °C. At 100 °C and up, the
operating temperature for bearing seals
is exceeded, which can cause lubricant
leakages and other subsequent damage. At over 200 °C, the rubber becomes
damaged, and pyrolysis begins in the tire
at temperatures of 260 °C or higher. The
flash point then follows at 350 °C.
“Hot” vehicles are “cooled off”
Once an alarm has been triggered by a
temperature that exceeds specified limits, the vehicle is pulled out of traffic in
time before entering the tunnel and is
given an opportunity to “cool off.”
It is thus possible to avoid disastrous
fires and accidents that can be caused
by overheating vehicles in a tunnel.
Further applications:
www.mysick.com/applications
More about the customer:
ZZZDVÀQDJDW
www.astra.admin.ch
37
INCREASED SAFETY FOR PEOPLE AND INVESTMENTS
SYSTEMATIC COLLISION PREVENTION
Modern production and logistics processes are designed not only for optimum efficiency, but also with the safety of people, systems, and equipment in mind. Damage
caused by collisions results in high repair costs, administrative expenses, and expensive downtimes.
>> When containers are loaded at a port
or in modern strip mines, the risk of collisions is high – and the consequences for
machines and humans can be serious.
Sensors and solutions from SICK offer
safe solutions for these challenging applications.
AOS Prime: Reliability in a
wide range of applications
The AOS Prime (Advanced Object Detection System) object detection system is
a self-testing system with excellent di-
38
agnostic capabilities. It was developed
to avoid costly collisions and is used in
countless areas such as ports, airports,
rail transport and the steel industry. The
AOS Prime is based on tried and tested
outdoor laser scanners and the Flexi
Soft safety controller from SICK.
In addition to optical sensor testing, the response times and output
signals of the sensors are continuously
checked during operation. The AOS
Prime thus fills the gap in outdoor applications – in situations where laser
scanners alone are not enough and
there is still a need to guarantee high
system reliability.
Port safety
DP World is one of the world’s leading
companies in the container handling
business. The company’s main objective
is to enable uninterrupted operations at
all times and to further improve its notably outstanding quality of service and
competitiveness. That’s why DP World
is equipping its expansion in the port of
Dschabal Ali with AOS Prime object detection systems from SICK.
More information:
ZZZVLFNLQVLJKWFRP
Collision prevention
RAS Prime: The assistance system
for reach stackers and empty
container handlers
Maximum efficiency without interruption: Container terminals that operate
24 hours a day, 365 days a year have
tough requirements in terms of availability and minimized downtime. The
growing trend towards automation,
and the accompanying increase in the
volume of containers that need to be
handled, present a high accident risk
for reach stacker operators. The RAS
Prime is a high-precision collision warning system that monitors the entire rear
area of a vehicle. An operator display
uses object contours to give the driver a
clear and easy-to-understand depiction
of the vehicle’s surroundings. In order
to lower the operator’s response time
to an absolute minimum, only objects
that could pose a collision threat are
displayed. In addition, added emphasis is placed on any object located in
direct proximity to the vehicle. The location on the vehicle where the threat of a
: FOCUS SCANNER AND VISION
collision is present is thus immediately
clear, which allows the operator to respond accordingly.
MINESIC100 TPS:
Ideal for use in surface mining
The MINESIC100 TPS (Truck Protection
System) is a warning system for collision prevention and lane monitoring and
was developed for dumpers of all sizes
and types. The TPS helps to monitor the
two critical areas in front of and behind
the truck and warns the driver whenever
necessary. Additionally, it determines
the position of the truck on the road. The
driver is also warned if the truck veers
too close to the edge of the roadway or
drifts into the opposite lane.
The heart of the system is a five-inch
touchscreen with an integrated computer
– similar to modern navigation systems.
When a critical situation is identified, the
driver receives appropriate visual warning signals on the display. An audible
alarm helps to ensure that the driver is
properly alerted.
MINESIC100 TPS with touchscreen: A warning system for collision prevention and lane monitoring
39
Visit us online:
ZZZVLFNLQVLJKWFRP
www.sick.com
Order No. 8017214
SICK AG
Erwin-Sick-Str. 1 | 79183 Waldkirch | Germany
Phone +49 7681 202-0 | Fax +49 7681 202-3863
[email protected]

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通 信 英語版 火事ですか、救急ですか。 Do you require an ambulance